Wire and Cable, Harnessing and Protection Products Table of Contents 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 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire and Cable, Harnessing and Protection Products Tyco Electronics Embraces the Most Valued Brand Names Worldwide As a truly global player, Tyco Electronics Corporation has facilities located throughout the world serving customers in a wide range of applications. Tyco Electronics Corporation - 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, industrial/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, heatshrink 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. 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 knowledgeable application engineers, sales representatives, and customer service personnel enables you to make your next generation of products successful. A significant result of this continued growth, and a ii Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire and Cable, Harnessing and Protection Products About Raychem Wire and Cable, Harnessing, and Heat-Shrinkable Products Tyco Electronics, for its Raychem products, pioneered the application of radiation crosslinking and the development of heat-shrinkable polymer tubing. The Tyco Electronics Raychem brand of heatshrinkable polymer products is recognized worldwide. It is backed by a history of proven performance, reliability, innovation and superior quality. Tyco Electronics manufactures the world's largest range of heatshrinkable tubing - tubing that provides cable protection offering exceptional insulation, mechanical protection, and strain relief. We are the recognized world leader in heat-shrinkable 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 -100C to +260C [-148F to 500F], the product line encompasses fire-resistant cable, small-size controlled electrical cables, multi-conductor cable, high-performance radiation crosslinked ETFE airframe wire, low fire hazard wire, high-performance 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 recognized standards and specifications 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 technologies. Developed from these technologies, Raychem products are sold into many industries including aerospace, automotive, electronics, construction, electrical power, utilities, manufacturing, pipeline, process, rail and mass transit, and telecommunications. iii Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire and Cable, Harnessing and Protection Products How To Use This Catalog This catalog has four main sections: Application Overview Electrical Interconnection System Design Products Supporting Information Application Overview (Section 1) presents general design ideas based on typical uses for Raychembrand wire and cable, heatshrinkable 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 generic 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 provides 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 provides: n An overview of the product group. n A table of contents that lets you see at a glance the product families in that product group. n A selection guide to help you determine which product family will satisfy the requirements of your application. n An explanation of the part numbering system for that product group. n Information pages on each product family. The product information pages provide some or all of the following information (depending on the product family): n n Product features/benefits. n Abbreviated installation guidelines. n Specifications and agency approvals. n Part number selection information n Product data (dimensions, properties, and materials). n Ordering information. n Location availability. Supporting Information (Section 11) provides: n Equivalents and conversion tables. n Temperature conversion table. n Glossary. Typical applications for the product family. Market Icons 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. Medical Automotive Commercial Electronics/Communications Industrial Aerospace Marine Military Rail Industries Space iv Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Seal It 1 Application Overview Advanced materials and product design have resulted in a complete line of products offering the most effective sealing available today: adhesive-lined tubing, molded parts, and a variety of solder and crimp connection devices. These easy-to-use products provide superior waterproofing, resistance to hydrocarbons and other chemicals, protection against corrosion and oxidation, and a barrier against dust and dirt. n n Heat-shrinkable, adhesive-lined products-- tubings with high shrink ratios, and molded parts--environmentally protect connector-tocable transitions. Waterblocked and anticapillary wire prevent water and most fluids from wicking between the conductor strands. Bundle sealing products block multiconductor cables. n n Adhesive-lined, heatshrinkable tubing and caps seal and protect electronic components and in-line wire splices from fluids, moisture, and corrosion while also providing strain relief. n Heat-shrinkable, moisture blocking systems are designed to provide reliable sealing of wire bundles preventing fluid ingress. Heat-shrinkable caps lined with an adhesive or encapsulant form a moisture-resistance barrier around stub splices and wire ends. 1-1 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 : 44-1793-528171 Applications Connect It Raychem electrical interconnect products offer reliable, more cost-effective alternatives to traditional connection methods--such as hand soldering, or crimping and then insulating by taping or overmolding. With our electrical interconnect products, you start with a precisely engineered, fluxed solder preform inside a transparent, heat-shrinkable sleeve. When the product is heated, the solder preform melts, and the sleeve shrinks to create a connection that is fully insulated and strainrelieved. This ease of use expands your options even as it enhances the quality of your end product, as in these applications: n n n Easy and reliable termination 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. Splicing of one component to another, such as a diode connected to one end of an LED. Coaxial terminations to PCBs and terminals. 1-2 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Insulate It 1 Application Overview Solving an insulation problem can be easier than you think, especially when you consider the family of Raychem products from Tyco Electronics that can provide superior alternatives to standard methods of insulation such as hand-taping or molding-in-place. n n When heated during installation, our radiationcrosslinked tubings shrink to conform to a variety of shapes, providing dependable insulation. Heat-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. n n General-purpose polyolefin tubing is widely used to insulate and strain-relieve wire terminations and connections. Delicate electrosurgical instruments can be insulated and protected from abrasion by using one of Raychem's medical-grade, heatshrinkable tubings specially formulated to meet the requirements of USP Class VI for medical use. n Components 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. 1-3 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Protect It Designing a brilliant solution is good. Protecting a brilliantly designed solution is even better. A whole family of protection products, made from a wide variety of materials, can provide comprehensive protection: mechanical protection, strain relief, resistance to abrasion and crushing, EMI and noise reduction, fluid resistance, and thermal insulation. n n n Tinel-Lock ring braid terminations can be used for applications where shielding is critical. These shape-memory-metal products attach metal braid shields to backshells and provide 360 protection against EMI and EMP. Heat-shrinkable tubings provide mechanical protection for hoses and pipes, and also reduce problems caused by wire chafing or cable abrasion. Easy-to-install heat-shrinkable tubing and molded parts provide excellent strain relief and electrical insulation for connectorto-cable transitions. n n n A heat-shrinkable molded part can relieve the strain on a multiconductor cable to a D-subminiature connector. Heat-shrinkable feedthroughs relieve the strain on cables entering junction boxes. Highly-flexible, heatshrinkable 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. n Heat-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 equipment, and commercial electronic products. 1-4 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Wire It 1 Application Overview Tyco Electronics is a leader in the development of high-performance wire and cable products for demanding applications, including aerospace, industrial equipment, instrumentation, marine, and automotive applications. Precision extrusion capability, materials expertise, and design knowledge provide wire products that are lightweight; smaller than comparable-performance constructions; highly flexible, yet mechanically tough; flame-retardant and resistant to a variety of industrial fluids. 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 components, tough but lightweight jacket materials, and optimized shielding. Tyco Electronics can also design complete wiring harnesses for industrial or military applications. n n The FlexLite family of hookup wire provides economical alternatives to fluoropolymers, silicones, and crosslinked polyethylene insulations for applications such as motors, appliances, and lighting, and for applications where thinner walls are needed because of space constraints. n Low-fire-hazard primary wires and cable are made from halogen-free, lowsmoke materials with a low toxicity index. They offer increased safety, with reduced size and weight, over traditional materials in mass transit and similar applications. Raychem high-temperature, dual-wall or singlewall aerospace wire saves space and weight on both military and commercial aircraft and space vehicles. 1-5 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Hold It To help you arrive at the best way to securely hold and position a component, take a look at the Raychem family of products and consider the many ways that you can use them: to keep components in place, bundle and route wires, create a formed shape for potting, or package components securely before final assembly. n n n n Thin-wall tubings allow bundling of wires to create very flexible, lightweight harnesses that can withstand harsh environments. Fiber and/or copper components can be bundled for a custom multicore cable. Cable legs can be held together with a Y-transition molded part. Multicore and film-bonded cables hold wires together and also provide EMI protection. n n n Tubing can hold a covering (braid or Convolex tubing) onto a substrate. Two components (such as a resistor and fuse) can be held together as a package by enclosing them with heat-shrinkable tubing. Heat-shrinkable fabric tubing will grip substrates, such as harnesses, tightly to provide secure wire bundles without additional fixing. 1-6 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Join It 1 Application Overview When you have a mechanical connection to make, consider the uniform circumferential recovery force of heat-shrinkable tubing and metals in your designs. n n n Join two dissimilar materials, such as a rubber flapper to the end of a nylon tube, or the handle of a medical instrument to the instrument's moving parts. Assemble a bellows by covering a spring with heat-shrinkable tubing. Use Tinel ring adapters to provide the even circumferential force necessary to attach a metal braid shield to a backshell. n n Clear, adhesive-lined tubing connects water tubes in appliances to provide a rugged and aesthetically appealing joint which is also inspectable. Heat-shrinkable tubing is used to join polyester cords to heddles in Jacquard weaving loom harnesses. 1-7 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Beautify It Enhancing the appearance of your brilliantly designed solutions couldn't be easier, when you use Raychem products. n n n n Heat-shrinkable tubing-- instead of tape--can create a smooth covering with no loose ends. Hot-stamp foils (gold or silver) can attractively showcase a company logo. Heat-shrinkable tubing can cover the mechanical attachment of one part to another. n n Tubing 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. Handles of a variety of tools can be covered with colorful, heat-shrinkable tubing to enhance the appearance of the final product. Tubing can attractively cover a metal railing, such as the type used for crowd control. 1-8 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Reduce It 1 Application Overview With the trend toward miniaturization and higher-density interconnections, products developed for commercial electronics applications must downsize as well. n Versafit 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 quickly. In addition to space savings, V4 tubing offers excellent mechanical protection and strain relief for sensitive components. n The MicroFit family of products can be used to connect and insulate finegauge wire (26 to 42 AWG) in such end products 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 onestep 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. n Tyco 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. 1-9 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Repair It Whether for repair or retrofitting, Tyco Electronics offers a whole family of Raychem products that can provide flexible, cost-effective solutions. For example, most failures in electrical wiring harnesses occur within the first six inches of the connector. Raychem products make repairs in this area more reliable, long-lived, and cost-effective. n n n High-shrink-ratio tubing can be slipped over the connector without depinning to reinsulate or strain relieve the connector-tocable transition. SolderShield repair splice kits provide the components necessary to splice shielded single-wire or multicore cables. Adapters and Uniboot molded parts can be combined to allow reentry to the back of the connector area for pin repair. n n Splash-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. Flexible, adhesive-lined tubing can be used to repair damaged wire insulation, providing a moisture seal that is resistant to bending of the wire substrate. 1-10 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Flex It 1 Application Overview In applications where flexibility or flex life are important, Raychem products meet the need--many performing even at low temperatures. n n NT 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 -70C [-94]) without cracking. Hi-Flex heat-shrinkable tubing was developed specifically for sealed cable-jacketing applications where cable flexibility is an important concern. It is also ideal for situations where the cable is subject to motion, such as in industrial machinery, transportation equipment, robotics, and welding. n n For applications where a flexible 90 bend right after the connector is desired, Uniboot molded parts can provide the perfect fit. DynaLink wire and cable is designed specifically for applications where flex life is critical: in the robotics industry; in lifts, typing machines, and sewer inspection equipment; and on ships where wire must be capable of unwinding from a large cable reel and then retracting smoothly without strain. 1-11 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications All of It At Tyco Electronics Corporation, we like the word "multitasking." So it should come as no surprise that Raychem products are designed to help you integrate several tasks--seal, connect, insulate, protect, wire, hold, join, beautify, reduce, repair, and flex. In the pages of this catalog, you will find literally hundreds of products designed to provide thousands of solutions--across a wide variety of industries. Although you will find the catalog features an extensive 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 onsite training. 1-12 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Application Guide Tyco Electronics manufactures 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. 1 Application Overview 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. 1-13 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Engineering Notes 1-14 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Table of Contents 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. 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 2 Electrical Interconnection System Design Tyco Electronics provides this information as a design aid and assumes no responsibility for and makes no representation regarding the suitability of a design for a specific application. Note: Users should independently evaluate the suitability of the product for their application. Before ordering, check with Tyco Electronics for most current data. 2-1 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Harness Design A Raychem molded part provides strain relief on the back end of a connector. Tyco Electronics offers a range of Raychem components 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. A variety of component material systems can be used to design a rugged, reliable, repairable, shielded, and environmentally sealed harness. We also offer individual components that can be used independently to meet a specific sealing, insulation, strain relief, protection, identification, or electrical interconnection need. Harnessing system components include: n Heat-shrinkable tubing n Heat-shrinkable molded shapes n Adhesives n Adapters n Assemblies n n n n Harness Design n Electrical interconnect components Wire and cable Solder termination devices Application equipment In many cases, properly selected components can raise the performance of a harness to acceptable levels compatible with even very demanding environments where cables are exposed to water, temperature extremes, EMI-radiated fields, or fluids. Tyco Electronics is the established leader in automotive, 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 a harness assembly for demanding environments. n Designing wiring harnesses for demanding applications such as defense and aerospace is a complex business: n n Many 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 are becoming more demanding. Weight and space are especially important in missile and aerospace applications. With the additional electrical equipment now in products such as cars, these factors are becoming a bigger issue in these industries. n Resistance to environmental hazards including corrosion, high temperature 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. Repair 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. Electromagnetic interference (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. 2-2 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Harness Design (Continued) The front or joining end of the connector is designed to mate only with a connector having the right configuration. The back end of the connector is where the wires are terminated to the metal contacts. The checklist on page 2-4 covers some of the factors to consider in the design of a harness. Wires 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, are joined to the conductors and are designed to mate or join with contacts of the opposite type. Connectors for indoor or internal use are generally not designed to resist moisture. Connectors that will be exposed to moisture are generally sealed to meet a specific requirement. 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. A copper 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 4 AWG wire. 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 information and the selection tables that follow, you will be able to choose from this catalog the right components for an integrated military or highperformance industrial harnessing system. A 26 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 a conductor depends on a number of factors: n n n n n n Operating, design, and excursion temperatures of the system Size and weight limitations Mechanical performance desired Flexibility requirements Resistance to various fluids Specialized requirements, such as: - low fire hazard or low halogen - low outgassing 2-3 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Harness Design (Continued) Harness Design Checklist Connectors Sealed or unsealed? Made of plastic or metal? Crimp or solder contacts? Pins or sockets? Mating frequency? Keyway angle? Exposed to electrical noise (EMI)? Geometry Dimensions? Point to point or branched? Configuration of ends - straight, 90, 45? Environment Exposed to sunlight? Exposed to moisture? Immersed? Temperature extremes? Temperature cycling? Normal operating temperature? Exposed to abrasion? Exposed to mechanical abuse? Exposed to dust? Exposed to corrosive fluids? Exposed to flexing? Repairable? Circuit identification? Cable identification?* Shielding effectiveness? 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 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 are compounded 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 damage caused by mechanical stress such as flex, torque and tensile load, and corrosion or electrical breakdown from fluid ingress, while retaining the ability to be repaired. All these influ- ences and more must be considered when choosing the termination protection method. Shielding and Shield Termination Step 3 of the component selection process discussed later in this section gives advice on choosing the appropriate shielding products for the gross shield. Consideration must also be given to the individual cable shield terminations. 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. Identification Circuit identification is important, both in manufacture, where an assembly operator must ensure correct wire to contact termination, and in repair, where a damaged connector may need replacing in difficult circumstances and contact positions have to be easily identified. Individual wire markers help with these two circumstances. Where a cable is severed and access to the ends is prevented, unique identification on the wires, or wire color coding aids repair. speed up plugging, particularly for multiconnector harnesses. It is also good practice to label the harness with its part numbers and other relevant information for traceability purposes. The Tyco Electronics Identification Products Group offers a variety of products that are compatible to the HarnWare software design process. For complete information regarding these products visit our website at www.tycoelectronics.com. 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 2-4 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Protection of Harness Components 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. Harness components are vulnerable to corrosion, stress, strain, and electromagnetic 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 tubelike voids--capillaries-- between the individual strands of copper that make up the conductor. Called "capillary action," the penetration 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 electrical loads and the metal will fail. Mechanical failure can thus occur anywhere in the wiring system. Even before mechanical failure occurs, electrical If a chemical solution contacting the electrical connection is itself conductive 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 temperature cycling in some situations cause condensation, the accumulation of which can also result in a short circuit. Depending on circumstances, 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 requirements 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 prevent strain from occurring in a weak 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. 2 Electrical Interconnection System Design 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 impedance mismatch, increase noise in a signal circuit, or modify the waveform. Even small amounts of corrosion or other contaminants can have a significant impact on contact surfaces and the efficiency with which signals flow through them. EMI (Electromagnetic Interference) EMI is similar to the noise heard on an AM radio when the radio is close to highvoltage 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 susceptible to two types of EMI: n n Radiated emissions (the electromagnetic energy a wiring system radiates to its surrounding environment), 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.) External radiated emissions (the electromagnetic 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. 2-5 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software Select optimum parts Check for problems & deviations from 'best practice' Generate parts lists & assembly time estimates Generate wiring schematics & schedules HarnWare Software Determine best cable lays, diameters & construction HarnWare Design 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). HarnWare software 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'. Determine wire routes & lengths Determine most suitable wire gauge Some HarnWare Software Outputs The following are some examples of the outputs that HarnWare software can generate: n n n n High quality engineering drawings. Clear and reliable drawings play a crucial role in the success of any design project. Point-to-point wiring lists, including calculated wire lengths. Fully 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. Assembly time estimates. HarnWare software automatically adds the design details into a `spread sheet' containing standard assembly time synthetics. n n n Wiring schematics and schedules are quickly produced using connector plan form data and wiring details from the wire list. Lists of codes of practice describing harness assembly techniques and other issues that are relevant to the parts included in the design. Files 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. A sample 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 2-6 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) n System Building Blocks Some key features of HarnWare software are: n n The user interface is similar to that of commonly used software such as Microsoft Word and Excel. n On-line help systems for guidance on using the system and on Raychem wiring harness products. Uses the Visio drag and drop drawing system for creating harness drawings more quickly and more easily than with other computer aided design (CAD) systems. HarnWare Software Database HarnWare Software HarnWare Software Help Drawing Wire List Wiring Schedule Wiring Schematic Cable X Sections Parts List Design Notes Labour Estimate Marker Page Visio n n n A growing library of 400 intelligent drawing shapes and a 110,000 record design database which can generate 100,000s of part descriptions for Raychem wiring harness products in their various material and finish permutations. Software that traces wire routes through harnesses and automatically creates wiring schematics and calculates wire lengths. 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. 2 Electrical Interconnection System Design n Runs under Microsoft Windows on affordable PC's. Software to help identify the parts most suitable for use within the given design constraints and to fit the mating parts, cables, etc. The HarnWare Software Design Wizard analyzes the drawing and lists the parts and operations in the suggested design sequence. The wizard also provides quick access to details on each part in 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 part dimensions, 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. Analysis options to determine the optimum lay of cables containing mixed diameter wires and to suggest the most appropriate wire gauge for specified current and temperature rise limits. 2-7 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) Wire Selection The wire most suited to the particular environment and service conditions is selected using design rules encoded in the HarnWare software and database. If the wire selected is a nonpreferred option, alternative types and colors can be identified which may also suit the design requirements and be available on shorter delivery times. Guidance is also available for choosing the wire gauge most suited to given current loading, ambient temperature, length, number of conductors, etc. For each available wire size HarnWare software estimates temperature rises, operating temperatures and voltage drops. 2-8 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) SK1 60 0 2 480 SK2 500 450 Electrical Interconnection System Design PL1 900 + SK3 WIRE LIST ITEM NO QTY FROM TO PART NO DIA LENGTH 1 2 4 PL1 SK1 44A1121-20-0/9-9 3.76 1800.00 2 2 5 PL1 SK2 44A1121-20-0/9-9 3.76 1668.00 3 1 19 PL1 SK3 44A0111-20-9 1.40 1590.00 SHELL = SK1 A B C D E F G H J WIRE NO SHELL PL1 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. 20 AWG Black 20 AWG White 20 AWG Black 20 AWG White 20 AWG Black 20 AWG White 20 AWG Black SHELL 20 AWG White A B C D E F G H J K L 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 SK2 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 SHELL A B C D E F G H J K SK3 Wire Selection (Continued) From-To connector references are specified to form a point-to-point wiring list. Wiring schematics can be generated automatically from the information included in the wire list. These schematic diagrams show the pin to pin wiring for all the connectors and wires in a harness design. n n HarnWare software automatically: n Traces the route of each wire in the point-to-point wire list through the harness geometry contained in the drawing. n Calculates wire lengths by summing the lengths of the harness legs through which each wire is routed. Adjustments are applied based on a variety of design rules relating to the parts through which wires pass. Determines the cable sub-assembly structure that would save the maximum amount of labor in assembling the harness. diameter and most even construction. In the example below, the listbox contains the quantity of each wire diameter for which HarnWare software has automatically developed 29 alternative design solutions. The minimum diameter alternative is shown which is 17.72 [.698] diameter and uses 2 fillers to achieve a sufficiently round lay. Determines the optimum lay of wires in each harness leg and produces a cable cross-section drawing. Alternative lays of cables containing mixed diameter wires are automatically analyzed to identify the smallest 2-9 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) Part Selection All the parts in a harness can be specified. The key steps in selecting parts include: n n Clicking a shape in the harness drawing or the design wizard. HarnWare software automatically obtains design data and dimensions from the shape and from mating parts in the harness assembly drawing. In the case of a Raychem boot, for example, HarnWare software extracts the required style of boot from the shape and the diameters from the mating harness leg and adapter. n The database is searched for parts suited to the dimensional constraints. The choice is further refined by the service conditions which determine the best materials, finishes and adhesives. When alternative parts are found in the database, 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 different service conditions. Among the parts that HarnWare software helps to select are: n Adapters n Braid n Connectors n Databus couplers, etc. n Feedthroughs n Heat-shrinkable tubing n Marker sleeves* n Molded parts n Adhesives n Solder sleeves n Wire *Tyco Electronics Identification product information available at www.tycoelectronics.com 2-10 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) PARTS LIST ITEM DESCRIPTION PART NUMBER SPEC/REMARKS QTY UNIT 1 Wire 44A0111-20-9 Raychem 30.3 M 2 Wire 44A1121-20-0/9-9 Raychem 15.6 M 3 Filler 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 6 Braid RAY-101-12.5 Raychem 1.2 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 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 20 Adaptor TXR40AB00-1208AI Raychem 21 Adaptor TXR40AB00-1410AI Raychem 22 Adaptor TXR40AB00-2014AI Raychem Pc PL1 1 Pc 1 MATES Pc WITH 1 CPU Pc- SK1 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 29 Solder Device B-051-02-01 Raychem 1 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 2 M Electrical Interconnection System Design PL1 M Pc Pc 22 19 13 9 26 17 34 2 31 30 7 39 32 HARNESS PROPOSAL DRAWING TITLE: Printed 13/03/01, 13:16:41 BRANCHED HARNESS ASSEMBLY 40 CREATOR: D Hammond FILENAME: PicHarn.vsd 13/03/01 DATE: 12 Page 3 of 8 Parts Listing Other Features During the parts listing process HarnWare software automatically: Among the other HarnWare software features and options are: n n n n Extracts part details from the drawing Generates a sorted and totalized parts list table Adds 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: n n n Retain existing item numbers when a design is modified. Include gaps in the item numbering sequence. n n 3D modelling system for visualizing harness designs. HarnWare software automatically 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. Lay-up (nail) board designs. Harness lay-up board design can be modeled with pegs automatically positioned along the harness legs. Drawn output can be used on the lay-up board. Weight calculation. Most components weights are stored in the HarnWare software database and this enables the software to estimate the weight of the harness. Convert part numbers to customer numbers or to VG or other industry standard numbers. 2-11 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) phrases, rather than individual words, are translated in order to achieve more meaningful and grammatically correct results. Other Features (Continued) n n n Labor 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 comparing the cost effectiveness of alternative design solutions. A labor estimate is contained in the attached sample HarnWare software document set. Cable 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. Drawing translator. Drawings can be translated into a number of foreign languages, including French and some Asian languages such as Korean and Japanese. Harnessing n n n Design 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 are all linked to an on-line help system which contains further details on each specific problem. Codes of practice. A list 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. 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. n User parts library for non-standard parts. A database to allow identification and retrieval of regularly used parts. n Multi-core cable database. A database to allow selection of standard or regularly used cables. n Databus module. Software for the design of MIL-C-1553 databus harness assemblies using Tyco Electronics components. n Conduit module. Software for the design of Tyco Electronics conduit harnesses. On-line help system. An extensive on-line help 2-12 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) y ar ts st Mo eff ect ive re fer Pre System Integration Benefits HarnWare software can be linked to many other computer systems using a variety of interfaces including: The five key benefits of using HarnWare software are: n n n n Parts list data can be exported in structured text files suitable for reading by such systems as spread sheets, databases and word processors. Drawings can be imported and exported using industry standard formats such as DXF and IGES. Cable marker data can be transferred to marker printing systems such as Tyco Electronics WinTotal* system. Wiring connectivity data export for test equipment. Electrical Interconnection System Design HarnWare Software co st n 2 ter Fas Ensures com pa tib ilit More detailed dp 1) More detailed and accurate design. 2) Up to 20 times faster design and quotation. 3) Preferred part selection, to ensure best delivery and price. 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. *Tyco Electronics Identification product information available at www.tycoelectronics.com 4) More cost effective design. 5) Ensures parts are compatible with the intended service conditions and with mating parts. Hundreds of users around the world can confirm the benefits of using HarnWare. X, Y coordinates of nail positions on lay-up (nail) board for NC drilling. 2-13 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) 1 2 3 SERVICE DRAWING NO./RAYCHEM DRAWING NO. 3 SHEET NO OF 4 5 6 7 0 1 8 8 50 9 100 150 10 11 200 12 13 OF 3 11 4 8 9 100 10 150 11 200 12 13 14 250 250 MILLIMETRES FULL SIZE SK1 A B B 24 60 0 2 2 SHELL 2 18 35 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. SK1 CABLE SECTION C 38 40 8 SK2 MATES WITH BOX 1 - PL2 A-A CABLE SECTION 28 27 14 7 25 21 13 30 31 4 2 SK2 500 D 29 27 A 15 14 450 7 50 20 11 MAIN MARKER ISSUE # SERIAL No. 6 0 - A 9 5 6 6 PL1 MATES WITH CPU - SK1 5 3rd ANGLE PROJECTION UNCLASSIFIED USED ON SK1 31 30 13 PL1 CABLE SECTION 4 1 8 SECURITY CLASSIFICATION 40 37 250 MILLIMETRES FULL SIZE 1 SHEET NO HBJC4/37-18/18652K 14 250 3rd ANGLE PROJECTION UNCLASSIFIED - A B C D E F G H J 2 HBJC4/37-18/18652K USED ON SHELL 1 SERVICE DRAWING NO./RAYCHEM DRAWING NO. SECURITY CLASSIFICATION 1 ITH 1 SK S W PL E AT 1 M OX B General Assembly, Wiring Schematic, Parts List, Labor Estimate, Marker Sleeve and Codes of Practice Pages 480 PL1 PL1 17 35 E A MA SK3 TE BO S WI X1 TH - PL 3 5 2 F 20 AWG Black 20 AWG White 20 AWG Black 20 AWG White 20 AWG Black C 20 AWG White 20 AWG Black SHELL 20 AWG White A B C D E F G H J K L 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 D SK2 20 AWG White 20 AWG White E 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White F 20 AWG White 19 13 22 9 26 17 34 34 17 20 AWG White 24 8 2 20 AWG White 12 31 30 20 AWG White 3 20 AWG White 10 7 20 AWG White 39 32 20 AWG White 40 1 23 900 9 20 AWG White SK2 CABLE SECTION 12 33 16 G 20 AWG White G 7 19 31 36 Q.C. APP'D 9 SK3 CABLE SECTION Q.C. APP'D - A B C D E F G H J K - H TECH APP'D SK3 45 SK3 - - PRODAPP'D CERTIFIED UNCONTROLLED COPY,CHECK REVISION BEFORE USE CHECKED - THIS DRAWING IS C.A.D. GENERATED AND MUST NOT BE MODIFIED MANUALLY DRAWN D.E.H. 1 17.06.99 --- - ISSUE DATE CHANGE NO CHK'D ISSUE DATE CHANGE NO CHK'D ISSUE DATE CHANGE NO CONTINUITY AND INSULATION RESISTANCE TESTS SHALL BE IN ACCORDANCE WITH MVEE 773 SECTIONS 7.1.2, 7.1.3 AND 7.1.4. CHK'D N.T.S. SCALE (ORIGINAL) DRAWING TO BE READ IN CONJUNCTION WITH B.S.308 AND DEF. STAN. 05-10 - TITLE 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 N.S.N. CERTIFIED - UNCLASSIFIED K 1 0 HARNESSING SYSTEMS CHENEY MANOR INDUSTRIAL ESTATE, SWINDON MOD ESTABLISHMENT/CUSTOMER 1 0 RAYCHEM DRAWING NO. HBJC4/37-18/18652K SERVICE DRAWING NO. - SHEET NO OF 1 8 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 SHEET NO OF - UNCONTROLLED COPY,CHECK REVISION BEFORE USE CHECKED - THIS DRAWING IS C.A.D. GENERATED AND MUST NOT BE MODIFIED MANUALLY A 2 78 79 80 N.T.S. SCALE (ORIGINAL) DRAWING TO BE READ IN CONJUNCTION WITH B.S.308 AND DEF. STAN. 05-10 SECURITY CLASSIFICATION DRAWN 1 1 H - RESPONSIBLE AUTHORITY BRANCHED HARNESS ASSEMBLY DIMENSIONS IN MILLIMETRES 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. SHELL TECH APP'D PRODAPP'D 17.06.99 --- CONTINUITY AND INSULATION RESISTANCE TESTS SHALL BE IN ACCORDANCE WITH MVEE 773 SECTIONS 7.1.2, 7.1.3 AND 7.1.4. - D.E.H. ISSUE DATE CHANGE NO CHK'D ISSUE DATE CHANGE NO CHK'D ISSUE DATE CHANGE NO CHK'D >50 - <=50 >50 - <=150 >150 - <=300 >300 - <=1000 >1000 - <=2000 >2000 - <=4000 >4000 ANGULAR +5 +10 +15 +25 +50 +75 +100 5 DESCRIPTION SPEC/REMARKS QTY UNIT Wire 44A0111-20-9 Raychem 30.3 M 2 Wire 44A1121-20-0/9-9 Raychem 15.6 M 3 Filler 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 6 Braid RAY-101-12.5 Raychem 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 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 1.2 M 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 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 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 202K163-25/225-0 Raychem MS27488-20 - Element Time (mins) Unpack Check Kit Cut EPD to Length Jacket Stripping for Con. Ends Remove EPD Jacket Identify Wires Strip/Crimp/Insert 15 1 5 5 1.3 2.5 Qty / Length Total mins UNCLASSIFIED K 1 0 1 0 RAYCHEM DRAWING NO. HARNESSING SYSTEMS HBJC4/37-18/18652K CHENEY MANOR INDUSTRIAL ESTATE, SWINDON MOD ESTABLISHMENT/CUSTOMER SERVICE DRAWING NO. 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 SHEET NO OF 1 8 SHEET NO OF - A 78 79 80 per end per metre per wire per cont. 4 20 0 60 50 0 78 125 Solder Wires Up to 16AWG (Tin/Strip/Insulate) 14 to 12AWG (Tin/Strip/Insulate) Power Cable 3.5 per term 10 35 5 per term 0 0 15 per term 0 0 Lugs Crimp Lugs Solder 10 per term per term 0 0 15 0 0 0.5 0.75 per wire per wire 60 0 30 0 Pc 20 Pc Repair Loops Up to 55 Way Con. Above 55 Way Con. Soldertact 4 3 6 per term per term per term 0 0 14 0 42 0 Insulating Screens Filler Plugs 2 1 per term per f/plug 4 20 8 20 Spare Wires 0.5 per wire 18 9 Ring Tags Crimp Ring Tags Solder RF one-step 2 2.5 8 per term per term per term 0 0 0 0 0 0 Adaptors (includes Braid Term / Torque) Spin Coupling Braided Adaptor Tinel Whipping/Soldering 7.5 12 10 5 0 0 4 0 0 0 40 0 per metre per metre per metre per metre } Enter } 0 for No }1 for Yes 0 1.50 1.43 0 0 0 0 0 10.5 14.3 0 0 0 0 per metre 2.93 5.86 per term per term per term per term 4 7 10 15 0.25 -.25 -.25 Tubing Installation on Multi-Leg Harness 2 0 0 0 0 0 0 Standard 11 to 42 52 to 63 74 85 12 15 20 25 per piece per piece per piece per piece 2 2 0 0 24 30 0 0 Uniboot 611 to 621 632 to 642 653 to 663 10 12 15 per piece per piece per piece 0 0 0 0 0 0 KTKK Small Medium Large 5 6 7 per piece per piece per piece 0 0 0 0 0 0 3 Outlets 11 to 19 22 to 48 56 to 91 4 Outlets 11 to 19 22 to 48 56 to 91 5 Outlets 11 to 19 22 to 48 56 to 91 Viton +50% Precoated -25% Potting +50% Packing Piece/Ext. Atum/Htat Straight Branch Transition Overlap Bandage 3.5 5 8 33 Protection Cap Installation Marker Sleeves Protection Sleeves Wire Cutting Qty / Length Total mins 16 20 23 per piece per piece per piece 0 2 0 0 40 0 21 25 29 per piece per piece per piece 0 0 0 0 0 0 25 per piece 28 per piece 33 per piece .50 } Enter -.25 } 0 for No .5 } 1 for Yes 5 per piece per piece 3 0 0 0 0 1 0 3 0 0 0 0 0 -23.5 0 15 0 per metre per metre per piece per piece 0 2.93 2 0 0 14.65 16 0 5 per piece 0 0 4 1 per piece per piece 5 5 20 5 1 per wire 37 37 Unravel / Count Cut Wires Wire Layup Legs <=4 Metres < 20 wires 20 - 30 wires >30 wires Legs >4 Metres < 20 wires 20 - 30 wires > 30 wires per piece per piece per piece Raybraid / Install Tubing DR25 < 1/4 1/4 to 1/2 3/4 to 1 1 1/2 + Viton, VPB +25% ZHTM -25% CGPT & Versafit Time (mins) 17 25 30 Transitions Screen Termination Individual Term. Coaxial Term. Element Rayaten 121 to 142 152 to 163 174 Moulded Parts 0 0 0 0 per kit per metre M 20 Filler Plug SECURITY CLASSIFICATION - LABOUR ESTIMATE PART NUMBER 1 40 3 N.S.N. Wiring Schematic PARTS LIST ITEM 2 - BRANCHED HARNESS ASSEMBLY TOLERANCES,UNLESS OTHERWISE STATED 1 General Assembly RESPONSIBLE AUTHORITY TITLE DIMENSIONS IN MILLIMETRES 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. Common Size Mixed Sizes 1 1.5 2 27.38 12.60 0 27.38 18.9 0 1.5 2 2.5 0 0 0 0 0 0 Enter 1 to add 30% for mixed wire sizes 0.1 0.3 per wire per wire 37 0 3.7 0 Enter 1 to add 5% allowance for QC Special Requirements (mins) Total Labour Time (mins) 0 0 679.67 Total Labour Time (hours) 11.33 Labour rate per hour Total Labour Cost 1 0.00 0.00 Enter 1 to Add Allowances for Prototypes: HARNESS PROPOSAL DRAWING 20% for Straight or Branched < 4 Ends 0 35% for Branched 4+ Ends 0 BRANCHED HARNESS ASSEMBLY TITLE: Printed 13/03/01, 13:16:41 CREATOR: D Hammond FILENAME: PicHarn.vsd DATE: 13/03/01 Page 3 of 8 MARKER PAGE Printed 13/03/01, 13:16:41 HARNESS PROPOSAL DRAWING TITLE: BRANCHED HARNESS ASSEMBLY CREATOR: D Hammond FILENAME: PicHarn.vsd 13/03/01 DATE: Page 5 of 8 CODES OF PRACTICE, FAX-ON-DEMAND AND DRAWING NOTES PL1 MATES WITH CPU - SK1 SK1 MATES WITH BOX 1 - PL1 Item:34 Quantity:1 Part Number:TMS-SCE-1-2.0-4 Colour:Yellow Font:10 cpi Standard Item:35 Quantity:1 Part Number:TMS-SCE-3/4-2.0-4 Colour:Yellow Font:10 cpi Standard MAIN MARKER ISSUE # SERIAL No. SK2 MATES WITH BOX 1 - PL2 Item:34 Quantity:1 Part Number:TMS-SCE-1-2.0-4 Colour:Yellow Font:10 cpi Standard Item:35 Quantity:1 Part Number:TMS-SCE-3/4-2.0-4 Colour:Yellow Font:10 cpi Standard Codes of Practice: Code Description 251 End stripping primary wire and cable Stripping wire and cable jackets 254 256 Laying hand laid sections of harnesses Applying Kevlar binder to hand-laid sections of harnesses 257 261 Preparing shielded and jacketed wire 301 Looping wire gauges 18 and below Terminating a primary wire to a cable shield using a solder sleeve with a pre-installed lead 368 361 Applying a single layer of braid to a hand laid cable Terminating overall shields formed by single layers of braid at a transition 363 551 Installing heat shrinkable tubing Preparing cable jackets for the installation of pre-coated tubings 610 Installing Tinel-Lock rings with a resistance heater 359 366 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 SK3 MATES WITH BOX 1 - PL3 Item:33 Quantity:1 Part Number:TMS-SCE-1/2-2.0-4 Colour:Yellow Font:10 cpi Standard HARNESS PROPOSAL DRAWING TITLE: Printed 13/03/01, 13:16:41 HARNESS PROPOSAL DRAWING BRANCHED HARNESS ASSEMBLY CREATOR: D Hammond FILENAME: PicHarn.vsd DATE: TITLE: 13/03/01 Page 6 of 8 Printed 13/03/01, 13:16:41 BRANCHED HARNESS ASSEMBLY CREATOR: D Hammond FILENAME: PicHarn.vsd DATE: 13/03/01 Page 8 of 8 2-14 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 2 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries 2 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, heatshrinkable components, and adhesives. Performance of these parts is assured because all components are tested separately and as part of an assembled system (see photo top left). 1. Primary wire and cable 2. Heat-shrinkable tubing 3. Backshell adapter 4. Molded part 5. Adhesive 6. Cable jacket 7. Marker sleeve* Military harness system components. Additional components for harnessing systems include the following: n n n n A typical designed harness consists of seven component parts (pictured at right): Electrical Interconnection System Design Assembled military harness. A wide range of special devices, such as SolderSleeve devices for primary wire interconnection. A selection of electrical shielding (screening) options, including braids and termination assemblies. Multiconductor (multicore) cables. Specialty adhesives and sealants for complete environmental sealing.** Table 1 on the next page serves as both a summary of Raychem products for specific harnessing systems and a selection table for harnessing system components. An explanation 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 2-15 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Table 1. Raychem Harnessing Systems and Their Components Components Wire System 10 System 20 System 25 System 30 System 100 System 200 System 300 44 44 44 55 99, 100A, 100G 55 55 ZHTM Viton(R) RT555 Versafit NT-FR DR25 VPB Tubing Adapter material and plating finish chosen for compatibility with the connectors. Molded part -3, -4, -71 -51 -25 -50 -100 -12 -55/-125 -35 -- -25S -- -100S -- -- S1017, S1030 S1124, S1048 S1048, S1125 S-1125, S-1255-04 S1030, S1125, S1125, S1255 S1255-04 /42, /180 -- /164,/86 -- /86, /225 S1184 -- -- /180 S1184 -- -- -- -- Cable jacket Thermorad NT-FR Viton(R) RT555 Marker sleeve* TMS-SCE HT-SCE HT-SCE Preinstalled Rayaten molded part Adhesive Precoated adhesive Conductive adhesive FDR-25 Thermorad Zerohal VPB TMS-SCE TMS-SCE TMS-SCE HX-SCE *Tyco Electronics Identification products information available at www.tycoelectronics.com. 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 adhesive 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. Step 1. Select the Material System. Detailed in Table 2 on the next page are the major material systems for use in a wide range of operating conditions and environments. Choose a material system that: n n Has the physical characteristics your harness requires. Will accommodate the operating temperature and the fluids and abuse to which the harness will be exposed. Each step is described on the pages that follow. A selection table accompanies each step. You can also use HarnWare software to design your harness. VITON is a trademark of Dupont Dow Elastomers LLC 2-16 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Table 2. Material System Selection Operating temperature Physical characteristics Flammability Typical applications Operating temperature Physical characteristics Flammability System 20 -55C to +121C [-67F to +250F] * Environmentally sealed * Tough * Flexible * Low profile * Flame-retarded * Self-extinguishing * Resists most commonly used military fuels, oils, and greases * Used in high-performance industrial applications, and in military communication and test equipment. * Specially suited to military vehicles and engine compartments, low profile shapes save space and weight. System 25 -75C to +150C* [-103F to +302F] * Environmentally sealed * Rugged * Abrasion-resistant * Very flexible * Flame-resistant * Self-extinguishing * Resists most common military fuels, oils, and greases. up to 70C [158F]. * Specially suited to military vehicles, aerospace and marine applications, and communication and test equipment. System 30 System 100 System 200 -55C to +150C [-67F to +302F] * Environmentally sealed * Tough * Flexible * Low profile -30C to +105C [-22F to +221F] * Environmentally sealed * Flexible -55C to +200C [-67F to +392F] * Environmentally sealed * Very flexible * Flame-retarded * Self-extinguishing Fluid resistance * Resists most of commonly used military fuels, oils, and greases. Typical applications * Specifically suited to military vehicles and engine compartments for higher temperature applications, low profile shapes save space and weight. * Low toxicity index (as defined by NES-13) * Low smoke emission (as defined by NES-711) * Low corrosive gas evolution * Resistant to a range of military fuels, oils, and greases. * Specially suitable for confined habitat areas in military and civil applications. * Extensively used in surface and submarine vessels and underground railways * Highly flame-retardant * Resists long-term immersion in military fuels, oils, and greases at elevated temperatures. Used where there is prolonged exposure to high temperatures. Used where a harness may be permanently immersed in difficult fuels, such as in fuel tanks. * * 2 Electrical Interconnection System Design Fluid resistance System 10 -20C to +60C [-4F to +140F] * Environmentally sealable * Lightweight * Small diameter * Flexible * Flame-retardant * Self-extinguishing * Resists common industrial and military cleaning solvents and degreasers. System 300 Operating temperature -55C to +200C [-67F to +392F] Physical characteristics * Environmentally sealed * Highly abrasion resistant * Low profile Flammability * Highly flame-retardant Fluid resistance Typical applications * Performs in aggressive fluids at extremely high temperatures * Permanent immersion in aggressive fluids *Per VG 95343. 2-17 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Raychem Harnessing Systems and Their Components -- NBC Survivable Systems* w NeProduct System System 780 770 44 55 Wire RT-770 RT-780 Tubing -770 -780 Molded part S-1264 S-1255-04 Adhesive RT-375 RT-375 Marker sleeve cover Marker sleeve** TMS-SCE NBC-SCE **Tyco Electronics Identification products information available at www.tycoelectronics.com. Components System 790 55 RT-790 -790/-791 S-1255-04 RT-375 NBC-SCE 2005 Material System Selection Operating temperature Physical characteristics Flammability Fluid resistance Typical applications Adhesive Selection System 770 -55C to +125C [-67F to +257F] * Environmentally sealed * NBC resistant * Flexible * Flame retarded * Self-extinguishing * Resistant to NBC uptake and decontamination * Base-line system for NBC resistant applications System 780 -65C to +175C [-85F to +347F] * Environmentally sealed * NBC resistant * Flexible * Flame retarded * Self-extinguishing * Resistant to NBC uptake and decontamination * High temperature system for NBC resistant applications System 790 -65C to 200C [-85F to +392F] * Environmentally sealed * NBC resistant * Flexible * Flame retarded * Self-extinguishing * Resistant to NBC uptake and decontamination * Extreme high temperature system for NBC resistant applications Material System System 770 Adhesive Type Two-part Epoxy Component Adhesive S-1264 Precoated Adhesive Designation -- Service Temperature 150C System 780 Thermoset tape S-1255-04 -- 200C System 790 Thermoset tape S-1255-04 -- 200C *Under Development - contact Tyco Electronics for additional information 2-18 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Step 2. Select the Adhesive System. Two types of adhesives are used to bond heat-shrinkable boots and transitions to tubing or wire jacketing: n n Thermosets, which include epoxies and other two-part systems. 2 Electrical Interconnection System Design Thermoplastics, 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 thermoplastics. Table 4 shows which adhesive type is appropriate for each harness material system. Table 3. Comparison of Adhesive Types Method of adhesion Application Cure time Strength Disassembly Repair/reassembly Table 4. Adhesive Selection Thermoset Cures through chemical reaction. Two-part types require mixing and application at assembly. Varies with cure temperature. Oven cure usually desirable. Retains most strength at elevated temperatures. Items can be forcibly peeled apart when heated sufficiently. Requires new adhesive or hot rollback to reenter behind connector without affecting adhesive bonds. Material System Adhesive Type System 10 Thermoplastic System 20 System 25 System 30 System 100 System 200 Thermoplastic Component Adhesive S-1030 Thermoplastic Melts, flows, and solidifies. Precoated types require no preparation at assembly. Not required. Adhesive functional when cooled to room temperature. Loses strength as melt temperature is approached. Items can be separated when heated to temperature of the adhesive. Can be reheated to form new bond if sufficient adhesive remains. Precoated Adhesive Designation /180 Service Temperature 80C S-1017 /42 60C S-1124 /164 105C S-1048 /86 120C Thermoplastic S-1048 /86 120C Two-part thermoset S-1125 /225 150C Thermoset Tape S-1255-04 -- 200C 150C Two-part thermoset Thermoplastic S-1125 -- S-1030 /180 80C S-1048 /86 120C Two-part thermoset S-1125 -- 150C Two-part thermoset S-1125 -- 150C Thermoset tape S-1255-04 -- 200C System 300 Thermoset tape S-1255-04 -- 200C System 770 -- S-1264 -- -- System 780 Thermoset tape S-1255-04 -- 200C System 790 Thermoset tape S-1255-04 -- 200C 2-19 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Step 3. Determine the Level of EMI Shielding Required. Tyco Electronics offer several methods and technologies for controlling electromagnetic interference (EMI) and noise in cable harnesses. Developed in response to well-established 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 practices. 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 susceptibility be obtained. The chosen level of shielding will be dependent on the: n n n n n Susceptibility of electrical system. 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 component characteristics. Components should only be used if they are qualified to a minimum level of EMI performance and the performance 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 system performance against EMI. All components form part of the external shield on the system and therefore should be considered in the overall EMI design process. Subjects covered in this topic are: n n Harness Types - point to point and branched Shielding Levels calculations Types of components used. Harness Types Harnesses are divided into two types, point-to-point and branched. The advantages and disadvantages of each from an EMI control standpoint are described below. No attempt has been made to analyze their relative merits in mechanical or installation terms. Point To Point: The three major components 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 consistency of performance. In the case of machine made cables all shields should be designed for optimum shielding effectiveness at radio frequency. Physical layout of the system. Equipment practices adopted. Anticipated EMI threat. 2-20 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Transitions Connector accessories, such as Raychem adapters, are available in many styles and therefore their performance varies with construction. For a level of consistency in performance it is essential that, as with connectors, a guarantee in performance level be achieved. Fittings not specified in this way may significantly degrade the overall system performance. Transitions, as with accessories, are very susceptible to performance variability with construction type. Branched In addition to those components described above, branched harnesses include transitions. This type of harness is usually made by hand and it is therefore difficult to incorporate 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 optimization depends on all the constructional parameters of the braid being accurately specified, unless braid is well constructed the shielding performance can suffer dramatically. Reductions in shield performance of 20-40 dB have been measured on badly made branched harnesses. The alternative method is to use pull on braids. If the cable bundle diameter is known the braid may be designed for optimized performance. For high performance harnesses these components should also have a guaranteed performance. In general the use of techniques such as hand soldering or the use of butted tape wraps are not recommended except where only a low performance of less that 40dB is required. Shield performance is specified in two ways, either as a power relationship 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. 2 Electrical Interconnection System Design Connector Accessories Shielding Levels and Component Performance System Performance To specify the overall requirements of a complete electronic system in terms of its EMI characteristics it is necessary to consider the performance of the individual components parts. The harnesses form one of the major entry points for interference and this as such can degrade a complete system performance by a significant amount. In general 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. n n n n n 40 to 50 dB Standard shielded systems for insensitive systems. 50 to 60 dB Military standard shielded systems for general applications. 60 to 80 dB As above but where full threat EMP & TEMPEST protection is required. 80 to 100 dB Severe TEMPEST and very sensitive systems. Over 100 dB Exceptional shielding requirements only. 2-21 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Safety Margins Connectors As with all designs EMI system design should not be performed to the "limit of performance safety margin should always be incorporated when determining the minimum shielding level appropriate for consistent operation of the system. A study 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 as dictated 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. The inter-relationship of shielding effectiveness measured in decibels and the surface transfer impedance in ohms presents the designer with a conversion difficulty. External harness circuits vary, as do the coupling characteristics and it is therefore only possible to give an approximate conversion. The normal conversion from decibels to ohms and vice versa is to a reasonable approximation: Screening Effectiveness (dB) = 36 - 20 log 10 (ZT (Ohms)) The constant term is developed from the expressions for the characteristic impedance of the line formed by the harness shield and the ground plane and the internal characteristic impedance of the inside of the harness. The translation from shielding effectiveness to surface transfer impedance is shown below in Table 5 for S.E. from 20 to 105dB. Table 5 - Screening Effectiveness (SE)/Surface Transfer Impedance (Zt) Relationships S.E. (dB) ZT (ohms) S.E. (dB) ZT (ohms) 20 25 30 35 40 45 50 55 60 6.309 3.548 1.995 1.122 0.631 0.355 0.200 0.112 0.063 65 70 75 80 85 90 95 100 105 0.0355 0.0200 0.0112 0.0063 0.0036 0.0020 0.0011 0.0006 0.0004 2-22 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Connector Accessories and Transitions In constructional terms the performance of the connector 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 performance is extremely variable as accessories have to fit a variety of different cable sizes and shapes. Where specified at all the relationship between the test method and the coupling mechanism for the EMI must be considered. Table 6 - Cable Performances Type of Screen Single optimized braid Double optimized braid Superscreened (2 braids + 1 wrap) 2 Electrical Interconnection System Design 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 penetration characteristic. For frequencies above or below 30Mhz, approximations, as for connectors, must be made. It should be noted that the performance specified at 30MHz in Table 6 for different cable types is the maximum that is allowed using Tyco Electronics' standard Q.C. values. Actual performance may be up to 20dB better. Diameter under screen Surface transfer Impedance Zt (mm) Up to 7.5 7.6 and up Up to 7.5 7.6 and up Up to 7.5 7.6 and up @ 30 Mhz (maximum) 100 milli ohms/metre 50 milli ohms/metre 10 milli ohms/metre 5 milli ohms/metre 100 micro ohms/metre 50 micro ohms/metre 2-23 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Connector Terminator Splice Transition Feedthrough Cable Braid Complete Harness When considering the complete harness the coupling calculations are relatively simple. In general terms they are the 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 determined 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 more complex subject and not discussed here. System improvements may be achieved by changing 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 considered to determine the true weighting effect. For the optimum in system design a balance of component performances should be achieved wherever possible such that each of the components is of similar performance level. General Considerations Although cables and harnesses are considered to be the most significant in terms of coupling into systems the construction of equipment boxes can play an important part in the overall EMI performance of a system. With the increasing use of high speed digital circuits and the generation of harmonics having high energy content relatively short printed circuit board tracks can radiate or pick up energy as efficiently as cables. If the boxes themselves 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. 2-24 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Table 7 - Screen System Guide Adapter Styles Harness System Components Termination Cable Braid (max. length in m/ft) TinelRayaten (by cable construction) Lock Assembly SO DO SSS System NO Connector <60 dB VG95328 VG95234 n n n -- 60 to 80 dB MIL-C-26482 Series 2 VG96912 Series 1 -- -- n -- -- <2/6.5 >80 dB MIL-C-38999 -- -- -- n -- -- Band Strap Braided <2/6.5 15/49 100/328 Transition Splice Feedthrough SolderSleeve device Tinel or solder devices SolderSleeve device Tinel or Rayaten assembly SolderSleeve device Tinel or Rayaten assembly DSS -- -- 7/22.9 100/328 -- <0.5/1.6 50/164 65/213 Shield tape & SolderSleeve device Shield tape & SolderSleeve device Not recommended 2 Electrical Interconnection System Design Shielding Level Required 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 Wire and Cable . . . . . . . . . . . . . . . . . . . . . . .Section 9 Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 6 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . .Section 7 Electrical Interconnect Products . . . . . . . . . .Section 8 Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 3 2-25 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Engineering Notes 2-26 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heat-Shrinkable Tubing Table of Contents 3 Heat-Shrinkable Tubing Note: Users should independently evaluate the suitability of the product for their application. Before ordering, check with Tyco Electronics for most current data. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 Tubing Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 Tubing Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4, 3-5 Specification Cross-Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 Single Wall Tubing Brightly colored, shiny, non-flame-retardant polyolefin tubing .3-7, 3-8 CGPE-105 CGPT General purpose, flame-retardant, polyolefin tubing . . . . . . . .3-9, 3-10 Semirigid, flame-retardant, polyolefin tubing . . . . . . . . . . . . .3-11, 3-12 CRN 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 Flexible, dual wall, moisture proof, RPPM heat-shrinkable tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45, 3-46 SCL Semirigid, encapsulant-lined, polyolefin tubing . . . . . . . . . .3-47, 3-48 Flame-retardant, adhesive-lined, semirigid polyolefin, SCT heat-shrinkable tubing (extended temperature range) . . . . .3-49, 3-50 TAT-125 Adhesive-lined, flexible polyolefin tubing . . . . . . . . . . . . . . .3-51, 3-52 Heavy Duty Tubing General purpose, heat-shrinkable tubing . . . . . . . . . . . . . . .3-53, 3-54 BSTS/BSTS-FR HF High-flex, heavy-wall, heat-shrinkable tubing . . . . . . . . . . . .3-55, 3-56 High-ratio, heat-shrinkable tubing . . . . . . . . . . . . . . . . . . . . .3-57, 3-58 HRHF/HRNF/ HRSR RHW Rugged, heavy wall, adhesive-lined, polyolefin heat-shrinkable tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-59, 3-60 Medium wall, polyolefin heat-shrinkable tubing . . . . . . . . . .3-61, 3-62 RMW SST/SST-FR Self-sealing, heat-shrinkable tubing . . . . . . . . . . . . . . . . . . .3-63, 3-64 3-1 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heat-Shrinkable Tubing Table of Contents (Continued) Special Purpose Tubing Heat-shrinkable, flexible, chemical and abrasion DR-25 resistant tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65, 3-66 ES Caps High-shrink-ratio, adhesive-lined, semirigid polyolefin caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-67, 3-68 Helical convolex tubing with a high crush resistance . . . . . .3-69, 3-70 HCTE HFT5000 Heat-shrinkable fabric tubing . . . . . . . . . . . . . . . . . . . . . . . .3-71, 3-72 Small-diameter, high-shrink-ratio tubing . . . . . . . . . . . . . . . .3-73, 3-74 MicroFit 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 temperature range . .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 Highly flexible, silicone rubber tubing . . . . . . . . . . . . . . . .3-111, 3-112 SRFR TFE and TFE-R High-temperature, chemically inert, modified tubing made of Teflon(R) Fluoropolymer . . . . . . . . . . . . . . .3-113, 3-114 Viton(R)/Viton(R)-HW/ Heat-shrinkable, chemical-resistant, high-temperature tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-115, 3-116 Viton(R)-E/ Viton(R)-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 3-2 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heat-Shrinkable Tubing Overview Tyco Electronics Raychem brand of tubing was developed 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. environmental damage. Encapsulants protect connections and components from splashes and corrosion. Adhesives go a step further, sealing to plastic, metal, rubber, or other substrates. 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 You can choose from tubings that are highly flexible or semirigid, designed for operation in high- or lowtemperature environments, and halogen-free and flame-retardant to meet a range of industry standards. 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. A range of automatic and semi-automatic installation equipment is available for high-volume applications. 3 Heat-Shrinkable Tubing 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. Tubing Categories Product Name Type Single Wall Dual Wall Very Flexible Flexible LSTT Versafit CGPE-105 CGPT DCPT Versafit V2 Versafit V4 RNF-100 RNF-3000 RP-4800 Semirigid CRN RT-3 Semi-flexible ATUM DWP-125 Flexible RPPM TAT-125 Semirigid ES1000 ES2000 FL2500 SCL SCT BSTS HF HRHF/HRNF/HRSR RMW RHW SST Elastomers DR-25 NT NT-MIL NTFR Viton(R)-E Viton(R)-TW Fluoropolymers RNF-150 RT-375 SFR SRFR Viton(R) Viton(R)-HW RT555 RW-175 Medical-grade MT1000 MT2000 MT3000 MT5000 MicroFit MFT-RW-175 MFT-MT1000 Caps ES Caps PD Caps Conduit HCTE Kits RayBlock 85 RayBlock 105 Low toxicity XFFR ZH-100 ZHTM Edging material Rayrim Fiber and fabric HFT5000 Braid RF-PET RF-PFR RF-PETM Heavy Duty Special Purpose TUGA HTAT TFE and TFE-R MFT-MT2000 VITON is a trademark of Dupont Dow Elastomers LLC 3-3 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heat-Shrinkable Tubing Min. full recovery temperature (C) [-40 to 257] [-67 to 275] [-22 to 257] [-22 to 257] 65 70 70 70 110 90 90 90 2:1 2:1 2:1 2:1 -70 to 105 -40 to 135 -55 to 135 -55 to 135 -55 to 135 -55 to 135 -55 to 125 -55 to 135 -55 to 135 -55 to 110 [-94 to 221] [-40 to 275] [-67 to 275] [-67 to 275] [-67 to 275] [-67 to 275] [-67 to 257] [-67 to 275] [-67 to 275] [-67 to 230] 85 80 95 95 80 95 85 110 110 80 110 120 120 121 120 121 110 135 135 110 -40 to 110 -55 to 125 -40 to 85 -55 to 110 -40 to 130 -40 to 130 -40 to 135 -55 to 110 -40 to 150 -55 to 90 -55 to 90 -55 to 90 -55 to 110 -55 to 110 -55 to 90 -75 to 150 -55 to 90 -70 to 121 -70 to 121 -75 to 180 -75 to 200 -40 to 200 -40 to 200 -55 to 200 -40 to 200 -55 to 150 -55 to 150 -65 to 200 -55 to 175 -67 to 250 [-40 to 230] [-67 to 257] [-40 to 185] [-67 to 230] [-40 to 266] [-40 to 266] [-40 to 275] [-67 to 230] [-40 to 302] [-67 to 194] [-67 to 194] [-67 to 194] [-67 to 230] [-67 to 230] [-67 to 194] [-103 to 302] [-67 to 194] [-94 to 250] [-94 to 250] [-103 to 356] [-103 to 392] [-40 to 392] [-40 to 392] [-67 to 392] [-40 to 392[ [-67 to 302] [-67 to 302] [-85 to 392] [-67 to 347] [-89 to 482] 80 80 60 95 110 110 110 125 110 90 80 80 110 110 90 150 90 90 90 135 135 100 100 100 100 110 125 150 155 330 125 110 80 121 135 135 135 135 135 121 121 121 125 125 121 175 135 135 135 175 175 175 175 175 175 150 150 220 175 340 -55 to 175 -40 to 105 -55 to 150 -70 to 105 -55 to 175 -55 to 125 -40 to 105 -40 to 105 -55 to 110 -55 to 200 -40 to 85 -40 to 105 -55 to 105 -30 to 105 -30 to 105 -55 to 80 -40 to 125 -50 to 150 -50 to 150 -50 to 150 [-67 to 347] [-40 to 221] [-67 to 302] [-94 to 221] [-67 to 347] [-67 to 257] [-40 to 221] [-40 to 221] [-67 to 230] [-67 to 392] [-40 to 185] [-40 to 221] [-67 to 221] [-22 to 221] [-22 to 221] [-67 to 176] [-40 to 257] [-58 to 302] [-58 to 302] [-58 to 302] 155 110 110 90 155 155 110 100 125 N/A 80 80 70 80 80 120 80 N/A N/A N/A 175 140 150 110 175 175 140 135 135 N/A 110 110 121 120 121 150 110 N/A N/A N/A 2:1 2:1 2:1 2:1 3:1 4:1 2:1 2:1 2.5:1 3:1 4:1 3:1 4:1 4:1 2:1 4:1 4:1 4:1 3:1 4:1 3:1 3:1 5.6:1 3:1 3:1 3:1 2:1 2:1 2:1 2:1 1.75:1 1.5:1 2:1 2:1 2:1 2:1 2:1 2:1 2:1 2:1 1.8:1/ 3.2:1 2:1 2.5:1 2:1 2:1 2.5:1 2.5:1 2.5:1 4:1 3:1 N/A 4:1 4:1 3:1 2:1 2:1 N/A 2:1 N/A N/A N/A Shrink ratio Min. shrink temperature (C) -40 to 125 -55 to 135 -30 to 125 -30 to 125 Operating Temperature C / [F] Elastomer Fluoropolymer Polyolefin Tubing Selection Guide PRODUCT Single Wall Very flexible Flexible Semirigid Dual wall [adhesive-and encapsulant-lined] Semiflexible Flexible Semirigid Heavy Duty Special Purpose Elastomers Fluoropolymers Medical-grade MicroFit Caps Conduit Kits Low Toxicity Edging Matl Fiber & Fabric Braids 3-4 l LSTT Versafit Versafit V2 Versafit V4 l l l l CGPE-105 CGPT DCPT RNF-100 RNF-3000 RP-4800 TUGA CRN RT-3 ATUM l l l l l l l l l DWP-125 HTAT RPPM TAT-125 ES1000 ES2000 FL2500 SCL SCT BSTS HF HRHF/HRNF/HRSR RHW RMW SST DR-25 NT NT-MIL NTFR SFR SRFR Viton(R) Viton(R)-HW Viton(R)-E Viton(R)-TW RNF-150 RT-375 RT555 RW-175 TFE and TFE-R MT1000 MT2000 MT3000 MT5000 MFT-RW-175 MFT-MT1000 MFT-MT2000 ES Caps PD Caps HCTE RayBlock 85 RayBlock 105 XFFR ZH-100 ZHTM Rayrim HFT5000 RF-PET RF-PFR RF-PETM l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l *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. Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heat-Shrinkable Tubing UL D486** ABS USP Class VI MIL Spec* VW-1 (UL/CSA) CSA UL 224 Flameretardant Clear Colored Size range (inside diameter as supplied) Tubing Selection Guide (Continued) DESCRIPTION l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l Brightly colored, general purpose polyolefin General purpose, flame-retardant polyolefin Green and yellow striped polyolefin High-performance flexible polyolefin 3:1 shrink ratio general-purpose polyolefin 4:1 shrink ratio polyolefin Brightly colored, tough polyolefin Flame-retardant polyolefin Semirigid polyolefin for terminal insulation 3:1 and 4:1 shrink ratio adhesive-lined polyolefin l l l l l l l l l l l l l l l l l l Non-flame-retardant polyolefin Highly flame-retardant, multi-spec polyolefin Highly flame-retardant polyolefin Very-thin-wall, highly flame-retardant polyolefin l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l 3:1 shrink ratio adhesive-lined polyolefin High-temperature adhesive-lined polyolefin Dual wall, moisture-proof polyolefin 2:1 adhesive-lined polyolefin Clear high-shrink-ratio adhesive-lined polyolefin Flame-retardant adhesive-lined polyolefin Fully flame-retardant, adhesive-lined polyolefin 3:1 shrink ratio encapsulant-lined polyolefin High-temperature adhesive-lined polyolefin Rugged, general purpose, thick-wall polyolefin Highly flexible, thick-wall polyolefin High-shrink-ratio repair sleeve Heavy wall adhesive-lined polyolefin Medium wall polyolefin Self-sealing, dual wall polyolefin Diesel-resistant elastomer Flexible general-purpose modified elastomer Flexible rugged modified elastomer Very flexible rugged neoprene Very flexible silicone Very flexible silicone rubber High-temperature flexible elastomer Heavy-walled Viton(R) elastomer High-temperature flexible elastomer High-temperature flexible elastomer High-performance flexible fluoropolymer Clear high-performance flexible fluoropolymer Fluid- and chemical-resistant fluoropolymer High-performance fluoropolymer High-temperature Teflon(R) fluoropolymer resin Autoclavable semirigid fluoropolymer Lubricious thin-wall polyolefin High-temperature flexible fluoropolymer Flexible polyolefin High performance fluoropolymer microtubing Semirigid medical-grade fluoropolymer microtubing Lubricious medical-grade polyolefin microtubing High-ratio, adhesive-lined caps Semirigid encapsulant-lined polyolefin caps Modified ETFE, helically convoluted tubing Heat-shrinkable water blocking system Heat-shrinkable water blocking system Halogen-free, flame-retardant polyolefin Thin-wall, low-fire-hazard polyolefin Low toxicity, flexible polyolefin Protective self-adhering edging material Heat-shrinkable, fabric tubing Expandable, braided polyester sleeving Expandable, braided polyester sleeving Expandable, 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. Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. 3 Heat-Shrinkable Tubing 1.6 mm to 38 mm 3/64" to 4" 1 mm to 30 mm 3/64" to 1" 1 mm to 10 mm 3/64" to 2" 1.6 mm to 38 mm 3 mm to 38 mm 3/64" to 5" 1.5 mm to 39 mm 3/4" to 4.5" 1.2 mm to 38 mm 3/64" to 3/4" .240" to .485" 3 mm to 40 mm 4 mm to 52 mm 1/8" to 1" 4 mm to 48 mm 4 mm to 16 mm 1/8" to 1 1/2" .225" to .700" .225" to .700" .300" to .700" 1/8" to 1" .300" to .700" .3" to 4.5" .4" to 2.7" .6" to 4" 9 mm to 180 mm 10 mm to 180 mm .3" to 4.5" 1/8" to 3" 1/8" to 4" 1/8" to 4" 1/8" to 3" 1/4" to 2" 2.9 mm to 51 mm 1/8" to 2" 1/8" to 2" 1/8" to 2" 1/8" to 2" 3/64" to 1" 3/64" to 1 1/2" 1/8" to 2" 3/64" to 1 1/2" 0.8 mm to 11.9 mm/ 2 mm to 32 mm 1/16" to 1" 1 mm to 10 mm 1/16" to 1" 1/16" to 1" .014" to .045" .014" to .045" .014" to .045" .225" to .427" 1/8" to 1/2" .187" to 2" 12 mm to 32 mm 12 mm to 32 mm .4" to 3" 1/8" to 2" 3 mm to 40 mm 0.8 mm to 4.5 mm 12 mm to 80 mm 1/8" to 2" 1/8" to 2" 3 mm to 50 mm USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 3-5 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heat-Shrinkable Tubing Specification Cross-Reference Guide Product Type ATUM BSTS BSTS-FR CGPE-105 CGPT CRN Type 1 (colors) CRN Type 2 (clear) DCPT DR-25 DWP-125 ES1000 ES2000 ES Caps FL2500 HCTE HF HFT5000 HRSR HRNF HRHF HTAT LSTT MFT-MT1000 MFT-MT2000 MFT-RW-175 MT1000*** MT2000*** MT3000 MT5000*** NT NT-MIL NTFR PD Caps RayBlock 85 RayBlock 105 Rayrim RF-PETM RF-PET RF-PFR RHW RMW RNF-100 Type 1 (colors) RNF-100 Type 2 (clear) RNF-150 RNF-3000 RPPM RP-4800 RT-3 RT-375 RT555 RW-175 SCL SCT SFR SRFR SST SST-FR TAT-125 Type 1 (colors) TAT-125 Type 2 (clear) TFE/TFE-R TUGA-GP Versafit Versafit V2 Versafit V4 Viton(R) Viton(R)-HW Viton(R)-E Viton(R)-TW XFFR ZH-100 ZHTM UL File E85381** CSA File E35586 E35586 LR31929 LR31929 E35586 LR31929 E35586 E85381 E85381 E85381 LR31929 AMS-DTL-23053* Sheet Class /4 3 /15 1 & 2*** /6 /6 1 2 MIL-PRF-46846 Type Class /16 /15 1*** /1 1&2 E199379 E35586 LR31929 E85381 Raychem Specification RW-2063 & RK-6024 RW-2017 RW-2017 CGPE-105 SCD RW-2059 RT-360, Type 1 RT-360, Type 2 RW-2056 RT-1116 DWP-125 SCD RT-1113 RT-1112 RW-3006 FL2500 SCD RT-1162 RW-2023 RW-2060 RW-2013 RW-2013 RW-2013 RW-2052 RW-2051 Altera MicroFit SCD Altera MicroFit SCD RW-175 MicroFit SCD MT1000 SCD MT2000 SCD MT3000 SCD MT5000 SCD RT-510 RW-3030 RT-511 PD Caps SCD RW-2101 RW-2102 RK-6182 RW-2069 E115664 E35586 LR31929 E35586 VW-1 E35586 LR31929 E35586 E35586 E35586 VW-1 E85381 E35586 VW-1 E85381 LR31929 LR31929 VW-1 LR31929 VW-1 /5 /5 /18 1 2 2 /5 1 /18 2 /8 /4 1 /10 ll 1 III 1 E85381 VW-1 E85381 E35586 VW-1 E35586 VW-1 E85381 VW-1 LR31929 VW-1 LR31929 VW-1 LR31929 VW-1 /15 /4 1&2 2 /5 1&3 /13 *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. RHW SCD RMW SCD RT-350, Type 1 RT-350, Type 2 RT-370 RW-2053 RK-6214 RT-1122 RT-360 RT-375 RT-555 RW-3029 RT-1301 SCT SCD RT-1140 RT-1142/RW-2057 RW-2011 RW-2011 TAT-125 SCD TAT-125 SCD RW-2054, RW-2055 RW-2201 RW-3009 RW-3023 RW-3023 RT-1146 RT-1145 RK-6014/1 RK-6014/2 RW 2016 RW-2031 RW-2058 Page No. 3-33 3-53 3-53 3-7 3-9 3-11 3-11 3-13 3-65 3-35 3-37 3-39 3-67 3-41 3-69 3-55 3-71 3-57 3-57 3-57 3-43 3-15 3-73 3-73 3-73 3-75 3-77 3-79 3-81 3-83 3-85 3-87 3-89 3-91 3-93 3-99 3-97 3-95 3-95 3-59 3-61 3-17 3-17 3-101 3-19 3-45 3-21 3-23 3-103 3-105 3-107 3-47 3-49 3-109 3-111 3-63 3-63 3-51 3-51 3-113 3-25 3-27 3-29 3-31 3-115 3-115 3-115 3-115 3-117 3-119 3-121 VITON is a trademark of Dupont Dow Elastomers LLC. 3-6 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing CGPE-105 Brightly Colored, Shiny, Non-Flame-Retardant Polyolefin Tubing Product Facts n Bright, shiny surface; clear version offers exceptional clarity n Can be easily hot-stamped n Economical, yet offers the improved performance of a crosslinked material n Conforms to substrates more uniformly and with less longitudinal change than most PVC-based materials 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range Attractive covering for many automotive, appliance, and consumer-goods applications. Commercial grade tubing for applications where a flame-retardant 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. Minimum shrink temperature: 85C [185F] -70C to 105C [-94F to 221F] Specifications/Approvals Minimum full recovery temperature: 110C [230F] for black; 100C [212F] for all other colors and clear Series CGPE-105 Available in: Americas Raychem CGPE-105 SCD Europe n Asia Pacific n 3-7 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing CGPE-105 (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 1.2 [0.046] 0.6 [0.023] 1.6 [0.063] 0.8 [0.031] 2.4 [0.093] 1.2 [0.046] 3.2 [0.125] 1.6 [0.062] 4.8 [0.187] 2.4 [0.093] 6.4 [0.250] 3.2 [0.125] 9.5 [0.375] 4.8 [0.187] 12.7 [0.500] 6.4 [0.250] 19.1 [0.750] 9.5 [0.375] 25.4 [1.000] 12.7 [0.500] 38.1 [1.500] 19.1 [0.750] 50.8 [2.000] 25.4 [1.000] Size 3/64 1/16 3/32 1/8 3/16 1/4 3/8 1/2 3/4 1 1 1/2 2 Recovered Wall Thickness** After Heating 0.40 0.08 [0.016 0.003] 0.43 0.08 [0.017 0.003] 0.51 0.08 [0.020 0.003] 0.51 0.08 [0.020 0.003] 0.51 0.08 [0.020 0.003] 0.64 0.08 [0.025 0.003] 0.64 0.08 [0.025 0.003] 0.64 0.08 [0.025 0.003] 0.76 0.08 [0.030 0.003] 0.89 0.12 [0.035 0.005] 1.02 0.15 [0.040 0.006] 1.14 0.18 [0.045 0.007] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description Standard Black (-0), white (-9), clear (-X), red (-2), blue (-6), yellow (-4) Nonstandard Green (-5), violet (-7) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools. Specify product name, size and color (for example, CGPE-105-1/4-0). 3-8 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing CGPT General Purpose, FlameRetardant* Polyolefin Tubing Product Facts n 2:1 and 3:1 shrink ratio Very good chemical and solvent resistance n Flexible n Excellent physical and electrical performance n Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range 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, colorcoding and identification of wires, cables, pipes, and electrical and electronic components, and mechanical protection. Minimum shrink temperature: 80C [176F] -40C to 135C [-40F to 275F] Series Minimum full recovery temperature: 120C [248F] UL CSA Raychem LR31929 600 V, 125C RW-2059 CGPT E35586 600 V, 125C *Clear product (-X) is not flame-retardant. Available in: Americas Europe Asia Pacific n 3-9 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing CGPT (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied Size Recovered Wall Thickness** After Heating 2:1 1.2/06 1.6/0.8 2.4/1.2 3.2/1.6 4.8/2.4 6.4/3.2 9.5/4.8 12.7/6.4 19/9.5 25.4/12.7 32/16 38/19 51/26 76/38 102/51 1.2 [0.046] 1.6 [0.062] 2.4 [0.093] 3.2 [0.125] 4.8 [0.187] 6.4 [0.250] 9.5 [0.375] 12.7 [0.500] 19.0 [0.748] 25.4 [1.000] 32.0 [1.250] 38.0 [1.496] 51.0 [2.000] 76.0 [2.992] 102.0 [4.016] 0.6 [0.023] 0.8 [0.031] 1.2 [0.046] 1.6 [0.062] 2.4 [0.093] 3.2 [0.125] 4.8 [0.187] 6.4 [0.250] 9.5 [0.375] 12.7 [0.500] 16.0 [0.630] 19.0 [0.748] 26.0 [1.000] 38.0 [1.496] 51.0 [2.008] 0.45 0.12 [0.018 0.005] 0.45 0.12 [0.018 0.005] 0.50 0.12 [0.019 0.005] 0.50 0.12 [0.019 0.005]*** 0.50 0.12 [0.019 0.005]*** 0.65 0.15 [0.026 0.006]*** 0.65 0.15 [0.026 0.006]*** 0.65 0.15 [0.026 0.006]*** 0.75 0.15 [0.029 0.006]*** 0.90 0.20 [0.035 0.008]*** 0.95 0.20 [0.037 0.008]*** 1.00 0.20 [0.039 0.008]*** 1.15 0.25 [0.045 0.010] 1.25 0.25 [0.049 0.010] 1.40 0.30 [0.055 0.012] 1.5/0.5 3/1 6/2 9/3 12/4 18/6 24/8 39/13 1.5 [0.059] 3.0 [0.118] 6.0 [0.236] 9.0 [0.354] 12.0 [0.472] 18.0 [0.709] 24.0 [0.945] 39.0 [1.540] 0.5 [0.020] 1.0 [0.040] 2.0 [0.079] 3.0 [0.118] 4.0 [0.157] 6.0 [0.236] 8.0 [0.315] 13.0 [0.512] 0.45 0.12 [0.018 0.005)*** 0.55 0.12 [0.022 0.005)*** 0.65 0.12 [0.026 0.005)*** 0.75 0.15 [0.030 0.006)*** 0.75 0.15 [0.030 0.006)*** 0.85 0.15 [0.033 0.006)*** 1.00 0.20 [0.039 0.008]*** 1.15 0.25 [0.045 0.010] 3:1 **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Standard Size selection Standard packaging**** Ordering description Black (-0), White (-9), red (-2), blue (-6), yellow (-4), green (-5), clear (-X), yellow/green (-45) as indicated by an *** Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools. 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 3-10 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing CRN Semirigid, Flame-Retardant, Polyolefin Tubing Product Facts n 2:1 shrink ratio High abrasion resistance n Transfer of flex stress away from typically weak points such as solder and crimp joints, helping ensure a reliable connection n Flame-retardance (colors only) n Outstanding physical and electrical performance n Excellent chemical and solvent-resistance properties n Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range 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. Minimum shrink temperature: 110C [230F] -55C to 135C [-67F to 275F] Series UL CRN Type 1 (colors) E35586 600 V, 125C CRN Type 2 (clear) -- Minimum full recovery temperature: 135C [275F] CSA Military Raychem LR31929 (black only) 600 V, 125C -- AMS-DTL-23053/6*, Class l Def. Stan. 59-97 Type 2C (not red) AMS-DTL-23053/6*, Class 2 RT-360, Type 1 RK-6003 RT-360, Type 2 *Formerly MIL-I-23053/6 and MIL-DTL-23053/6. Available in: Americas Europe Asia Pacific n n n 3-11 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing CRN (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 1.2 [0.046] 0.6 [0.023] 1.6 [0.063] 0.8 [0.031] 2.4 [0.093] 1.2 [0.046] 3.2 [0.125] 1.6 [0.062] 4.8 [0.187] 2.4 [0.093] 6.4 [0.250] 3.2 [0.125] 9.5 [0.375] 4.8 [0.187] 12.7 [0.500] 6.4 [0.250] 19.1 [0.750] 9.5 [0.375] Size 3/64 1/16 3/32 1/8 3/16 1/4 3/8 1/2 3/4 Recovered Wall Thickness** After Heating 0.51 0.08 [0.020 0.003] 0.51 0.08 [0.020 0.003] 0.51 0.08 [0.020 0.003] 0.51 0.08 [0.020 0.003] 0.64 0.08 [0.025 0.003] 0.64 0.08 [0.025 0.003] 0.76 0.08 [0.030 0.003] 0.76 0.08 [0.030 0.003] 0.89 0.12 [0.035 0.005] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description*** Standard Black (-0) Clear (-X, not flame-retardant) Nonstandard Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. In 1.2-meter [4-foot] lengths. 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. 3-12 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing DCPT Flexible, Flame-Retardant, Dual-Color, Polyolefin Tubing Product Facts n 2:1 and 3:1 shrink ratio Dual colors (yellow/green) for instant identification n Co-extrusion of tubing colors, giving color permanence superior to that of conventional ink marking n Flame-retardance n Flexibility: able to conform to irregular shapes n Excellent physical, chemical, and electrical properties that meet industry standards for highly reliable, general purpose tubing n 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range Used to identify "ground" on wires and in cables, and to jacket and insulate light-duty harnesses. Minimum shrink temperature: 95C [203F] -55C to 135C [-67F to 275F] Minimum full recovery temperature: 120C [248F] Easily marked by conventional techniques for additional identification of wires and cables. Specifications/Approvals Series UL DCPT E35586 600 V, 125C Available in: CSA Military Agency LR31929 600 V, 125C Def Stan 59-97 Issue 3 Type 2B VG 95343 Pt 5 Type A AFS 2270 RW-2056 DIN 29807 VDE 0341 Pt 9005 Type A Americas Europe Asia Pacific n n n Raychem 3-13 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing DCPT (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied Size Recovered Wall Thickness* After Heating 2:1 3/1.5 6/3 8/4 10/5 12/6 19/9 26/13 38/19 51/19 3:1 (Europe only) 3/1 6/2 9/3 12/4 18/6 24/8 3 [0.118] 6 [0.236] 8 [0.315] 10 [0.394] 12 [0.472] 19 [0.748] 26 [1.024] 38 [1.500] 51 [2.000] 1.5 [0.059] 3.0 [0.118] 4.0 [0.158] 5.0 [0.197] 6.0 [0.236] 9.0 [0.354] 13.0 [0.512] 19.0 [0.748] 19.0 [0.748] 0.51 0.10 [0.020 0.004] 0.58 0.10 [0.023 0.004] 0.64 0.10 [0.025 0.004] 0.64 0.10 [0.025 0.004] 0.64 0.10 [0.025 0.004] 0.76 0.12 [0.030 0.005] 0.89 0.12 [0.035 0.005] 1.00 0.12 [0.039 0.005] 1.02 0.15 [0.040 0.006] 3.0 [0.118] 6.0 [0.236] 9.0 [0.354] 12.0 [0.472] 18.0 [0.709] 24.0 [0.945] 1.0 [0.039] 2.0 [0.079] 3.0 [0.118] 4.0 [0.157] 6.0 [0.236] 8.0 [0.315] 0.55 0.10 [0.022 0.004] 0.65 0.10 [0.026 0.004] 0.75 0.15 [0.030 0.006] 0.75 0.15 [0.030 0.006] 0.85 0.15 [0.033 0.006] 1.00 0.20 [0.039 0.008] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description** Standard Yellow/green stripe (-45) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools. 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. 3-14 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing LSTT Low-Shrink-Temperature, Non-Flame-Retardant, Heat-Shrinkable, Polyolefin tubing Product Facts n 2:1 shrink ratio Rapid recovery at low temperatures n Can be used with temperature-sensitive materials n Flexible n Not flame-retardant n Excellent physical and electrical performance n 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range 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 flameretardant, LSTT meets the automotive flame propagation standard MVSS 302. Minimum shrink temperature: 65C [149F] -40C to 125C [-40F to 257F] Minimum full recovery temperature: 110C [230F] Typical applications include electrical termination insulation, color-coding, covering of heat-sensitive devices, cosmetic coverings, and mechanical protection. Specifications/Approvals Series LSTT Available in: Industry MVSS302 Americas Raychem RW-2051 Europe Asia Pacific n 3-15 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing LSTT (Continued) Product Dimensions Size Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 1.6 [0.063] 0.8 [0.031] 1.6 2.4 [0.093] 1.2 [0.046] 2.4 3.2 [0.125] 1.6 [0.062] 3.2 4.8 [0.187] 2.4 [0.093] 4.8 6.4 [0.250] 3.2 [0.125] 6.4 9.5 [0.375] 4.8 [0.187] 9.5 12.7 [0.500] 6.4 [0.250] 12.7 19.0 19.0 [0.748] 9.5 [0.375] 25.4 25.4 [1.000] 12.7 [0.500] 32.0 32.0 [1.260] 16.0 [0.630] 38.0 38.0 [1.496] 19.0 [0.748] 52.0** 52.0 [2.047] 26.0 [1.024] *Wall thickness will be les if tubing recovery is restricted during shrinkage. **Available in black only. Ordering Information Recovered Wall Thickness* After Heating 0.50 0.12 [0.018 0.005] 0.55 0.12 [0.022 0.005] 0.55 0.12 [0.022 0.005] 0.55 0.12 [0.022 0.005] 0.65 0.15 [0.026 0.006] 0.65 0.15 [0.026 0.006] 0.65 0.15 [0.026 0.006] 0.80 0.15 [0.032 0.006] 0.95 0.18 [0.037 0.007] 1.05 0.20 [0.041 0.008] 1.05 0.20 [0.041 0.008] 1.14 0.18 [0.045 0.007] 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 3-16 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing RNF-100 Flexible, Flame-Retardant, General Purpose, Polyolefin Tubing Product Facts n 2:1 shrink ratio Superior abrasion and solvent resistance when compared with that of many flexible, general purpose polyolefin tubings n Excellent physical, chemical, and electrical properties that meet or exceed industrial and military standards for highly reliable, general purpose tubing n Flexible; conforms to irregular shapes n Flame-retardant (colors only) n Wide range of sizes and colors n Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range 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 terminations 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. Minimum shrink temperature: 95C [203F] -55C to 135C [-67F to 275F] Series UL Minimum full recovery temperature: 121C [250F] CSA Military Industry Raychem AMS-DTL-23053/5*, Class 1 Def. Stan. 59-97 Type 2B AMS-DTL-23053/5*, Class 2 VG 95343 Pt 5 Type B VDE 0341 Pt 9005 Type A and B RT-350, Type 1 RK-6001 -- RT-350, Type 2 RK-6001 RNF-100 Type 1 (colors) E35586 600 V, 125C LR31929 600 V, 125C RNF-100 Type 2 (clear) -- -- *Formerly MIL-I-23053/5 and MIL-DTL-23053/5. Available in: Americas Europe Asia Pacific n n n 3-17 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing RNF-100 (Continued) Product Dimensions Size 3/64 1/16 3/32 1/8 3/16 1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2 3 4 5 Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 1.2 [0.046] 0.6 [0.023] 1.6 [0.063] 0.8 [0.031] 2.4 [0.093] 1.2 [0.046] 3.2 [0.125] 1.6 [0.062] 4.8 [0.187] 2.4 [0.093] 6.4 [0.250] 3.2 [0.125] 9.5 [0.375] 4.8 [0.187] 12.7 [0.500] 6.4 [0.250] 19.1 [0.750] 9.5 [0.375] 25.4 [1.000] 12.7 [0.500] 31.8 [1.250] 15.9 [0.625] 38.1 [1.500] 19.1 [0.750] 50.8 [2.000] 25.4 [1.000] 76.2 [3.000] 38.1 [1.500] 101.6 [4.000] 50.8 [2.000] 127.0 [5.000] 63.5 [2.500] Recovered Wall Thickness** After Heating 0.40 0.08 [0.016 0.003] 0.43 0.08 [0.017 0.003] 0.51 0.08 [0.020 0.003] 0.51 0.08 [0.020 0.003] 0.51 0.08 [0.020 0.003] 0.64 0.08 [0.025 0.003] 0.64 0.08 [0.025 0.003] 0.64 0.08 [0.025 0.003] 0.76 0.08 [0.030 0.003] 0.89 0.12 [0.035 0.005] 1.02 0.15 [0.040 0.006] 1.02 0.15 [0.040 0.006] 1.14 0.16 [0.045 0.007] 1.27 0.20 [0.050 0.008] 1.40 0.23 [0.055 0.009] 1.52 0.23 [0.060 0.009] **Wall thickness will be less if tubing recovery is restricted during shrinkage. 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. 3-18 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing RNF-3000 Flexible, High-Shrink-Ratio, Flame-Retardant, General Purpose, Polyolefin Tubing Product Facts n 3:1 shrink ratio easily accommodates awkward, irregular shapes n Few sizes cover a wide range of diameters, allowing reduced inventory n Excellent physical, chemical, and electrical properties meet industry standards for highly reliable, general purpose tubing n Flame-retardant (colors only) Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range 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. Minimum shrink temperature: 80C [176F] -55C to 135C [-67F to 275F] Series UL Minimum full recovery temperature: 120C [248F] CSA Military Industry Raychem LR31929 600 V, 125C Def. Stan. 59-97 Type 2B VG 95343 Pt 5 Type A (color) VG 95343 Pt 5 Type B (clear) VDE 0341 Pt 9005 Type A and B RW-2053 RNF-3000 E35586 600 V, 125C Available in: Americas Europe Asia Pacific n n n 3-19 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing RNF-3000 (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 1.5 [0.060] 0.5 [0.019] 3 [0.118] 1 [0.039] 4.5 [0.177] 1.5 [0.059] 6 [0.236] 2 [0.079] 9 [0.354] 3 [0.118] 12 [0.472] 4 [0.157] 18 [0.709] 6 [0.236] 24 [0.944] 8 [0.315] 39 [1.534] 13 [0.512] Size 1.5/0.5 3/1 4.5/1.5 6/2 9/3 12/4 18/6 24/8 39/13 Recovered Wall Thickness** After Heating 0.45 0.10 [0.018 0.003] 0.55 0.10 [0.022 0.003] 0.55 0.10 [0.022 0.003] 0.65 0.10 [0.026 0.003] 0.75 0.12 [0.030 0.004] 0.75 0.12 [0.030 0.004] 0.85 0.12 [0.033 0.004] 1.00 0.18 [0.039 0.007] 1.15 0.20 [0.045 0.008] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging*** Ordering description**** Standard** Black (-0), white (-9), red (-2), blue (-6), yellow (-4), green (-5), clear (-X) Nonstandard Brown (-1), orange (-3), violet (-7), gray (-8) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools or in 1.2-meter [4-foot] lengths. 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. 3-20 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing RP-4800 High-Shrink-Ratio, Flame-Retardant, Polyolefin Tubing Product Facts n 4:1 shrink ratio n Conforms well to highly variable substrate dimensions n Has excellent physical, chemical, and electrical properties that meet or exceed industrial and military standards n Shows no significant degradation when exposed to common solvents and chemicals, including aviation fuel and hydraulic fluid Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range 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. Minimum shrink temperature: 95C [203F] -55C to 135C [-67F to 275F] Series UL Minimum full recovery temperature: 121C [250F] Military Industry Raychem AMS-DTL-23053/5*, Class 1 Overexpanded VG 95343 Pt 5 Type A VDE 0341 Pt 9005 Type A RT-1122 RP-4800 E35586 600V, 125C (black only) *Formerly MIL-I-23053/5 and MIL-DTL-23053/5. Available in: Americas Europe Asia Pacific n n n 3-21 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing RP-4800 (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 25.4 [1.000] 7.0 [0.275] 50.8 [2.000] 14.0 [0.550] 76.2 [3.000] 20.6 [0.810] 101.6 [4.000] 26.7 [1.050] 25.4 [1.000] 11.7 [0.462] 60.3 [2.375] 17.3 [0.680] 76.2 [3.000] 21.3 [0.840] 95.3 [3.750] 23.6 [0.930] 114.3 [4.500] 36.8 [1.450] 38.1 [1.500] 9.5 [0.375] 19.1 [0.750] 4.6 [0.180] Size No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8 No. 9 No. 10 No. 11 Recovered Wall Thickness** After Heating 1.14 0.18 [0.045 0.007] 1.14 0.18 [0.045 0.007] 1.14 0.18 [0.045 0.007] 1.14 0.18 [0.045 0.007] 1.14 0.18 [0.045 0.007] 1.14 0.18 [0.045 0.007] 1.14 0.18 [0.045 0.007] 1.14 0.18 [0.045 0.007] 1.14 0.18 [0.045 0.007] 1.14 0.18 [0.045 0.007] 1.14 0.18 [0.045 0.007] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Standard Size selection Standard packaging Ordering description*** Black (-0) White (-9), red (-2), blue (-6), yellow (-4), green (-5), brown (-1), Nonstandard orange (-3), violet (-7), gray (-8) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools or in 1.2-meter [4-foot] lengths. 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. 3-22 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing RT-3 Semirigid, FlameRetardant, Polyolefin Tubing Product Facts n 2.5:1 shrink ratio n Tightly controlled expanded diameters n High abrasion resistance n Semirigidity that transfers flex stress away from typically weak points such as solder and crimp joints, helping to ensure a reliable connection n Excellent chemical and solvent resistance n Outstanding physical and electrical performance Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Suitable for wire strain-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. Minimum shrink temperature: 110C [230F] -55C to 135C [-67F to 275F] Minimum full recovery temperature: 135C [275F] Series UL RT-3 E35586 600 V, 125C CSA Raychem LR31929 (black only) 600 V, 125C RT-360* *Except dimensions and longitudinal change. Available in: Americas Europe n Asia Pacific n 3-23 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing RT-3 (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 6.1 0.4 [0.240 0.015] 2.4 [0.095] 8.1 0.4 [0.320 0.015] 3.2 [0.125] 9.5 0.5 [0.375 0.020] 3.8 [0.150] 12.3 0.5 [0.485 0.020] 5.1 [0.200] Size No. 1 No. 2 No. 3 No. 4 Recovered Wall Thickness** After Heating 0.79 0.08 [0.031 0.003] 0.79 0.08 [0.031 0.003] 0.79 0.08 [0.031 0.003] 0.79 0.08 [0.031 0.003] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description Black only Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. In 1-inch cut pieces or in 1.2-meter [4-foot] lengths. Specify product name, size and color (for example, RT-3 No. 1-0). 3-24 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing TUGA-GP Brightly Colored, Shiny, Non-Flame-Retardant, Polyolefin Tubing Product Facts n 2:1 Shrink ratio n Can be easily hot-stamped n Bright, shiny surface; clear version offers exceptional clarity n Semiflexible, non-flameretardant, halogen free n Conforms to substrates more uniformly and with less longitudinal change than most PVC-based materials 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range 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 are important. TUGA-GP makes an attractive covering for many automotive, appliance, and consumergoods applications. Exceptional transparency of clear vision makes it an ideal choice for protecting marked surfaces. Minimum shrink temperature: 85C [85F] -55C to 125C [-67F to 257F] Specifications/Approvals Available in: Minimum full recovery temperature: 110C [230F] for black; 100C [212F] for all other colors and clear. Series Raychem TUGA-GP RW-2201 Americas Europe Asia Pacific n 3-25 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing TUGA-GP (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 1.2 [0.046] 0.6 [0.023] 1.6 [0.062] 0.8 [0.031] 2.4 [0.093] 1.2 [0.046] 3.0 [0.118] 1.5 [0.059] 5.0 [0.197] 2.5 [0.098] 6.4 [0.250] 3.2 [0.125] 8.0 [0.315] 4.0 [0.157] 9.5 [0.375] 4.8 [0.187] 11.0 [0.433] 5.5 [0.217] 12.7 [0.500] 6.4 [0.250] 15.0 [0.591] 7.5 [0.295] 20.0 [0.787] 10.0 [0.394] 25.4 [1.000] 12.7 [0.500] 38.0 [1.496] 19.0 [0.748] Size 1.2/0.6 1.6/0.8 2.4/1.2 3/1.5 5/2.5 6.4/32 8/4 9.5/4.8 11/5.5 12.7/6.4 15/7.5 20/10 25.4/12.7 38/19 Recovered Wall Thickness* Nominal After Heating 0.4 [0.016] 0.4 [0.016] 0.5 [0.019] 0.5 [0.019] 0.5 [0.019] 0.6 [0.024] 0.6 [0.024] 0.6 [0.024] 0.6 [0.024] 0.6 [0.024] 0.8 [0.031] 0.8 [0.031] 0.9 [0.035] 1.0 [0.039] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description Standard Black (-0), white (-9), red (-2) Nonstandard Yellow (-4), clear (-X) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes available upon request. On spools. Specify product name, size and color (for example, TUGA 3/1.5-0). 3-26 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing Versafit Highly Flame-Retardant, Very Flexible, Low-ShrinkTemperature, Polyolefin Tubing Product Facts n 2:1 shrink ratio Low shrink temperature reduces installation time and the risk of damage to temperature-sensitive components n Very flexible; doesn't easily wrinkle when bent n Highly flame-retardant n Hot stamps extremely well n Higher temperature rating, better thermal stability, and higher resistance to physical abuse than noncrosslinked materials n Free of polybrominated biphenyls (PBBs) and polybrominated biphenyl oxides and ethers (PBBOs and PBBEs), which are classified as environmentally hazardous substances n Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Cost-effective choice for many commercial and military applications; electrically insulates and protects in-line components, disconnect terminals, and splices. Bundles wires for very flexible light-duty harnesses. Strain-relieves electrical wire connections for commercial applications. Identifies or color-codes wires, cables, terminals, and components. Minimum shrink temperature: 70C [158F] -55C to 135C [-67F to 275F] Series UL Minimum full recovery temperature: 90C [194F] CSA Military Raychem LR31929 VW-1 600 V, 125C AMS-DTL-23053/5* Classes 1 & 3 RW-3009 Versafit E35586 VW-1 600 V, 125C *Formerly MIL-I-23053/5 and MIL-DTL-23053/5. Available in: Americas Europe Asia Pacific n n n 3-27 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing Versafit (Continued) Product Dimensions Size 3/64 1/16 3/32 1/8 3/16 1/4 3/8 1/2 5/8*** 3/4 1 1 1/4*** 1 1/2 2 3 4 Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 1.63 0.2 [0.064 0.008] 0.6 [0.023] 1.85 0.2 [0.073 0.008] 0.8 [0.031] 2.79 0.2 [0.110 0.008] 1.2 [0.046] 3.43 0.2 [0.135 0.008] 1.6 [0.062] 5.21 0.3 [0.205 0.010] 2.4 [0.093] 7.11 0.3 [0.280 0.010] 3.2 [0.125] 10.16 0.4 [0.400 0.015] 4.8 [0.187] 13.72 0.4 [0.540 0.015] 6.4 [0.250] 16.90 0.4 [0.665 0.015] 8.0 [0.315] 20.45 0.4 [0.805 0.015] 9.5 [0.375] 25.53 0.4 [1.055 0.015] 12.7 [0.500] 33.40 0.7 [1.315 0.025] 15.9 [0.625] 39.88 0.8 [1.570 0.030] 19.1 [0.750] 52.83 1.0 [2.080 0.040] 25.4 [1.000] 78.49 1.0 [3.090 0.040] 38.1 [1.500] 104.14 1.3 [4.100 0.050] 50.8 [2.000] Recovered Wall Thickness** After Heating 0.40 0.08 [0.016 0.003] 0.43 0.08 [0.017 0.003] 0.51 0.08 [0.020 0.003] 0.51 0.08 [0.020 0.003] 0.51 0.08 [0.020 0.003] 0.64 0.08 [0.025 0.003] 0.64 0.08 [0.025 0.003] 0.64 0.08 [0.025 0.003] 0.76 0.08 [0.030 0.003] 0.76 0.08 [0.030 0.003] 0.89 0.12 [0.035 0.005] 1.02 0.15 [0.040 0.006] 1.02 0.15 [0.040 0.006] 1.14 0.16 [0.045 0.007] 1.27 0.20 [0.050 0.008] 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. Ordering Information Color Size selection Standard packaging**** Ordering description***** Standard Black (-0), white (-9), red (-2), blue (-6), yellow (-4), green (-5) Nonstandard Brown (-1), orange (-3), violet (-7), gray (-8) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools. 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. 3-28 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing Versafit V2 Highly Flame-Retardant, Very Flexible, Low-ShrinkTemperature, Polyolefin Tubing Product Facts n 2:1 shrink ratio Low shrink temperature reduces installation time and the risk of damage to temperature-sensitive components n Very flexible; doesn't easily wrinkle when bent n Highly flame-retardant n Hot stamps extremely well n Higher temperature rating, better thermal stability, and higher resistance to physical abuse than noncrosslinked materials n Free of polybrominated biphenyls (PBBs) and polybrominated biphenyl oxides and ethers (PBBOs and PBBEs), which are classified as environmentally hazardous substances n Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Cost-effective choice for many commercial applications; electrically insulates and protects in-line components, disconnect terminals, and splices. Bundles wires for very flexible light-duty harnesses. Strain-relieves electrical wire connections. Identifies or color-codes wires, cables, terminals, and components. Minimum shrink temperature: 70C [158F] -30C to 125C [-22F to 257F] Series Minimum full recovery temperature: 90C [194F] UL CSA Raychem LR31929 VW-1 600 V, 125C RW-3023 Versafit V2 Available in: E35586 VW-1 600 V, 125C Americas Europe Asia Pacific n n n 3-29 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing Versafit V2 (Continued) Product Dimensions Size 1.0 1.5 2.0 2.5 3.0 3.5 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 18.0 20.0 22.0 25.0 27.0 28.0 30.0 Inside Diameter Maximum Recovered Expanded After Heating as Supplied 1.5 0.2 [0.059 0.008] 0.50 [0.020] 2.1 0.2 [0.075 0.008] 0.75 [0.030] 2.6 0.2 [0.102 0.008] 1.00 [0.039] 3.1 0.2 [0.122 0.008] 1.25 [0.049] 3.6 0.2 [0.142 0.008] 1.50 [0.059] 4.1 0.3 [0.161 0.012] 1.75 [0.069] 4.6 0.3 [0.181 0.012] 2.00 [0.079] 5.6 0.3 [0.221 0.012] 2.50 [0.098] 6.6 0.3 [0.260 0.012] 3.00 [0.118] 7.6 0.3 [0.299 0.012] 3.50 [0.138] 8.6 0.3 [0.339 0.012] 4.00 [0158] 9.6 0.3 [0.378 0.012] 4.50 [0.177] 10.4 0.3 [0.409 0.012] 5.00 [0.197] 11.4 0.3 [0.449 0.012] 5.50 [0.217] 12.7 0.3 [0.500 0.012] 6.00 [0.236] 13.5 0.3 [0.532 0.012] 6.50 [0.256] 14.4 0.4 [0.567 0.016] 7.00 [0.276] 15.7 0.4 [0.618 0.016] 7.50 [0.295] 16.9 0.4 [0.665 0.016] 8.00 [0.315] 19.0 0.4 [0.748 0.016] 9.00 [0.354] 21.4 0.4 [0.843 0.016] 10.00 [0.394] 11.00 [0.433] 23.2 0.4 [0.913 0.016] 26.8 0.4 [1.055 0.016] 12.50 [0.492] 28.2 0.5 [1.110 0.020] 12.50 [0.492] 30.0 0.5 [1.181 0.020] 14.00 [0.551] 32.1 0.5 [1.264 0.020] 15.00 [0.591] Wall Thickness Expanded as Recovered* Supplied (Nominal) After Heating (Minimum) 0.20 [0.008] 0.33 [0.013] 0.20 [0.008] 0.35 [0.014] 0.25 [0.010] 0.43 [0.017] 0.25 [0.010] 0.43 [0.017] 0.25 [0.010] 0.43 [0.017] 0.25 [0.010] 0.43 [0.017] 0.25 [0.010] 0.43 [0.017] 0.30 [0.012] 0.56 [0.022] 0.30 [0.012] 0.56 [0.022] 0.30 [0.012] 0.56 [0.022] 0.30 [0.012] 0.56 [0.022] 0.30 [0.012] 0.56 [0.022] 0.30 [0.012] 0.56 [0.022] 0.30 [0.012] 0.56 [0.022] 0.30 [0.012] 0.56 [0.022] 0.35 [0.014] 0.66 [0.026] 0.35 [0.014] 0.68 [0.027] 0.35 [0.014] 0.68 [0.027] 0.35 [0.014] 0.68 [0.027] 0.40 [0.016] 0.76 [0.030] 0.40 [0.016] 0.76 [0.030] 0.45 [0.018] 0.89 [0.035] 0.45 [0.018] 0.89 [0.035] 0.45 [0.018] 0.89 [0.035] 0.45 [0.018] 0.89 [0.035] 0.45 [0.018] 0.89 [0.035] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Standard Nonstandard Size selection Standard packaging Ordering description Black (-0) White (-9), red (-2), blue (-6), yellow (-4), green (-5), orange (-3), violet (-7), brown (-1), gray (-8) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools. Specify product name, size and color (for example, Versafit V2-3.0-0). 3-30 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing Versafit V4 Very-Thin-Wall, Very Flexible, Highly Flame-Retardant, Polyolefin Tubing Product Facts n 2:1 shrink ratio Very thin wall provides space savings and rapid shrinking n Low shrink temperature further reduces installation time and risk of damage to temperature-sensitive components n Very flexible; doesn't easily wrinkle when bent n Free of polybrominated biphenyls (PBBs) and polybrominated biphenyl oxides and ethers (PBBOs and PBBEs), which are classified as environmentally hazardous substances n Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Typically used where space saving is important. Offers the ability to pack components more closely than is possible with standard tubings. Costeffective choice for many commercial applications; electrically insulates and protects in-line components, disconnect terminals, and splices. Used for strain relief on high-density connectors. Minimum shrink temperature: 70C [158F] -30C to 125C [-22F to 257F] Series Minimum full recovery temperature: 90C [194F] UL CSA Raychem LR31929 VW-1 150 V, 125C RW-3023 Versafit V4 Available in: E85381 VW-1 300 V, 125C Americas Europe Asia Pacific n n n 3-31 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Single Wall Tubing Versafit V4 (Continued) Product Dimensions Metric Size 0.6/0.3 0.8/0.4 1.0/0.5 1.5/0.75 2.0/1.0 2.5/1.25 3.0/1.5 3.5/1.75 4.0/2.0 5.0/2.5 6.0/3.0 7.0/3.5 8.0/4.0 9.0/4.5 10.0/5.0 Inside Diameter Maximum Recovered Expanded After Heating as Supplied 0.95 0.25 [0.037 0.010] 0.30 [0.012] 1.20 0.25 [0.047 0.010] 0.40 [0.016] 1.40 0.25 [0.055 0.010] 0.50 [0.020] 1.90 0.25 [0.075 0.010] 0.75 [0.030] 2.30 0.25 [0.091 0.010] 1.00 [0.039] 2.80 0.25 [0.110 0.010] 1.25 [0.049] 3.30 0.25 [0.130 0.010] 1.50 [0.059] 3.80 0.25 [0.150 0.010] 1.75 [0.069] 4.40 0.25 [0.173 0.010] 2.00 [0.079] 5.50 0.25 [0.217 0.010] 2.50 [0.098] 6.50 0.40 [0.256 0.016] 3.00 [0.118] 7.50 0.40 [0.295 0.016] 3.50 [0.138] 8.50 0.40 [0.335 0.016] 4.00 [0.158] 9.50 0.40 [0.374 0.016] 4.50 [0.177] 10.50 0.50 [0.413 0.020] 5.00 [0.197] Wall Thickness Expanded as Recovered* Supplied (Nominal) After Heating (Minimum) 0.10 [0.004] 0.25 [0.010] 0.10 [0.004] 0.25 [0.010] 0.10 [0.004] 0.25 [0.010] 0.10 [0.004] 0.25 [0.010] 0.10 [0.004] 0.25 [0.010] 0.15 [0.006] 0.25 [0.010] 0.15 [0.006] 0.25 [0.010] 0.15 [0.006] 0.25 [0.010] 0.15 [0.006] 0.25 [0.010] 0.15 [0.006] 0.25 [0.010] 0.15 [0.006] 0.28 [0.011] 0.15 [0.006] 0.28 [0.011] 0.15 [0.006] 0.28 [0.011] 0.15 [0.006] 0.28 [0.011] 0.15 [0.006] 0.28 [0.011] Inside Diameter Maximum Recovered Minimum Expanded as Supplied After Heating 1.2 [0.046] 0.6 [0.023] 1.6 [0.062] 0.8 [0.031] 2.4 [0.093] 1.2 [0.046] 3.2 [0.125] 1.6 [0.062] 4.8 [0.187] 2.4 [0.093] 6.4 [0.250] 3.2 [0.125] 9.5 [0.375] 4.8 [0.187] 12.7 [0.500] 6.4 [0.250] 19.1 [0.750] 9.5 [0.375] 25.4 [1.000] 12.7 [0.500] Inch Size 3/64 1/16 3/32 1/8 3/16 1/4 3/8 1/2 3/4 1 Recovered Wall Thickness* After Heating 0.30 0.05 [0.012 0.002] 0.30 0.05 [0.012 0.002] 0.30 0.05 [0.012 0.002] 0.33 0.05 [0.013 0.002] 0.33 0.05 [0.013 0.002] 0.36 0.08 [0.014 0.003] 0.36 0.08 [0.014 0.003] 0.36 0.08 [0.014 0.003] 0.43 0.08 [0.017 0.003] 0.51 0.08 [0.020 0.003] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Marking Ordering description Standard Black (-0) Nonstandard Other colors available upon request. Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools. Marked with UL/CSA/-F- legends (metric sizes) or unmarked (inch sizes). Specify product name, size (mm or in.) and color (for example, Versafit V4-1.0-0). 3-32 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) ATUM High-Shrink-Ratio, Adhesive-Lined Polyolefin Tubing Product Facts n 3:1 and 4:1 shrink ratios allow for connector-to-cable sealing n Tubing environmentally seals and protects components and interconnections n Medium wall provides increased mechanical protection n ATUM adhesive bonds to a wide variety of plastics, rubbers, and metals, including polyethylene, aluminum, steel, and copper Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Environmentally seals and protects a wide variety of electrical applications, including back end connector sealing, breakouts, and connectorto-cable transitions. High expansion ratio makes it possible to repair most damaged cable jackets without removing connectors. Minimum shrink temperature: 80C [176F] -55C to 110C [-67F to 230F] Series Minimum full recovery temperature: 110C [230F] UL** Military Raychem AMS-DTL-23053/4*, Class 3 RW-2063 - Black RK-6024 - Colors and clear ATUM E85381 600V, 110C *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. Available in: Americas Europe Asia Pacific n n n 3-33 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) ATUM (Continued) Product Dimensions Size Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied Recovered Wall Thickness** Total Wall Adhesive Wall After Heating After Heating (Nominal) 3:1 3/1 4.5/1.5 6/2 9/3 12/4 19/6 24/8 40/13 3.0 [0.118] 4.5 [0.177] 6.0 [0.236] 9.0 [0.354] 12.0 [0.472] 19.0 [0.748] 24.0 [0.940] 40.0 [1.570] 1.0 [0.039] 1.5 [0.059] 2.0 [0.079] 3.0 [0.118] 4.0 [0.157] 6.0 [0.236] 8.0 [0.315] 13.0 [0.512] 1.00 0.28 [0.039 0.010] 1.10 0.25 [0.043 0.011] 1.00 0.28 [0.039 0.010] 1.40 0.28 [0.055 0.010] 1.78 0.38 [0.070 0.015] 2.25 0.55 [0.088 0.022] 2.54 0.55 [0.100 0.022] 2.54 0.55 [0.100 0.022] 0.50 [0.020] 0.50 [0.020] 0.50 [0.020] 0.61 [0.024] 0.76 [0.030] 0.76 [0.030] 1.02 [0.040] 1.02 [0.040] 4.0 [0.158] 8.0 [0.315] 12.0 [0.472] 16.0 [0.630] 24.0 [0.945] 32.0 [1.260] 52.0 [2.050] 1.0 [0.039] 2.0 [0.079] 3.0 [0.118] 4.0 [0.158] 6.0 [0.236] 8.0 [0.315] 13.0 [0.512] 1.00 0.28 [0.039 0.010] 1.00 0.28 [0.039 0.010] 1.40 0.28 [0.055 0.010] 1.78 0.38 [0.070 0.015] 2.25 0.55 [0.088 0.022] 2.54 0.55 [0.100 0.022] 2.54 0.55 [0.100 0.022] 0.50 [0.020] 0.50 [0.020] 0.61 [0.024] 0.76 [0.030] 0.76 [0.030] 1.02 [0.040] 1.02 [0.040] 4:1 4/1 8/2 12/3 16/4 24/6 32/8 52/13 **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Standard Nonstandard Black (-0) 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. 3-34 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) DWP-125 Flexible, High-ShrinkRatio, Adhesive-Lined, Polyolefin Tubing Product Facts n 3:1 shrink ratio allows for insulation and sealing of irregular shapes n Medium wall provides increased mechanical protection while maintaining flexibility when installed n Adhesive bonds to a wide variety of plastics, rubber, and metals, including polyethylene, neoprene, and steel Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Environmentally seals and protects a wide variety of electrical applications, including wire splices, breakouts, and connectorto-cable transitions. Ideal for applications where UL recognized/CSA certified adhesive-lined tubing is required. Minimum shrink temperature: 80C [176F] -40C to 110C [-40F to 230F] Series Minimum full recovery temperature: 125C [257F] Military CSA UL Raychem DWP-125 E35586 LR31929 AMS-DTL-23053/4*, DWP-125 SCD Class 3 (colors only) 600 V, 125C 600 V, 125C *Formerly MIL-I-23053/4 and MIL-DTL-23053/4. Meets the material properties except for Sealing Efficiency. Available in: Americas Europe Asia Pacific n n n 3-35 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) DWP-125 (Continued) Product Dimensions Size 1/8 3/16 1/4 3/8 1/2 3/4 1 Inside Diameter Maximum Minimum Recovered Expanded After Heating as Supplied 3.2 [0.125] 1.0 [0.040] 4.8 [0.187] 1.5 [0.060] 6.4 [0.250] 2.0 [0.080] 9.5 [0.375] 3.0 [0.120] 12.7 [0.500] 4.0 [0.157] 19.1 [0.750] 6.0 [0.230] 25.4 [1.000] 8.0 [0.320] Recovered Wall Thickness* Nominal Nominal Total Wall Adhesive Wall After Heating After Heating 1.02 [0.040] 0.25 [0.010] 1.40 [0.055] 0.51 [0.020] 1.45 [0.057] 0.56 [0.022] 1.65 [0.065] 0.68 [0.027] 1.78 [0.070] 0.76 [0.030] 2.03 [0.080] 0.76 [0.030] 2.50 [0.100] 0.76 [0.030] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Standard Nonstandard Size selection Standard packaging Ordering description Black (-0) White (-9), red (-2), blue (-6), yellow (-4), green (-5), clear (-X, non-flame-retardant jacket). Other colors available upon request. Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. In 1.2-meter [4-foot] lengths. Specify product name, size and color (for example, DWP-125 1/4-0). 3-36 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) ES1000 Clear, High-Shrink-Ratio, Adhesive-Lined, Semirigid Polyolefin Tubing Product Facts n 4:1 shrink ratio allows a few sizes to cover a wide range of splice and component diameters n Mechanically tough tubing provides strain relief and abrasion protection of wire splices, terminals and other components n Thick adhesive liner forms an effective barrier against fluids and moisture and performs well at an extended temperature range Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Specially designed for environmental sealing and electrical insulation of wire splices, terminations, and components where seethrough inspection is required. Minimum shrink temperature: 110C [230F] -40C to 130C [-40F to 266F] Minimum full recovery temperature: 135C [275F] Series UL ES1000 E85381 600 V, 125C Available in: Americas Raychem Europe n RT-1113 Asia Pacific n 3-37 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) ES1000 (Continued) Product Dimensions Part Number ES1000-No.1 ES1000-No.2 ES1000-No.3 ES1000-No.4 Inside Diameter (Including Core) Minimum Maximum Expanded Recovered After Heating as Supplied 5.72 [0.225] 1.27 [0.050] 7.44 [0.293] 1.65 [0.065] 10.85 [0.427] 2.41 [0.095] 17.78 [0.700] 4.45 [0.175] Minimum Total Wall After Heating 1.20 [0.047] 1.52 [0.060] 1.91 [0.075] 2.41 [0.095] Recovered Wall Thickness* Minimum Minimum Jacket Wall Adhesive Wall After Heating After Heating 0.64 [0.025] 0.56 [0.022] 0.76 [0.030] 0.76 [0.030] 0.89 [0.035] 1.02 [0.040] 1.04 [0.041] 1.37 [0.054] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Marking Ordering description Standard Clear (-X) Always order the largest size that will shrink snugly over the component to be covered. Cut pieces. Tubing will be printed with its numbered size (such as ES-1, ES-2, ES-3, or ES-4). Specify product name, numbered size, color, and cut length (for example, ES1000-NO.2-X-50MM). 3-38 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) ES2000 Flame-Retardant, HighShrink-Ratio, AdhesiveLined Semirigid Polyolefin Tubing Product Facts n 4:1 shrink ratio allows a few sizes to cover a wide range of splice and component diameters n Flame-retardant and mechanically tough, the tubing provides strain relief and abrasion protection of wire splices, terminals, and other components n Thick adhesive liner forms an effective barrier against fluids and moisture and performs well at an extended temperature range n UL recognized Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Specially designed for environmental sealing and electrical insulation of wire splices, terminations, and components. Minimum shrink temperature: 110C [230F] -40C to 130C [-40F to 266F] Minimum full recovery temperature: 135C [275F] Series UL ES2000 E85381 600 V, 125C Available in: Americas Raychem RT-1112 Europe n Asia Pacific n 3-39 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) ES2000 (Continued) Product Dimensions Part Number ES2000-No.1 ES2000-No.2 ES2000-No.3 ES2000-No.4 Inside Diameter (Including Core) Minimum Maximum Expanded Recovered After Heating as Supplied 5.72 [0.225] 1.27 [0.050] 7.44 [0.293] 1.65 [0.065] 10.85 [0.427] 2.41 [0.095] 17.78 [0.700] 4.45 [0.175] Minimum Total Wall After Heating 1.20 [0.047] 1.52 [0.060] 1.91 [0.075] 2.41 [0.095] Recovered Wall Thickness* Minimum Minimum Jacket Wall Adhesive Wall After Heating After Heating 0.64 [0.025] 0.56 [0.022] 0.76 [0.030] 0.76 [0.030] 0.89 [0.035] 1.02 [0.040] 1.04 [0.041] 1.37 [0.054] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Marking Ordering description Standard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. Cut pieces. Tubing will be printed with its numbered size (such as ES-1, ES-2, ES-3, or ES-4). Specify product name, numbered size, color, and cut length (for example, ES2000-NO.2-0-50MM). 3-40 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) FL2500 Fully Flame-Retardant, Adhesive-Lined, Polyolefin Heat-Shrinkable Tubing Product Facts n 4:1 shrink ratio allows a few sizes to cover a wide range of wire terminations and components n Flame-retardant tubing jacket and adhesive provide full flame-retardancy n Fully flame-retardant and mechanically tough, the tubing provides strain relief and abrasion protection of wire splices, terminals and other components n Thick high-performance adhesive lining offers permanent sealing of splices, fusible links, terminals and in-line components 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range Tough flame-retardant polyolefin tubing lined with a flame-retardant adhesive provides the optimum solution for applications where full flame-retardancy is preferred or specified. Minimum shrink temperature: 110C [230F] -40C to 135C [-40F to 275F] Minimum full recovery temperature: 135C [275F] Rated to 135C [275F] 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. Specifications/Approvals Series FL2500 Available in: Raychem FL2500 SCD Americas Europe Asia Pacific n n n 3-41 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) FL2500 (Continued) Product Dimensions Part Number FL2500-No. 1 FL2500-No. 2 FL2500-No. 3 FL2500-No. 4 Inside Diameter (Including Core) Minimum Maximum Expanded Recovered After Heating as Supplied 7.62 [0.300] 1.65 [0.065] 9.02 [0.355] 2.29 [0.090] 11.56 [0.455] 2.54 [0.100] 17.79 [0.700] 4.45 [0.175] Recovered Wall Thickness* Total Minimum Wall Adhesive Wall After Heating After Heating 1.52 0.3 [0.060 0.012] 0.762 [0.030] 1.52 0.3 [0.060 0.012] 0.762 [0.030] 2.29 0.3 [0.090 0.012] 1.397 [0.055] 2.54 0.3 [0.100 0.012] 1.524 [0.060] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Marking Ordering description Black (-0) with a white adhesive liner Always order the largest size that will shrink snugly over the component to be covered. Cut pieces. Tubing will be marked with its numbered size (such as FL-1, FL-2, FL-3, FL-4). Specify product name, size, color, and cut length (for example, FL2500-NO.2-0-50MM). 3-42 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) HTAT Semiflexible, Dual Wall, Moisture-Resistant, Heat-Shrinkable Tubing Product Facts n 4:1 shrink ratio Environmental sealing n High-strength bonding n Ideal connector sealing covering large diameter differences n 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range Designed to provide environmental sealing for a range of substrates, at elevated temperatures. Manufactured by Tyco Electronics from radiationcrosslinked 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 -55C to 125C [-67F to 257F] 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. Minimum shrink temperature: 80C [176F] -55C to 125C [-67F to 257F] Specifications/Approvals Minimum full recovery temperature: 110C [230F] Series HTAT Available in: Raychem RW-2052 Americas Europe Asia Pacific n n n 3-43 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) HTAT (Continued) Product Dimensions Size 4/1 8/2 12/3 16/4 24/6 32/8 48/13 Inside Diameter Maximum Minimum Recovered Expanded After Heating as Supplied 4.0 [0.158] 1.0 [0.039] 8.0 [0.315] 2.0 [0.079] 12.0 [0.472] 3.0 [0.118] 16.0 [0.630] 4.0 [0.158] 24.0 [0.945] 6.0 [0.236] 32.0 [1.260] 8.0 [0.315] 48.0 [1.890] 13.0 [0.512] Recovered Wall Thickness* Nominal Nominal Total Wall Adhesive Wall After Heating After Heating 1.00 [0.039] 0.40 [0.016] 1.00 [0.039] 0.50 [0.020] 1.40 [0.055] 0.60 [0.024] 1.75 [0.069] 0.75 [0.030] 2.25 [0.088] 0.80 [0.032] 2.50 [0.098] 1.00 [0.039] 2.55 [0.100] 1.00 [0.039] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description Standard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. In 1.2 meter [4-ft] lengths. Specify product name, size and color (for example, HTAT 8/2-0). 3-44 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) RPPM Flexible, Dual Wall, Moisture Proof, Heat-Shrinkable Tubing Product Facts n Environmental sealing Excellent mechanical strength n Abrasion resistance n 4:1 shrink ratio n 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range RPPM is a flexible, heatshrinkable, 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. Minimum shrink temperature: 60C [140F] -40C to 85C [-40F to 185F] Specifications/Approvals Minimum full recovery temperature: 80C [176F] Series RPPM Available in: Raychem RK-6214 Americas Europe Asia Pacific n n n 3-45 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) RPPM (Continued) Product Dimensions Ordering Information Inside Diameter Recovered Wall Thickness* Maximum Nominal Nominal Minimum Size Recovered Total Wall Adhesive Wall Expanded After Heating After Heating After Heating as Supplied 4.0 [0.158] 1.0 [0.039] 0.8 [0.032] 0.3 [0.012] 4/1 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 Size selection Standard packaging Ordering description Standard Clear (-X) Nonstandard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools, In 1.2 meter [4-foot] lengths or cut pieces. Specify product name, size and color (for example, RPPM 4/1-X). 3-46 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) SCL Semirigid, Encapsulant-Lined, Polyolefin Tubing Product Facts n 3:1 shrink ratio Splash-resistant, moistureresistant covering; not intended for use where immersion in fluids is required n Rugged protection against abrasion, vibration, and flexing n Excellent strain relief and insulation of weak points n Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Encapsulates components, splices, and terminations where moisture 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. Minimum shrink temperature: 125C [257F] -55C to 110C [-67F to 230F] Minimum full recovery temperature: 135C [275F] Series UL SCL E85381 600 V, 125C Military Raychem AMS-DTL-23053/4*, Class 1 RT-1301 *Formerly MIL-I-23053/4 and MIL-DTL-23053/4. Available in: Americas Europe Asia Pacific n n n 3-47 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) SCL (Continued) Product Dimensions Size Additional Standard Color 1/8 3/16 1/4 3/8 1/2 3/4 1 Brown Gray White Red Blue Yellow N/A Inside Diameter Minimum Maximum Expanded Recovered as Supplied After Heating 3.2 [0.125] 0.6 [0.023] 4.8 [0.187] 1.5 [0.060] 6.4 [0.250] 2.0 [0.080] 9.5 [0.375] 3.4 [0.135] 12.7 [0.500] 5.0 [0.195] 19.1 [0.750] 8.0 [0.313] 25.4 [1.000] 10.2 [0.400] Recovered Wall Thickness** Meltable Wall Total Wall After Heating After Heating (Nominal) 0.96 0.15 [0.038 0.006] 0.51 [0.020] 1.09 0.15 [0.043 0.006] 0.64 [0.025] 1.19 0.15 [0.047 0.006] 0.69 [0.027] 1.27 0.18 [0.050 0.007] 0.76 [0.030] 1.39 0.18 [0.055 0.007] 0.89 [0.035] 1.65 0.18 [0.065 0.007] 1.02 [0.040] 1.90 0.18 [0.075 0.007] 1.02 [0.040] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information 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. 3-48 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) SCT Flame-Retardant, Adhesive-Lined, Semirigid Polyolefin Tubing (Extended Temperature Range) Product Facts n 4:1 shrink ratio allows a few sizes to cover a wide range of splice and component diameters n Flame-retardant and mechanically tough, the tubing provides strain relief and abrasion protection of wire splices, terminals, and other components n Thick adhesive liner forms an effective barrier against fluids and moisture and performs well at an extended temperature range 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range Specially designed to insulate and seal automotive wire splices and components in an under-the-hood automotive environment. Specially formulated to function at an extended temperature range. Minimum shrink temperature: 110C [230F] -40C to 150C [-40F to 302F] Specifications/Approvals Minimum full recovery temperature: 135C [266F] Series SCT Available in: Raychem SCT SCD Americas Europe Asia Pacific n n n 3-49 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) SCT (Continued) Product Dimensions Part Number SCT No. 1 SCT No. 2 SCT No. 3 SCT No. 4 Inside Diameter Minimum Maximum Expanded Recovered After Heating as Supplied 7.6 [0.300] 1.7 [0.065] 9.0 [0.355] 2.3 [0.090] 11.6 [0.455] 2.5 [0.100] 17.8 [0.700] 4.4 [0.175] Recovered Wall Thickness* Meltable Wall Total Wall After Heating After Heating (Nominal) 1.52 0.30 [0.060 0 .012] 0.76 [0.030] 1.52 0.30 [0.060 0 .012] 0.76 [0.030] 2.29 0.30 [0.090 0.012] 1.40 [0.055] 2.54 0.30 [0.100 0.012] 1.52 [0.060] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Marking Ordering description Black Always order the largest size that will shrink snugly over the component being covered. Special order sizes are available upon request. Cut pieces. Tubing will be printed with its numbered size (such as SCT-1, SCT-2, SCT-3, SCT-4). Specify product name, numbered size, color and cut length (for example, SCT-NO.3-0-75MM). 3-50 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) TAT-125 Adhesive-Lined, Flexible, Polyolefin Tubing Product Facts n 2:1 shrink ratio n Thin adhesive lining that bonds to outer tubing and surface below, forming a positive environmental seal n Flexibility of both tubing and adhesive n Moisture seal that is resistant to bending of the substrate n Good mechanical strength and cut-through resistance n Adhesive that bonds to a wide variety of plastics, rubbers, and metals, including polyethylene, neoprene, lead, and steel Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Seals and protects simple in-line splices, bimetallic joints, and components from fluids, moisture, and corrosion. Repairs damaged wire insulation, especially where flexibility is required. Provides onestep electrical insulation and moisture sealing. Minimum shrink temperature: 95C [203F] -55C to 110C [-67F to 230F] Minimum full recovery temperature: 121C [250F] UL Series Military Raychem AMS-DTL-23053/4*, Class 2 TAT-125 SCD -- TAT-125 SCD TAT-125 Type 1 (colors) E85381 600 V, 125C -- TAT-125 Type 2 (clear) *Formerly MIL-I-23053/4 and MIL-DTL-23053/4. Sizes 1/4" through 1 1/2" only. Available in: Americas Europe n Asia Pacific n 3-51 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Dual Wall Tubing (Adhesive & Encapsulant-Lined) TAT-125 (Continued) Product Dimensions Size 1/8 3/16 1/4 3/8 1/2 3/4 1 1 1/2 Inside Diameter Maximum Minimum Recovered Expanded After Heating as Supplied 3.2 [0.125] 1.6 [0.062] 4.8 [0.187] 2.4 [0.093] 6.4 [0.250] 3.2 [0.125] 9.5 [0.375] 4.8 [0.187] 12.7 [0.500] 6.4 [0.250] 19.1 [0.750] 9.5 [0.375] 25.4 [1.000] 12.7 [0.500] 38.1 [1.500] 19.1 [0.750] Recovered Wall Thickness** Total Wall Adhesive Wall After Heating After Heating (Nominal) (Nominal) 0.69 [0.027] 0.23 [0.009] 0.71 [0.028] 0.25 [0.010] 0.74 [0.029] 0.13 [0.005] 0.74 [0.029] 0.13 [0.005] 0.76 [0.030] 0.15 [0.006] 0.89 [0.035] 0.15 [0.006] 1.07 [0.042] 0.20 [0.008] 1.19 [0.047] 0.28 [0.011] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Standard Nonstandard Size selection Standard packaging Ordering description Black (-0) White (-9), red (-2), blue (-6), yellow (-4), green (-5), brown (-1), orange (-3), violet (-7), gray (-8), clear (-X , not flame-retardant) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. In 1.2-meter [4-foot] lengths. Specify product name, size and color (for example, TAT-125 1/4-0). 3-52 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heavy-Duty Tubing BSTS/BSTS-FR General Purpose, Heat-Shrinkable Tubing Product Facts n Excellent thick-wall insulation and abrasion protection n No adhesive - can be removed easily n Expansion ratios as high as 3:1 n Availability in flameretardant material with FR callout (see "Ordering information and Part numbering system" on the next page) n BSTS has the following agency approvals: - ABS (American Bureau of Shipping) - DNV (Det Norske Veritas) - Lloyd's (Lloyd's Register of Shipping) Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range 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 where insulation, abrasion resistance, and strain relief are important. When used with SFTS tape sealant, it can provide a watertight system in nonpressurized applications. Minimum shrink temperature: 90C [194F] -55C to 90C [-67F to 194F] Series BSTS BSTS-FR Minimum full recovery temperature: 121C [250F] Military -- AMS-DTL-23053/15*, Class 1 and Class 2** Industry Raychem -- RW-2017 RW-2017 ASTM D 685, nonburning 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. Available in: Americas Europe Asia Pacific n n n 3-53 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heavy-Duty Tubing BSTS/BSTS-FR (Continued) Product Dimensions Inside Diameter Maximum Minimum recovered Expanded After Heating as Supplied 7.62 [0.300] 2.54 [0.100] 10.16 [0.400] 3.81 [0.150] 19.05 [0.750] 5.59 [0.220] 19.05 [0.750] 5.59 [0.220] 27.94 [1.100] 9.52 [0.375] 27.94 [1.100] 9.52 [0.375] 33.02 [1.300] 9.52 [0.375] 33.02 [1.300] 9.52 [0.375] 38.10 [1.500] 12.70 [0.500] 38.10 [1.500] 12.70 [0.500] 43.18 [1.700] 12.70 [0.500] 43.18 [1.700] 12.70 [0.500] 19.05 [0.750] 50.80 [2.000] 50.80 [2.000] 19.05 [0.750] 65.58 [2.700] 22.86 [0.900] 76.20 [3.000] 31.75 [1.250] 88.90 [3.500] 31.75 [1.250] 101.60 [4.000] 44.45 [1.750] 114.30 [4.500] 44.45 [1.750] Size BSTS-03 BSTS-04 BSTS-07M*** BSTS-07 BSTS-11M BSTS-11 BSTS-13M BSTS-13 BSTS-15M BSTS-15 BSTS-17M BSTS-17 BSTS-20M BSTS-20 BSTS-27 BSTS-30 BSTS-35 BSTS-40 BSTS-45 Wall Thickness (Nominal) Expanded as Supplied Recovered After Heating**** 0.63 [0.025] 0.63 [0.025] 0.51 [0.020] 0.76 [0.030] 0.76 [0.030] 1.02 [0.040] 0.63 [0.025] 0.89 [0.035] 0.89 [0.035] 1.27 [0.050] 1.02 [0.040] 1.14 [0.045] 1.27 [0.050] 1.27 [0.050] 1.27 [0.050] 1.27 [0.050] 1.27 [0.050] 1.27 [0.050] 1.27 [0.050] 1.52 [0.060] 1.52 [0.060] 1.52 [0.060] 2.41 [0.095] 2.67 [0.110] 3.05 [0.120] 2.67 [0.110] 3.05 [0.120] 3.05 [0.120] 3.56 [0.140] 3.05 [0.120] 3.56 [0.140] 3.05 [0.120] 3.94 [0.160] 3.94 [0.160] 3.94 [0.160] 3.94 [0.160] 3.94 [0.160] 3.94 [0.160] ***M = Medium wall tubing. ****Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description Part Numbering System Standard Black (-0) Nonstandard Red (-2), white (-9), clear (-X not flame-retardant) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. 1.2-meter [4-foot] or 7.5-meter [25-foot] lengths. See below. BSTS - _ _ x _ _ / _ / _ "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 Example: BSTS-11MX4/NM 3-54 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heavy-Duty Tubing HF High-Flex, Heavy-Wall, Heat-Shrinkable Tubing Product Facts n Offers high flexibility Provides excellent insulation and abrasion-protection, per U.S. Mine Safety and Health Administration (MSHA) regulations n Flame-retardant n HF has the following agency approvals: - ABS (American Bureau of Shipping) - DNV (Det Norske Veritas) - Lloyd's (Lloyd's Register of Shipping) n 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range Developed for cable jacketing applications where cable 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. Minimum shrink temperature: 80C [176F] -55C to 90C [-67F to 194F] Specifications/Approvals Series HF Minimum full recovery temperature: 121C [250F] Military AMS-DTL-23053/15* Class 1** Raychem RW-2023 *Formerly MIL-I-23053/15 and MIL-DTL-23053/15. **Except for coatings requirement. Available in: Americas Europe Asia Pacific n n n 3-55 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heavy-Duty Tubing HF (Continued) Product Dimensions Size HF04 HF07 HF11 HF13 HF15 HF17 HF20 HF27 Standard Nominal Length (m/ft) 1.2, 7.5 [4, 25] 1.2, 7.5 [4, 25] 1.2, 7.5 [4, 25] 1.2, 7.5 [4, 25] 1.2, 7.5 [4, 25] 1.2, 7.5 [4, 25] 1.2, 7.5 [4, 25] 1.2, 7.5 [4, 25] Minimum Expanded as Supplied 10.16 [0.40] 19.05 [0.75] 27.94 [1.10] 33.02 [1.30] 38.10 [1.50] 43.14 [1.70] 50.80 [2.00] 68.58 [2.70] Inside Diameter Maximum Recovered After Heating 3.81 [0.150] 5.59 [0.220] 9.52 [0.375] 9.52 [0.375] 12.70 [0.500] 12.70 [0.500] 19.05 [0.750] 22.86 [0.900] Wall Thickness** Nominal Recovered After Heating 1.52 [0.060] 1.52 [0.060] 2.67 [0.105] 2.67 [0.105] 3.05 [0.120] 3.05 [0.120] 3.56 [0.140] 3.94 [0.155] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description Part Numbering System Standard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. 1.2-meter [4-foot] or 7.5-meter [25-foot] lengths. Nonstandard lengths are available upon request. See below. HF - _ _ X _ / _ "NM" - no mark Length in feet (4 and 25 feet standard) "FR" - flame-retardant Size Product Name Example: HF-17FRX25/NM 3-56 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heavy-Duty Tubing HRHF/HRNF/HRSR High-Ratio, Heat-Shrinkable Tubing Product Facts n Offers toughness and durability n Provides excellent insulation and abrasion protection n Is available in flameretardant material. n Shrinks to fit (5.6:1) n FR callouts meet the flame-retardant material requirements of AMS-DTL-23053/15* n HRHF and HRSR have the following agency approvals: - ABS (American Bureau of Shipping) - DNV (Det Norske Veritas) - Lloyd's (Lloyd's Register of Shipping) 3 Heat-Shrinkable Tubing Applications High-ratio (HR) heatshrinkable 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 Specifications/Approvals Series HRSR HRHF HRNF and adhesives. The waterproofing 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. Military AMS-DTL-23053/15* AMS-DTL-23053/15* -- Agency ABS, DNV, Lloyd's ABS, DNV, Lloyd's -- Installation Minimum shrink temperature: 80C [176F] Minimum full recovery temperature: 121C [250F] Operating Temperature Range -55C to 90C [-67F to 194F] Raychem RW-2013 RW-2013 -- *Formerly MIL-I-23053/15 and MIL-DTL-23053/15. Available in: Americas Europe Asia Pacific n n n 3-57 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heavy-Duty Tubing HRHF/HRNF/HRSR (Continued) Product Dimensions Inside Diameter Minimum Expanded as Supplied 15.24 [0.60] 31.75 [1.25] 44.45 [1.75] 50.80 [2.00] 63.50 [2.50] 76.20 [3.00] 101.60 [4.00] Size HR**060 HR**125 HR**175 HR**200 HR**250 HR**300 HR**400 Maximum Recovered After Heating 3.81 [0.150] 5.59 [0.220] 8.00 [0.315] 9.52 [0.375] 12.70 [0.500] 19.05 [0.750] 22.86 [0.900] Recovered Wall Thickness Nominal After Heating 1.52 [0.060] 1.52 [0.060] 2.41 [0.095] 2.67 [0.105] 3.05 [0.120] 3.05 [0.120] 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. Ordering Information Color Size selection Standard packaging Ordering description Standard Black (-0) Clear (-X) available on request (not flame-retardant) Nonstandard Always order the largest size that will shrink snugly over the component to be covered. Other sizes are available upon request. 10-inch-maximum* lengths. See below. *Cutting tolerance is .125". Part Numbering System - Military Approved Part Numbers HRHF - _ _- _ /_ _ "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 Example: HRHF-125FR-10/226-NM 3-58 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heavy-Duty Tubing RHW Rugged, Heavy Wall, Adhesive-Lined, Polyolefin Heat-Shrinkable Tubing Product Facts n Withstands mechanical abuse for increased product reliability n Highly resistant to impact and abrasion n Provides high level of strain relief when installed on splices and joints n Resistant to chemicals, moisture and oils n Provides a complete moisture-proof seal preventing corrosion of underlying components 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range 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 industry standards. Minimum shrink temperature: 110C [230F] -55C to 110C [-67F to 230F] Minimum full recovery temperature: 125C [257F] 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. Specifications/Approvals Series RHW **Sizes 9/3 through 70/21 only. Available in: UL** Raychem File E115664 RHW SCD Americas Europe Asia Pacific n n n 3-59 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heavy-Duty Tubing RHW (Continued) Product Dimensions Inside Diameter Recovered Minimum After Expanded Heating as Supplied 9 [0.354] 3 [0.118] 13 [0.512] 4 [0.158] 20 [0.787] 6 [0.236] 33 [1.299] 8 [0.315] 43 [1.693] 12 [0.472] 51 [2.008] 16 [0.630] 70 [2.756] 21 [0.827] 85 [3.346] 25 [0.984] 105 [4.134] 30 [1.181] 130 [5.118] 36 [1.417] 160 [6.299] 50 [1.968] 180 [7.087] 50 [1.968] Size 9/3 13/4 20/6 33/8 43/12 51/16 70/21 85/25 105/30 130/36 160/50 180/50 Recovered Wall Thickness** Nominal Nominal Jacket Adhesive Wall Wall 2.0 [0.079] 0.25 [0.010] 2.4 [0.094] 0.30 [0.012] 2.5 [0.098] 0.35 [0.014] 3.2 [0.126] 0.35 [0.014] 4.3 [0.169] 0.40 [0.016] 4.5 [0.177] 0.40 [0.016] 4.4 [0.173] 0.40 [0.016] 4.3 [0.169] 0.40 [0.016] 4.3 [0.169] 0.45 [0.018] 4.3 [0.169] 0.45 [0.018] 4.3 [0.169] 0.45 [0.018] 4.3 [0.169] 0.50 [0.020] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Standard Size selection Standard packaging Marking Ordering description Black (-0) is available in all sizes Red (-2) is available in sizes 9/3, 13/4, 20/6 and 33/8 Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. 1200mm lengths 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 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) 3-60 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heavy-Duty Tubing RMW Medium Wall, Polyolefin Heat-Shrinkable Tubing Product Facts n Withstands mechanical abuse for increased product reliability n Highly resistant to impact and abrasion n Installation is fast and easy n Resistant to chemicals and moisture n Adhesive-lined version provides a complete moisture-proof seal preventing corrosion of underlying components 3 Heat-Shrinkable Tubing 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. Specifications/Approvals 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. Series RMW Available in: Installation Minimum shrink temperature: 110C [230F] Minimum full recovery temperature: 125C [257F] Operating Temperature Range -55C to 110C [-67F to 230F] Raychem RMW SCD Americas Europe Asia Pacific n n n 3-61 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heavy-Duty Tubing RMW (Continued) Product Dimensions Ordering Information Inside Diameter Recovered Wall Thickness** Recovered Nominal Nominal Minimum Size After Jacket Adhesive Expanded Heating Wall Wall as Supplied 10 [0.394] 3 [0.118] 1.0 [0.039] 0.25 [0.010] 10/3 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 [5.512] 42 [1.654] 3.1 [0.122] 0.45 [0.018] 140/42 160 [6.299] 50 [1.968] 3.2 [0.126] 0.50 [0.020] 160/50 60 [2.362] 3.2 [0.126] 0.50 [0.020] 180 [7.087] 180/60 **Wall thickness will be less if tubing recovery is restricted during shrinkage. Color Size selection Standard packaging Marking Ordering description Standard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. 1200mm lengths Tubing will be marked with the product name, size and batch number. Specify product name, size, cut length, coating option and color (for example, RMW 25/81200/ADH-0 or RMW 75/22-1200/U-0 (ADH = Adhesive-lined, U = Uncoated, 0= Black) 3-62 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heavy-Duty Tubing SST/SST-FR Self-Sealing, Heat-Shrinkable Tubing Product Facts n Thick adhesive liner forms an effective barrier against fluids and moisture n Thick-wall insulation, strain relief and abrasion protection n No need for greases, tape, or epoxy n Expansion ratios as high as 3:1 n Available in flame-retardant material n SST has the following agency approvals: - ABS (American Bureau of Shipping) - DNV (Det Norske Veritas) - Lloyd's (Lloyd's Register of Shipping) Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range SST provides a simple, positive splice-sealing method that offers protection under adverse environmental conditions. Tubing supplied with standard sealant provides water sealing and environmental 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. Minimum shrink temperature: 90C [195F] -55C to 90C [-67F to 194F] Series SST SST-FR Minimum full recovery temperature: 121C [250F] Military -- AMS-DTL-23053/15*, Classes 1 and 2 Industry -- ASTM D 685, nonburning 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 Raychem RW- 2011 RW -2011 *Formerly MIL-I-23053/I5 and MIL-DTL-23053/15. Available in: Americas Europe Asia Pacific n n n 3-63 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Heavy-Duty Tubing SST/SST-FR (Continued) Product Dimensions (inches) Size Standard Nominal Length SST*-03 SST*-04 SST*-07M SST*-07 SST*-11M SST*-11 SST*-13M SST*-13 SST*-15M SST*-15 SST*-17M SST*-17 SST*-20M SST*-20 SST*-27 SST*-30 SST*-40 SST*-45 6, 30 6, 30 6, 9, 12, 48 6, 9, 12, 48 6, 9, 12, 48 6, 9, 12, 48 6, 9, 12, 48 6, 9, 12, 48 6, 9, 12, 48 6, 9, 12, 48 6, 9, 12, 48 6, 9, 12, 48 6, 9, 12, 48 6, 9, 12, 48 12, 18, 24, 48 12, 18, 24, 48 12, 18, 24, 48 12, 18, 24, 48 Inside Diameter Maximum Minimum Expanded Recovered After Heating as Supplied 0.300 0.100 0.400 0.150 0.750 0.220 0.750 0.220 1.100 0.375 1.100 0.375 1.300 0.375 1.300 0.375 1.500 0.500 1.500 0.500 1.700 0.500 1.700 0.500 2.000 0.750 2.000 0.750 2.700 0.900 3.000 1.250 4.000 1.750 4.500 1.750 Wall Thickness Recommended Nominal Wall Cable Expanded After Range for Heating 600-Volt Cable 0.025 0.060 18 through 14 AWG 0.025 0.060 14 through 10 AWG 0.020 0.060 8 through 1 AWG 0.030 0.095 8 through 1 AWG 0.030 0.105 2 through 4/0 AWG 0.040 0.120 2 through 4/0 AWG 0.025 0.105 2 through 4/0 AWG 0.035 0.120 2 through 4/0 AWG 0.035 0.120 2/0 AWG through 500 MCM 0.050 0.140 2/0 AWG through 500 MCM 0.030 0.120 2/0 AWG through 500 MCM 0.045 0.140 2/0 AWG through 500 MCM 0.040 0.120 350 MCM through 1000 MCM 0.050 0.155 350 MCM through 1000 MCM 0.050 0.155 500 MCM through 1250 MCM 0.050 0.155 900 MCM through 1500 MCM 0.050 0.155 1500 MCM through 2500 MCM 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. Ordering Information Color Size selection Standard packaging Ordering description Part Numbering System Standard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. See Product Dimensions table. Specify product name, cut length, size and color (for example, SST 48-07/FR/RS). SST - _ - _ _ / _ / _ / _ / _ "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 Example: SST-48-07M/FR/97/NM 3-64 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing DR-25 Heat-Shrinkable, Flexible, Chemical and Abrasion Resistant Tubing Product Facts n Flame-retardant System 25 tubing n Shrink ratio 2:1 n 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range Specially formulated for optimum high temperature fluid resistance, and long term heat resistance. Resistant to aviation and diesel fuels, hydraulic fluids and lubricating oils. Minimum shrink temperature: 150C [302F] -75C to 150C [-103F to 302F] (per VG 95343 Part 5 Type D) Minimum full recovery temperature: 175C [347F] 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. Specifications/Approvals Military AMS-DTL-23053/16* VG95343 Part 5 Type D VDE 0341/Pt 9005 Def Stan 59-97 Issue 3 Type 6B BS 4G-198 Part 3 10A Series DR-25 Raychem RT-1116 RK-6008/1 *Formerly MIL-I-23053/16 and MIL-DTL-23053/16. Available in: Americas Europe Asia Pacific n n n 3-65 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing DR-25 (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 3.2 [0.125] 1.6 [0.062] 4.8 [0.187] 2.4 [0.093] 6.4 [0.250] 3.2 [0.125] 9.5 [0.375] 4.8 [0.187] 12.7 [0.500] 6.4 [0.250] 19.0 [0.748] 9.5 [0.375] 25.4 [1.000] 12.7 [0.500] 38.0 [1.500] 19.0 [0.748] 51.0 [2.000] 25.4 [1.000] 76.0 [3.000] 38.0 [1.500] Size 1/8 3/16 1/4 3/8 1/2 3/4 1 1 1/2 2 3 Recovered Wall Thickness** After Heating 0.76 0.15 [0.030 0.006] 0.84 0.15 [0.033 0.006] 0.89 0.15 [0.035 0.006] 1.02 0.20 [0.040 0.008] 1.22 0.20 [0.048 0.008] 1.45 0.28 [0.057 0.011] 1.78 0.28 [0.070 0.011] 2.41 0.41 [0.095 0.016] 2.79 0.41 [0.110 0.016] 3.18 0.50 [0.125 0.020] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description*** Standard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools. 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. 3-66 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing ES Caps High-Shrink-Ratio, Adhesive-Lined, Semirigid Polyolefin Caps Product Facts n 4:1 shrink ratio allows a few sizes to cover a wide range of splice and component diameters n Mechanically tough jacket provides strain relief and abrasion protection n Thick adhesive liner forms an effective barrier against fluids and moisture and performs well at an extended temperature range 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range Specially designed to provide mechanical and environmental protection of stub splices in electrical harnesses. Clear caps allow see-through inspection; black caps are flameretardant. Minimum shrink temperature: 100C [212F] -40C to 105C [-40F to 221F] Specifications/Approvals Minimum full recovery temperature: 135C [275F] Series UL ES Caps E85381 600 V, 125C Available in: Raychem RW-3006 Americas Europe Asia Pacific n n n 3-67 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing ES Caps (Continued) Product Dimensions Part Number ES Cap-No.1 ES Cap-No.2 ES Cap-No.3 Inside Diameter (Including Core) Standard Minimum Maximum Length* as Supplied Expanded Recovered as supplied After Heating (Millimeters) 30, 35 5.72 [0.225] 1.27 [0.050] 30, 35 7.44 [0.293] 1.65 [0.065] 40, 50 10.85 [0.427] 2.41 [0.095] Recovered Wall Thickness** Minimum Minimum Minimum Total Wall Jacket Wall Adhesive Wall After Heating After Heating After Heating 1.20 [0.047] 0.64 [0.025] 0.56 [0.022] 1.52 [0.060] 0.76 [0.030] 0.76 [0.030] 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. Ordering Information Color Size selection Standard packaging Marking Ordering description Standard Black (-0), clear (-X) Always order the largest size that will shrink snugly over the component to be covered. Other cap lengths available on request. In pieces. Caps will be marked with their numbered size (such as ES-1, ES-2, or ES-3). Specify product name, size, color, and length (for example, ES CAP-NO.2-X-35MM). 3-68 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing HCTE Helical Convolex Tubing with a High Crush Resistance Product Facts n Highly flame-retardant Highly flexible and fluid resistant n Not heat-shrinkable n High crush resistance n System 300 conduit tubing n 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range 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. 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. -55C to 200C [-67F to 392F] Specifications/Approvals Series HCTE Available in: Military VG 96936 Part 6 Raychem RT-1162 Americas Europe Asia Pacific n n n 3-69 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing HCTE (Continued) Product Dimensions Inside Diameter Minimum 4.60 [0.181] 6.90 [0.273] 7.70 [0.306] 9.20 [0.364] 10.80 [0.427] 12.30 [0.485] 15.40 [0.608] 17.90 [0.730] 21.80 [0.860] 24.70 [0.975] 30.70 [1.210] 36.50 [1.437] 39.60 [1.562] 42.67 [1.688] 49.20 [1.937] Size 0187 0281 0312 0375 0437 0500 0625 0750 0875 1000 1250 1500 1625 1750 2000 Ordering Information Color Size selection Standard packaging Ordering description Outside Diameter Maximum 8.10 [0.320] 10.50 [0.414] 11.80 [0.450] 12.90 [0.510] 14.50 [0.571] 16.50 [0.650] 19.50 [0.770] 23.60 [0.930] 27.20 [1.073] 31.10 [1.226] 35.30 [1.539] 46.50 [1.832] 50.17 [1.975] 52.88 [2.082] 59.23 [2.332] Maximum Wall Thickness 0.46 [0.018] 0.46 [0.018] 0.46 [0.018] 0.46 [0.018] 0.46 [0.018] 0.58 [0.023] 0.58 [0.023] 0.58 [0.023] 0.58 [0.023] 0.58 [0.023] 0.58 [0.023] 0.58 [0.023] 0.58 [0.023] 0.58 [0.023] 0.58 [0.023] Standard Black (-0) Always order a conduit size that will ensure that a "fill factor" of 70% is not exceeded. On spools. Specify product name, size and color (for example, HCTE-0187-0). 3-70 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing HFT5000 Heat-Shrinkable Fabric Tubing Product Facts n 3 Heat-Shrinkable Tubing Highly flexible woven fabric tubing n Polyethylene/polyester construction for excellent abrasion resistance n Halogen free n Heat-shrinkable to grip substrates tightly without additional fixing n 2:1 shrink ratio for easy installation onto different substrate diameters and sizes n Highly flexible woven fabric construction for easy, compliant installation onto awkward substrates such as bent hoses n Outstanding abrasion resistance over a wide temperature range n Easily cut with standard industrial cutting equipment n Resistant to harsh environments n Multifilament construction that ensures soft, safe handling n Low shrink temperature for safe installation onto heat sensitive substrates Applications Installation Operating Temperature Range 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. Minimum shrink temperature: 80C [176F] 3000 hours: -40C to 125C [-40F to 257F] Minimum full recovery temperature: 110C [230F] Maximum storage temperature: 60C [140F] 1000 hours: -40C to 150C [-40F to 302F] 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. Specifications/Approvals Raychem Series UL HFT5000 E199379 Rated 135C Available in: RW-2060 Americas Europe Asia Pacific n n n 3-71 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing HFT5000 (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied Size Standard 12/6 20/10 30/15 40/20 50/25 60/30 70/35 Nonstandard High Volume 25/12 34/17 80/40 Ordering Information Color Standard packaging Ordering description 12 [0.47] 20 [0.79] 30 [1.18] 40 [1.57] 50 [1.97] 60 [2.36] 70 [2.76] 6 [0.24] 10 [0.39] 15 [0.59] 20 [0.79] 25 [0.98] 30 [1.18] 35 [1.38] 25 [0.98] 34 [1.34] 80 [3.15] 12 [0.47] 17 [0.67] 40 [1.57] Standard Black (-0) On spools. Specify product name, size and color (for example, HFT5000-12/6-0) 3-72 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing MicroFit Small-Diameter, High-Shrink-Ratio Tubing Product Facts n Small diameter High shrink ratio n Thin wall n Polyolefin and fluoropolymer materials n 3 Heat-Shrinkable Tubing Specifications/Approvals Applications Installation Operating Temperature Range The MicroFit family of smalldiameter, 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. Minimum full recovery temperature: MT1000: -55C to 175C [-67F to 347F] 175C [347F] (MT1000) MT2000: -40C to 105C [-40F to 221F] Series Altera MicroFit RW-175 MicroFit Available in: 140C [284F] (MT2000) 175C [347F] (RW-175) RW-175: -55C to 175C [-67F to 347F] Raychem Altera MicroFit SCD Material USP Class VI (MT1000) USP Class VI (MT2000) -- Master File Number MAF-444 (MT1000) MAF-727 (MT2000) -- Americas Europe Asia Pacific n n n RW-175 MicroFit SCD 3-73 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing MicroFit (Continued) Product Dimensions Size MFT-*-No. 1-** MFT-*-No. 2-** MFT-*-No. 33-** MFT-*-No. 65-** Inside Diameter Maximum Minimum Recovered Expanded After Heating as Supplied 0.356 [0.014] 0.178 [0.007] 0.610 [0.024] 0.305 [0.012] 1.143 [0.045] 0.432 [0.017] 0.635 [0.025] 0.254 [0.010] Wall Thickness As Supplied (Nominal) Recovered*** (Maximum) 0.076 [0.003] 0.064 [0.0025] 0.064 [0.0025] 0.127 [0.005] 0.127 [0.005] 0.152 [0.006] 0.178 [0.007] 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. Ordering Information MT2000 RW-175 Black (-0), clear (-X) Translucent (-X) 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). Color Standard Nonstandard MT1000 Translucent (-X) Black (-0) ****MFT-MT1000 and MFT-MT2000 are double bagged. 3-74 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing MT1000 Altera Medical-Grade, USP Class VI, High-Temperature, Semirigid, Fluoropolymer Tubing Product Facts n 2:1 shrink ratio Tough, semirigid, very-thin-wall insulation n Excellent resistance to a variety of fluids n Optional inner adhesive lining in sizes 1/8" and larger (MT1000A) n USP Class VI material, no heavy metals n Double-bagged packaging n Compatibility with gamma, ETO, steam, and dry-heat sterilization n 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range Ideal for electrical insulation and strain relief of components that are exposed to high temperatures - either during operation or during sterilization. Minimum shrink temperature: 155C [311F} -55C to 175C [-67F to 347F] Minimum full recovery temperature: 175C [347F] Thin-wall construction is well suited for applications with clearance constraints. Specifications/Approvals Series MT1000 MT1000A Available in: Material USP Class VI USP Class VI Master File Number MAF-444 MAF-798 Raychem MT1000 SCD MT1000A SCD Americas Europe Asia Pacific n n n 3-75 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing MT1000 (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 1.17 [0.046] 0.58 [0.023] 1.6 [0.063] 0.8 [0.031] 2.4 [0.093] 1.2 [0.046] 3.2 [0.125] 1.6 [0.062] 4.7 [0.187] 2.4 [0.093] 6.4 [0.250] 3.2 [0.125] 9.5 [0.375] 4.7 [0.187] 12.7 [0.500] 6.4 [0.250] 19.1 [0.750] 9.5 [0.375] 25.4 [1.000] 12.7 [0.500] Size 3/64** 1/16 3/32 1/8 3/16 1/4 3/8 1/2 3/4** 1** Recovered Wall Thickness** After Heating 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.33 0.05 [0.013 0.002] 0.33 0.05 [0.013 0.002] 0.33 0.05 [0.013 0.002] 0.43 0.08 [0.017 0.003] 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. Ordering Information Color Size selection Standard packaging Ordering description Standard Translucent (-X) Nonstandard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. In 1.2-meter (4-foot) lengths, double bagged. Specify product name, size and color (for example, MT1000-1/8-X). Specify MT1000A for adhesive-lined constructions (special order). 3-76 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing MT2000 Altera Medical-Grade, USP Class VI, Lubricious, Thin-Wall, Polyolefin Tubing Product Facts n 2.5:1 shrink ratio Lubricity comparable to FEP n Excellent electrical insulation properties n Can be manufactured with a very thin wall n Optional inner adhesive lining in sizes 3.0 and larger (MT2000A) n USP Class VI material, no heavy metals n Plastic spools and double-bagged packaging n Compatibility with gamma and ETO sterilization n Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Especially suitable for medical applications requiring lubricity, flexibility, and excellent electrical insulation performance. A cost-effective alternative to FEP (fluorinated ethylene-propylene) while maintaining performance after gamma sterilization. Minimum shrink temperature: 110C [230F] -40C to 105C [-40F to 221F] Series MT2000 MT2000A Available in: Minimum full recovery temperature: 140C [284F] Material USP Class VI USP Class VI Master File Number MAF-727 MAF-799 Raychem MT2000 SCD MT2000A SCD Americas Europe Asia Pacific n n n 3-77 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing MT2000 (Continued) Product Dimensions Inside Diameter Maximum Minimum Recovered Expanded After Heating as Supplied 1.0 [0.040] 0.45 [0.018] 2.0 [0.080] 0.80 [0.032] 3.0 [0.120] 1.20 [0.048] 6.0 [0.240] 2.40 [0.096] 10.0 [0.400] 4.00 [0.160] Size 1.0 2.0 3.0 6.0 10.0 Wall Thickness As Supplied (Nominal) Recovered* After Heating 0.12 [0.005] 0.12 [0.005] 0.12 [0.005] 0.12 [0.005] 0.15 [0.006] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.36 0.05 [0.014 0.002] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description Standard Black (-0), clear (-X) Nonstandard White (-9), red (-2), blue (-6), yellow (-4), orange (-3) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On plastic spools, double-bagged. Specify product name, size and color (for example, MT2000-3.0-0). Specify MT2000A for adhesive-lined constructions (special order). 3-78 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing MT3000 Altera Medical-Grade, USP Class VI, High-Temperature, Flexible, Fluoropolymer Tubing Product Facts n 2:1 shrink ratio Tough, flexible, very-thin-wall insulation n Excellent resistance to a variety of fluids n USP Class VI material, no heavy metals n Plastic spools and double-bagged packaging n Compatibility with steam (limited cycles), gamma, ETO, and dry-heat sterilization n Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Used for electrical insulation and strain relief of components that are exposed 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. Minimum shrink temperature: 110C [230F] -55C to 150C [-67F to 302F] Series MT3000 Available in: Minimum full recovery temperature: 150C [302F] Material USP Class VI Master File Number MAF-472 Raychem MT3000 SCD Americas Europe Asia Pacific n n n 3-79 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing MT3000 (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 1.17 [0.046] 0.58 [0.023] 1.6 [0.063] 0.8 [0.031] 2.4 [0.093] 1.2 [0.046] 3.2 [0.125] 1.6 [0.062] 4.7 [0.187] 2.4 [0.093] 6.4 [0.250] 3.2 [0.125] 9.5 [0.375] 4.7 [0.187] 12.7 [0.500] 6.4 [0.250] 19.1 [0.750] 9.5 [0.375] 25.4 [1.000] 12.7 [0.500] Size 3/64** 1/16 3/32 1/8 3/16 1/4 3/8 1/2 3/4** 1** Recovered Wall Thickness* After Heating 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.30 0.05 [0.012 0.002] 0.30 0.05 [0.012 0.002] 0.30 0.05 [0.012 0.002] 0.43 0.08 [0.017 0.003] 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. Ordering Information Color Size selection Standard packaging Ordering description Standard Black (-0) Nonstandard White (-9) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On plastic spools, double-bagged. Specify product name, size and color (for example, MT3000 1/4-0). 3-80 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing MT5000 Altera Medical-Grade, USP Class VI, Flexible, Polyolefin Tubing Product Facts n 2:1 shrink ratio n Flexibility; variety of colors n Excellent electrical insulation properties n Inner adhesive lining optional in sizes 1/8" and larger (MT5000A) n USP Class VI material, no heavy metals n Plastic spools and double-bagged packaging n Compatibility with gamma and ETO sterilization Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range 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. Minimum shrink temperature: 90C [194F] -70C to 105C [-94F to 221F] Series MT5000 MT5000A Available in: Minimum full recovery temperature: 110C [230F] Material USP Class VI USP Class VI Master file number MAF-469 MAF-800 Raychem MT5000 SCD MT5000A SCD Americas Europe Asia Pacific n n n 3-81 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing MT5000 (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 1.17 [0.046] 0.58 [0.023] 1.6 [0.063] 0.8 [0.031] 2.4 [0.093] 1.2 [0.046] 3.2 [0.125] 1.6 [0.062] 4.8 [0.187] 2.4 [0.093] 6.4 [0.250] 3.2 [0.125] 9.5 [0.375] 4.8 [0.187] 12.7 [0.500] 6.4 [0.250] 19.1 [0.750] 9.5 [0.375] 25.4 [1.000] 12.7 [0.500] Size 3/64** 1/16 3/32 1/8 3/16 1/4 3/8 1/2 3/4** 1** Recovered Wall Thickness* After Heating 0.40 0.08 [0.016 0.003] 0.43 0.08 [0.017 0.003] 0.51 0.08 [0.020 0.003] 0.51 0.08 [0.020 0.003] 0.51 0.08 [0.020 0.003] 0.64 0.08 [0.025 0.003] 0.64 0.08 [0.025 0.003] 0.64 0.08 [0.025 0.003] 0.76 0.08 [0.030 0.003] 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. Ordering Information Color Size selection Standard packaging Ordering description Standard Black (-0), clear (-X), and blue (-6) Nonstandard White (-9), red (-2), yellow (-4) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On plastic spools, double-bagged. Specify product name, size and color (for example, MT5000-1/4-0). Specify MT5000A for adhesive-lined constructions (special order). 3-82 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing NT Flexible, General Purpose Modified Elastomeric Tubing Product Facts n Remains flexible at temperatures as low as -55C [-67F] n Offers good resistance to abrasion and physical abuse while providing the flexibility and strain relief needed in general-purpose harnessing applications n Resistant to most common fluids and solvents 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range 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. Minimum shrink temperature: 90C [194F] -55C to 90C [-67F to 194F] Minimum full recovery temperature: 135C [275F] Specifications/Approvals Series UL NT UL E35586 600V, 90C CSA Raychem CSA LR31929 600V, 90C RT-510 Available in: Americas Europe Asia Pacific n n n 3-83 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing NT (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 3.2 [0.125] 1.6 [0.061] 4.8 [0.187] 2.5 [0.100] 6.4 [0.250] 3.6 [0.143] 9.5 [0.375] 5.4 [0.211] 12.7 [0.500] 7.3 [0.286] 15.9 [0.625] 9.1 [0.357] 19.1 [0.750] 10.9 [0.428] 22.2 [0.875] 12.7 [0.500] 25.4 [1.000] 14.5 [0.570] 31.8 [1.250] 18.1 [0.714] 38.1 [1.500] 21.8 [0.857] 44.5 [1.750] 25.4 [1.000] 50.8 [2.000] 29.0 [1.140] 76.2 [3.000] 43.4 [1.710] 101.6 [4.000] 57.9 [2.280] Size 1/8 3/16 1/4 3/8 1/2 5/8 3/4 7/8 1 1 1/4 1 1/2 1 3/4 2 3 4 Recovered Wall Thickness** After Heating 0.69 0.20 [0.027 0.008] 0.84 0.25 [0.033 0.010] 0.89 0.25 [0.035 0.010] 1.01 0.25 [0.040 0.010] 1.21 0.38 [0.048 0.015] 1.32 0.38 [0.052 0.015] 1.44 0.38 [0.057 0.015] 1.65 0.38 [0.065 0.015] 1.77 0.51 [0.070 0.020] 2.20 0.51 [0.087 0.020] 2.41 0.51 [0.095 0.020] 2.71 0.51 [0.107 0.020] 2.79 0.51 [0.110 0.020] 3.17 0.51 [0.125 0.020] 3.55 0.51 [0.140 0.020] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description Standard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools. Specify product name, size and color (for example, NT 1/4-0). 3-84 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing NT-MIL Flexible, Rugged, Modified Elastomeric Tubing Product Facts n n n n Specifications/Approvals 3 Heat-Shrinkable Tubing n Remains flexible at temperatures as low as -70C [-94F] without cracking Withstands heat shock at 200C [392F] without dripping, flowing or cracking Offers outstanding resistance to abrasion and physical abuse while providing flexibility and strain relief needed in rugged harnessing applications Resistant to most fluids and solvents, including aviation and ground vehicle fuels, lubricating oil, and hydraulic fluids Meets the stringent requirements of SAE-AMS-DTL-23053/1, Classes 1 and 2 Applications Installation Operating Temperature Range 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. Minimum shrink temperature: 90C [194F] -70C to 121C [-94F to 250F] Minimum full recovery temperature: 135C [275F] Series Military AMS-DTL-23053/1*, Classes 1 & 2 NT-MIL *Formerly MIL-I-23053/1 and MIL-DTL-23053/1 Available in: Raychem RW-3030 Americas Europe Asia Pacific n n n 3-85 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing NT-MIL (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 3.2 [0.125] 1.6 [0.061] 4.8 [0.187] 2.5 [0.100] 6.4 [0.250] 3.6 [0.143] 9.5 [0.375] 5.4 [0.211] 12.7 [0.500] 7.3 [0.286] 15.9 [0.625] 9.1 [0.357] 19.1 [0.750] 10.9 [0.428] 22.2 [0.875] 12.7 [0.500] 25.4 [1.000] 14.5 [0.570] 31.8 [1.250] 18.1 [0.714] 38.1 [1.500] 21.8 [0.857] 44.5 [1.750] 25.4 [1.000] 50.8 [2.000] 29.0 [1.140] 76.2 [3.000] 43.4 [1.710] 101.6 [4.000] 57.9 [2.280] Size 1/8 3/16 1/4 3/8 1/2 5/8 3/4 7/8 1 1 1/4 1 1/2 1 3/4 2 3 4 Recovered Wall Thickness* After Heating 0.69 0.20 [0.027 0.008] 0.84 0.25 [0.033 0.010] 0.89 0.25 [0.035 0.010] 1.01 0.25 [0.040 0.010] 1.21 0.38 [0.048 0.015] 1.32 0.38 [0.052 0.015] 1.44 0.38 [0.057 0.015] 1.65 0.38 [0.065 0.015] 1.77 0.51 [0.070 0.020] 2.20 0.51 [0.087 0.020] 2.41 0.51 [0.095 0.020] 2.71 0.51 [0.107 0.020] 2.79 0.51 [0.110 0.020] 3.17 0.51 [0.125 0.020] 3.55 0.51 [0.140 0.020] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description Standard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools. Specify product name, size and color (for example, NT-MIL 1/4-0). 3-86 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing NTFR Very Flexible, Rugged Neoprene Elastomer Tubing Product Facts n Remains flexible at low temperatures without cracking n Offers outstanding resistance to abrasion and physical abuse while providing the flexibility and strain relief needed for rugged applications n Resistant to most fluids and solvents, including aviation and ground-vehicle fuels, lubricating oil, and hydraulic fluids (see Raychem Specification RT-511) n Performance exceeds the stringent requirements of SAE-AMS-DTL-23053/1, Class 2 n System 20 Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range 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 exposure to fluids and solvents at elevated temperatures. Minimum shrink temperature: 90C [194F] -70C to 121C [-94F to 250F] Series NTFR Available in: Minimum full recovery temperature: 135C [275F] Military SC-X-15112 Agency AMS 3623 Raychem RT-511 Americas Europe Asia Pacific n n n 3-87 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing NTFR (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 3.2 [0.125] 1.6 [0.061] 4.8 [0.187] 2.5 [0.100] 6.4 [0.250] 3.6 [0.143] 9.5 [0.375] 5.4 [0.211] 12.7 [0.500] 7.3 [0.286] 15.9 [0.625] 9.1 [0.357] 19.1 [0.750] 10.9 [0.428] 22.2 [0.875] 12.7 [0.500] 25.4 [1.000] 14.5 [0.570] 31.8 [1.250] 18.1 [0.714] 38.1 [1.500] 21.8 [0.857] 44.5 [1.750] 25.4 [1.000] 50.8 [2.000] 29.0 [1.140] 76.2 [3.000] 43.4 [1.710] Size 1/8 3/16 1/4 3/8 1/2 5/8 3/4 7/8 1 1 1/4 1 1/2 1 3/4 2 3 Recovered Wall Thickness** After Heating 0.69 0.20 [0.027 0.008] 0.84 0.25 [0.033 0.010] 0.89 0.25 [0.035 0.010] 1.01 0.25 [0.040 0.010] 1.21 0.38 [0.048 0.015] 1.32 0.38 [0.052 0.015] 1.44 0.38 [0.057 0.015] 1.65 0.38 [0.065 0.015] 1.77 0.51 [0.070 0.020] 2.20 0.51 [0.087 0.020] 2.41 0.51 [0.095 0.020] 2.71 0.51 [0.107 0.020] 2.79 0.51 [0.110 0.020] 3.17 0.51 [0.125 0.020] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description Standard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools. Specify product name, size and color (for example, NTFR 1/4-0). 3-88 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing PD Caps Semirigid, Encapsulant-Lined, Polyolefin Caps Product Facts n 3:1 shrink ratio Permanent or temporary way to terminate wires n Rapid, simple installation n Rugged protection against abrasion, vibration, and flexing n PD caps provide a splashresistant, moisture-resistant covering (but not intended for use where immersion in fluids is required) n 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range 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 vibrationproof caps are used to insulate and terminate dead-end electrical cables, fixtures, connectors, and other electrical components. Minimum shrink temperature: 125C [257F] -55C to 110C [-67F to 230F] Specifications/Approvals Minimum full recovery temperature: 135C [275F] Series UL PD Caps E85381 600 V, 125C Available in: Raychem PD Caps SCD Americas Europe Asia Pacific n n n 3-89 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing PD Caps (Continued) Product Dimensions Size 1/8 3/16 1/4 3/8 1/2 Length Minimum Open Nominal Barrel as Overall as Supplied* Supplied 22.0 [0.87] 12.7 [0.50] 25.4 [1.00] 15.2 [0.60] 28.4 [1.12] 15.2 [0.60] 31.8 [1.25] 18.3 [0.72] 38.1 [1.50] 21.6 [0.85] Inside Diameter Minimum Maximum Expanded Recovered as Supplied After Heating 3.2 [0.125] 0.58 [0.023] 4.8 [0.187] 1.52 [0.060] 6.4 [0.250] 2.03 [0.080] 9.5 [0.375] 2.29 [0.090] 12.7 [0.500] 2.29 [0.090] Recovered Wall Thickness** Total Wall After Heating 1.22 0.15 [0.048 0.006] 1.57 0.20 [0.062 0.008] 1.98 0.25 [0.078 0.010] 2.08 0.25 [0.082 0.010] 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. Ordering Information Color Size selection Standard packaging Ordering description Standard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. In pieces. Specify product name, size and color (for example, PD Caps 1/4-0). 3-90 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing RayBlock 85 Heat-Shrinkable Water-Blocking System Product Facts n Environmentally seals wire bundles of up to 20 wires n Withstands temperature excursions to 105C [221F] n Provides excellent strain relief and reduces noise n Offers a low-profile installed product only marginally larger than the cable bundle itself 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range 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 a flame-retardant, radiationcrosslinked 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 moistureresistant seal. Minimum shrink temperature: 80C [176F] -40C to 85C [-40F to 185F] Specifications/Approvals Minimum full recovery temperature: 110C [230F] Series RayBlock 85 Available in: Raychem RayBlock 85 SCD RW-2101 Americas Europe Asia Pacific n n n 3-91 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing RayBlock 85 (Continued) Product Dimensions No. of Channels Part No. RayBlock 85 Kit 0102-A0 RayBlock 85 Kit 0203-A0 RayBlock 85 Kit 0504-A0 RayBlock 85 Kit 0405-A0 RayBlock 85 Kit 0107-A0 RayBlock 85 Kit 0510-A0 Ordering Information Color Size selection Standard packaging 2 3 4 5 7 10 Profile Outside Height 8.5 [0.335] 8.5 [0.335] 8.5 [0.335] 8.5 [0.335] 8.5 [0.335] 8.5 [0.335] Length 2.75 [0.108] 2.75 [0.108] 2.75 [0.108] 2.75 [0.108] 2.75 [0.108] 2.75 [0.108] Width 8.50 [0.335] 12.25 [0.482] 16.00 [0.630] 19.75 [0.778] 27.25 [1.070] 38.50 [1.520] Minimum Expanded as Supplied 12.0 [0.472] 24.0 [0.945] 16.0 [0.630] 24.0 [0.945] 24.0 [0.945] 32.0 [1.260] Tubing Inside Diameter Maximum Recovered After Heating 3.0 [0.118] 6.0 [0.236] 4.0 [0.158] 6.0 [0.236] 6.0 [0.236] 8.0 [0.315] Nominal Length 40 [1.57] 47 [1.85] 40 [1.57] 45 [1.77] 65 [2.56] 55 [2.17] Standard Black (-0) 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. One kit (contains 1000 pcs. of profile and 1000 pcs. of tubing). 3-92 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing RayBlock 105 Heat-Shrinkable Water-Blocking System Product Facts n Environmentally seals wire bundles of up to 20 wires n Withstands temperature excursions to 120C [248F] n Provides excellent strain relief and reduces noise n Offers a low-profile installed product only marginally larger than the cable bundle itself 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range 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, heatshrinkable tubing with a flame-retardant radiationcrosslinked 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. Minimum shrink temperature: 80C [176F] -40C to 105C [-40F to 221F] Specifications/Approvals Minimum full recovery temperature: 110C [230F] Raychem RayBlock 105 SCD RW-2102 Series RayBlock 105 Available in: Americas Europe Asia Pacific n n n 3-93 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing RayBlock 105 (Continued) Product Dimensions Part No. No. of Channels RayBlock 105 Kit 0102-A0 RayBlock 105 Kit 0103-A0 RayBlock 105 Kit 0504-A0 RayBlock 105 Kit 0105-A0 RayBlock 105 Kit 0107-A0 RayBlock 105 Kit 0110-A0 Ordering Information 2 3 4 5 7 10 Profile Outside Height 8.5 [0.335] 8.5 [0.335] 8.5 [0.335] 8.5 [0.335] 8.5 [0.335] 8.5 [0.335] Length 2.75 [0.108] 2.75 [0.108] 2.75 [0.108] 2.75 [0.108] 2.75 [0.108] 2.75 [0.108] Width 8.50 [0.335] 12.25 [0.482] 16.00 [0.630] 19.75 [0.778] 27.20 [1.070] 38.50 [1.520] Minimum Expanded as Supplied 12.0 [0.472] 16.0 [0.630] 16.0 [0.630] 24.0 [0.945] 24.0 [0.945] 32.0 [1.260] Tubing Inside Diameter Maximum Recovered After Heating 3.0 [0.118] 4.0 [0.158] 4.0 [0.158] 6.0 [0.236] 6.0 [0.236] 8.0 [0.315] Nominal Length 40 [1.57] 40 [1.57] 45 [1.77] 45 [1.77] 65 [2.56] 65 [2.56] Color Size selection Standard Black (-0) 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). 3-94 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing Rayflex Tubing PET and PFR Expandable, Braided, Polyester Sleeving Product Facts n n n n n n Specifications/Approvals 3 Heat-Shrinkable Tubing n Excellent abrasion and cut-through resistance Lightweight Flexible (even at low temperatures) Fungus-proof Not affected by most chemicals and solvents, non-hygroscopic PFR meets UL VW-1, FAR25, and is Self-Extinguishing Fiber diameter is 0.254 [0.010] Applications Installation Operating Temperature Range Rayflex tubing is suited for the mechanical protection of wire harnesses, 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. This product is cold applied. -50C to 150C [-58F to 302F] Series (220C [428F] for short periods) UL CSA Raychem Rayflex PET Rayflex PFR Available in: RW-2069 E197586 Rated 125C Americas LR31929 Rated 125C Europe Asia Pacific n n 3-95 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing Rayflex Tubing (Continued) Product Dimensions Nominal Size Size RAYFLEX PET expandable polyester braid 3 [0.125] 1/8 6 [0.250] 1/4 3/8 10 [0.375] 13 [0.500] 1/2 19 [0.750] 3/4 1-1/4 32 [1.250] 1-3/4 45 [1.750] 51 [2.000] 2 Size Range 2.4-6.4 [0.094-0.250] 3.2-9.5 [0.125-0.375] 4.7-16 [0.188-0.630] 6.4-19 [0.250-0.750] 13-32 [0.500-1.250] 19-45 [0.750-1.750] 32-70 [1.250-2.750] 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] 6 [0.250] 3.2-9.5 [0.125-0.375] 1/4 10 [0.375] 4.7-16 [0.188-0.630] 3/8 13 [0.500] 6.4-19 [0.250-0.750] 1/2 3/4 19 [0.750] 13-32 [0.500-1.250] 32 [1.250] 19-45 [0.750-1.750] 1-1/4 45 [1.750] 32-70 [1.250-2.750] 1-3/4 2 51 [2.000] 38-76 [1.500-3.000] Ordering Information Color Standard RF-PET: Black (-0) RF-PFR: Black with white X-Cross tracers (-09) Standard packaging Ordering description On spools. Specify product name, size and color (for example, RF-PET 1/8-0). 3-96 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing Rayflex PETM Tubing Expandable, Braided, Polyester Sleeving Product Facts n n n n n 3 Heat-Shrinkable Tubing n Excellent abrasion and cut-through resistance Lightweight construction with 0.22 [.009] fiber Flexible (even at low temperatures) Fungus-resistant Resistant to most chemicals and solvents, non-hygroscopic Wide range of metric sizes Applications Installation Operating Temperature Range Rayflex tubing is suited for the mechanical protection of wire harnesses, 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. This product is cold applied. -50C to 150C [-58F to 302F] Available in: Americas (220C [428F] for short periods) Europe Asia Pacific n n 3-97 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing Rayflex PETM Tubing (Continued) Product Dimensions Ordering Information Nominal Size 3 [0.119] 4 [0.158] 5 [0.197] 6 [0.236] 8 [0.315] 10 [0.394] 12 [0.472] 15 [0.591] 20 [0.787] 25 [0.984] 30 [1.181] 40 [1.575] 50 [1.969] Size Range Minimum 1 [0.039] 2 [0.079] 3 [0.118] 4 [0.158] 5 [0.197] 7 [0.276] 8 [0.315] 10 [0.394] 14 [0.551] 18 [0.709] 20 [0.787] 30 [1.181] 40 [1.575] Color Standard packaging Ordering description Maximum 5 [0.197] 7 [0.276] 9 [0.354] 12 [0.472] 12 [0.472] 15 [0.591] 17 [0.669] 20 [0.787] 26 [1.024] 34 [1.339] 40 [1.575] 50 [1.969] 60 [2.362] Standard Black (-0), Grey (-8) On spools. Specify product name, size and color (for example, RF-PETM-03-0). 3-98 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing Rayrim Edging Material Commercial Protective, Self-Adhering, Edging Material Product Facts n Flexible to allow for protection of curved edges 3 Heat-Shrinkable Tubing 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. 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 -55C to +80C [-67F to 176F] means that the product can give protection under the most testing circumstances. Installation Minimum shrink temperature: 120C [248F] Minimum full recovery temperature: 150C [302F] Operating Temperature Range -55C to 80C [-67F to 176F] Manufactured from a Raychem radiation crosslinked polyolefin material, the profile offers a clean and rapid means of covering metal, wood and glass edges for all-round protection. Specifications/Approvals Raychem RK-6182 Series Rayrim Available in: Americas Europe Asia Pacific n n n 3-99 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing Rayrim Edging Material (Continued) Product Dimensions D A B C Adhesive E A (maximum) 0.6 [0.024] 1.0 [0.039] 2.0 [0.079] 4.2 [0.165] Size Nr. 6 Nr. 7 Nr. 8 Nr. 9 Application range Ordering Information Plate SWG 30-24 23-16 15-10 9-5 B (minimum) 0.5 [0.020] 0.9 [0.035] 0.9 [0.035] 0.9 [0.035] Thickness 0.31-0.56 [0.012-0.022] 0.61-1.63 [0.026-0.064] 1.83-3.25 [0.072-0.128] 3.66-5.38 [0.144-0.212] Color Size selection Standard packaging Ordering description C (minimum) 3.5 [0.138] 4.8 [0.189] 6.6 [0.260] 13.5 [0.532] D (minimum) 0.8 [0.032] 1.6 [0.063] 2.5 [0.098] 4.5 [0.177] E (typical) 1.25 [0.049] 1.25 [0.049] 2.25 [0.089] 2.20 [0.087] Recommended minimum bend radius 10 [0.394] 15 [0.591] 20 [0.787] 25 [0.984] Standard Black (-0) Always order the largest size that will shrink snugly on edge of the panel. 1.2-meter [4-foot] lengths. Specify product name, size number and color (for example, Rayrim Nr.6-0). 3-100 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing RNF-150 High-Performance, Flame-Resistant, Flexible, Fluoropolymer Tubing Product Facts n 2:1 shrink ratio Approximately 40 percent thinner walls than most general purpose polyolefin tubings n High flame-resistance n Excellent physical and electrical properties after exposure to many chemicals and solvents at 50C [122F] (but not recommended for use in direct contact with ketones) n Recommended maximum temperature for use as a primary insulator: 135C [275F] n Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Can be used for jacketing and bundling of wires to form light-duty harnesses, especially where a low 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. Minimum shrink temperature: 110C [230F] -55C to 150C [-67F to 302F] Minimum full recovery temperature: 150C [302F] Series UL RNF-150 E35586 VW-1 600 V, 150C Military Raychem AMS-DTL-23053/18*, Class 2 RT-370 *Formerly MIL-I-23053/18 and MIL-DTL-23053/18. Available in: Americas Europe Asia Pacific n n n 3-101 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing RNF-150 (Continued) Product Dimensions Size 3/64 1/16 3/32 1/8 3/16 1/4 3/8 1/2 3/4 1 Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 1.2 [0.046] 0.6 [0.023] 1.6 [0.063] 0.8 [0.031] 2.4 [0.093] 1.2 [0.046] 3.2 [0.125] 1.6 [0.062] 4.8 [0.187] 2.4 [0.093] 6.4 [0.250] 3.2 [0.125] 9.5 [0.375] 4.8 [0.187] 12.7 [0.500] 6.4 [0.250] 19.1 [0.750] 9.5 [0.375] 25.4 [1.000] 12.7 [0.500] Recovered Wall Thickness** After Heating 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.30 0.08 [0.012 0.003] 0.30 0.08 [0.012 0.003] 0.30 0.08 [0.012 0.003] 0.43 0.08 [0.017 0.003] 0.48 0.08 [0.019 0.003] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information 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. 3-102 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing RT-375 Clear, Flame-Resistant, Flexible, Fluoropolymer Tubing Product Facts n 2:1 shrink ratio n Exceptional clarity and clarity stability n Toughness, chemical resistance, and high-temperature performance n High flame-resistance n Approximately 40 percent thinner walls than most general purpose polyolefin tubings n Recommended maximum temperature for use as a primary insulator: 135C [275F] Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Protects wire and 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. Minimum shrink temperature: 125C [257F] -55C to 150C [-67F to 302F] Series UL RT-375 E35586 VW-1 600 V, 150C Minimum full recovery temperature: 150C [302F] CSA Military Raychem LR31929 VW-1 600 V, 150C AMS-DTL-23053/18*, Class 2 RT-375 *Formerly MIL-I-23053/18 and MIL-DTL-23053/18. Available in: Americas Europe Asia Pacific n n n 3-103 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing RT-375 (Continued) Product Dimensions Size 3/64 1/16 3/32 1/8 3/16 1/4 3/8 1/2 3/4 1 Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 1.2 [0.046) 0.6 [0.023] 1.6 [0.063] 0.8 [0.031] 2.4 [0.093] 1.2 [0.046] 3.2 [0.125] 1.6 [0.062] 4.8 [0.187] 2.4 [0.093] 6.4 [0.250] 3.2 [0.125] 9.5 [0.375] 4.8 [0.187] 12.7 [0.500] 6.4 [0.250] 19.1 [0.750] 9.5 [0.375] 25.4 [1.000] 12.7 [0.500] Recovered Wall Thickness** After Heating 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.30 0.08 [0.012 0.003] 0.30 0.08 [0.012 0.003] 0.30 0.08 [0.012 0.003] 0.43 0.08 [0.017 0.003] 0.48 0.08 [0.019 0.003] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard Clear (-X) 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. 3-104 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing RT555 Fluid-Resistant, ChemicalResistant, Crosslinked Fluoropolymer Tubing with Extended Temperature Range Product Facts n Resistance to high temperatures, solvents, corrosive chemicals, and radiation n Extreme resistance to hydrocarbons n Low outgassing (successfully tested for NASA outgassing requirements) n Highly flame-retardant n 40 percent lighter weight than tubing made with Viton(R) fluoroelastomer n System 300 tubing Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range 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. Minimum shrink temperature: 150C [302F] -65C to 200C [-85F to 392F] Minimum full recovery temperature: 220C [428F] Series UL RT555 Listed for 185C for 100,000-hr continuous use (File E85381) Listed for 200C for 40,000-hr cumulative intermittent exposure Raychem VITON is a trademark of Dupont Dow Elastomers LLC. Available in: RT-555 Americas Europe Asia Pacific n n n 3-105 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing RT555 (Continued) Product Dimensions Inside diameter Size Minimum expanded as supplied 1/8 3/16 1/4 3/8 1/2 5/8 3/4 1 1 1/4 1 1/2 2 3.18 [0.125] 4.75 [0.187] 6.35 [0.250] 9.53 [0.375] 12.70 [0.500] 15.88 [0.625] 19.05 [0.750] 25.40 [1.000] 31.75 [1.250] 38.10 [1.500] 50.80 [2.000] Maximum recovered after heating 1.57 [0.062] 2.36 [0.093] 3.18 [0.125] 4.75 [0.187] 6.35 [0.250] 7.95 [0.313] 9.53 [0.375] 12.70 [0.500] 15.88 [0.625] 19.05 [0.750] 25.40 [1.000] Recovered wall thickness* After heating Minimum 0.25 [0.010] 0.28 [0.011] 0.33 [0.013] 0.41 [0.016] 0.41 [0.016] 0.48 [0.019] 0.61 [0.024] 0.71 [0.028] 0.76 [0.030] 0.86 [0.034] 0.94 [0.037] Maximum 0.41 [0.016] 0.46 [0.018] 0.51 [0.020] 0.58 [0.023] 0.58 [0.023] 0.66 [0.026] 0.79 [0.031] 0.89 [0.035] 0.94 [0.037] 1.04 [0.041] 1.12 [0.044] Nominal 0.30 [0.012] 0.36 [0.014] 0.41 [0.016] 0.48 [0.019] 0.48 [0.019] 0.56 [0.022] 0.69 [0.027] 0.79 [0.031] 0.84 [0.033] 0.94 [0.037] 1.02 [0.040] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description Standard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools. Specify product name, size and color (for example, RT555 1/8-0). 3-106 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing RW-175 High temperature, Chemical-Resistant, Polyvinylidene Fluoride Tubing Product Facts n 2:1 shrink ratio Tough, semirigid, very-thinwall insulation n High flame-resistance, meeting the requirements of AMS-DTL-23053*, Test C, with UL and CSA VW-1 rating n High-temperature performance that meets or exceeds military and industrial standards n Protection from most industrial solvents, fuels, and chemicals n Recommended maximum temperature for use as a primary insulator: 135C [275F] n Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Especially suitable for applications requiring hightemperature performance, 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. Minimum shrink temperature: 155C [311F] -55C to 175C [-67F to 347F] Series UL RW-175 E35586 VW-1 600 V, 150C Minimum full recovery temperature: 175C [347F] CSA Military Industry Raychem LR31929 VW-1 600 V, 150C AMS-DTL-23053/8* Def. Stan. 59-97 Type 3 VG 95343 Pt 5 Type F BS 3G 198 Pt4 VDE 0341 Pt 9005 RW-3029/1 RW-3029/2 *Formerly MIL-I-23053 and MIL-DTL-23053/8. Available in: Americas Europe Asia Pacific n n n 3-107 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing RW-175 (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 1.2 [0.046] 0.6 [0.023] 1.6 [0.063] 0.8 [0.031] 2.4 [0.093] 1.2 [0.046] 3.2 [0.125] 1.6 [0.062] 4.8 [0.187] 2.4 [0.093] 6.4 [0.250] 3.2 [0.125] 9.5 [0.375] 4.8 [0.187] 12.7 [0.500] 6.4 [0.250] 19.1 [0.750] 9.5 [0.375] 25.4 [1.000] 12.7 [0.500] 38.1 [1.500] 19.1 [0.750] Size 3/64 1/16 3/32 1/8 3/16 1/4 3/8 1/2 3/4 1 1 1/2 Recovered Wall Thickness** After Heating 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.25 0.05 [0.010 0.002] 0.33 0.05 [0.013 0.002] 0.33 0.05 [0.013 0.002] 0.33 0.05 [0.013 0.002] 0.43 0.08 [0.017 0.003] 0.48 0.08 [0.019 0.003] 0.51 0.08 [0.020 0.003] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description*** Standard Clear (-X) Nonstandard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. In 1.2-meter [4-foot] lengths. 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. 3-108 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing SFR Very Flexible, Flame-Retardant, Silicone Elastomer Tubing Product Facts n Outstanding low-temperature flexibility n Resistance to hydraulic fluids, fuel, and lubricating oil n Very good ablative characteristics: when exposed to flame, surface turns to insulative char or "ablates" 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range Provides cable jacketing, harness protection, and strain relief for electronic components, semiconductor leads, and wire splices. Ideal for applications that require flexibility over a wide range of operating temperatures. Minimum shrink temperature: 135C [285F] -75C to 180C [-103F to 356F] Specifications/Approvals Minimum full recovery temperature: 175C [347F] Military AMS-DTL-23053/10* MIL-PRF-46846, Type II, Class 1 Series SFR Raychem RT-1140 *Formerly MIL-I-23053/10 and MIL-DTL-23053/10. Available in: Americas Europe Asia Pacific n n n 3-109 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing SFR (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 6.4 [0.250] 3.6 [0.143] 9.5 [0.375] 5.4 [0.214] 12.7 [0.500] 7.3 [0.286] 15.9 [0.625] 9.1 [0.357] 19.1 [0.750] 10.9 [0.428] 22.2 [0.875] 12.7 [0.500] 25.4 [1.000] 14.5 [0.570] 31.8 [1.250] 18.1 [0.714] 38.1 [1.500] 21.8 [0.857] 44.5 [1.750] 25.4 [1.000] 50.8 [2.000] 29.0 [1.140] Size 1/4 3/8 1/2 5/8 3/4 7/8 1 1 1/4 1 1/2 1 3/4 2 Recovered Wall Thickness** After Heating 0.88 0.25 [0.035 0.010] 1.02 0.25 [0.040 0.010] 1.21 0.38 [0.048 0.015] 1.32 0.38 [0.052 0.015] 1.44 0.38 [0.057 0.015] 1.65 0.38 [0.065 0.015] 1.77 0.51 [0.070 0.020] 2.21 0.51 [0.087 0.020] 2.41 0.51 [0.095 0.020] 2.71 0.51 [0.107 0.020] 2.79 0.51 [0.110 0.020] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description*** Standard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools. 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. 3-110 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing SRFR Highly Flexible, Silicone Rubber Tubing Product Facts n Highly flame-retardant Extremely flexible at high and low temperatures n Shrink ratio 1.5:1 minimum except sizes 4/2.9 and 29/20 n 3 Heat-Shrinkable Tubing 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 nonburning 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. Installation Minimum shrink temperature: 135C [275F] Minimum full recovery temperature: 175C [347F] Operating Temperature Range -75C to 200C [-103F to 392F] Specifications/Approvals Raychem Series UL SRFR E85381 VW-1 600V, 200C Available in: RT-1142 RW- 2057 Americas Europe Asia Pacific n n n 3-111 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing SRFR (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 2.9 [0.114] 1.7 [0.067] 4.0 [0.158] 2.9 [0.114] 7.8 [0.307] 4.6 [0.181] 10.0 [0.394] 6.5 [0.256] 15.0 [0.591] 9.6 [0.378] 21.0 [0.827] 13.0 [0.512] 29.0 [1.142] 20.0 [0.787] 41.0 [1.614] 27.0 [1.063] 51.0 [2.008] 33.0 [1.299] Size 2.9/1.7 4/2.9 7.8/4.6 10/6.5 15/9.6 21/13 29/20 41/27 51/33 Recovered Wall Thickness** After Heating (Nominal) 1.0 0.50 [0.039 0.020] 1.0 0.50 [0.039 0.020] 1.0 0.50 [0.039 0.020] 1.5 0.50 [0.059 0.020] 1.5 0.50 [0.059 0.020] 2.0 0.75 [0.079 0.030] 2.0 0.75 [0.079 0.030] 3.0 1.00 [0.118 0.039] 3.0 1.00 [0.118 0.039] **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description Standard Gray (-8) Always order the largest size that will shrink snugly over the component to be covered. On spools. Specify product name, size and color (for example, SRFR 2.9/1.7-8). 3-112 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing TFE and TFE-R High-Temperature, Chemically Inert, Modified Tubing made with Teflon(R) Fluoropolymer Product Facts n Shrink ratio: 1.8:1 (TFE) 3.2:1 (TFE-R) n High flame-resistance n Excellent chemical resistance 3 Heat-Shrinkable Tubing Applications Installation Operating Temperature Range 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. Minimum shrink temperature: 330C [625F] -67C to 250C [-88.6F to 482F] Minimum full recovery temperature: 340C [644F] Specifications/Approvals Series Military Raychem AMS-DTL-23053/12*, Classes 1 and 3 Def. Stan. 59-97 Type 5A (TFE) Def. Stan. 59-97 Type 5B (TFE-R) *Formerly MIL-I-23053/12 and MIL-DTL-23053/12. TFE, TFE-R TEFLON is a trademark of E.I. du Pont de Nemours and Company Available in: Americas RW-2055 (TFE) RW-2054 (TFE-R) Europe Asia Pacific n n 3-113 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing TFE and TFE-R (Continued) Product Dimensions (millimeters) Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied TFE TFE-R TFE TFE-R 0.8 2.0 0.38 0.6 0.9 3.2 0.46 1.0 1.1 6.4 0.56 1.6 1.2 9.5 0.68 2.4 1.4 12.7 0.81 3.7 1.5 15.9 0.99 4.5 1.9 19.0 1.24 5.7 2.3 25.4 1.55 7.1 3.0 32.0 1.83 8.8 3.8 2.26 4.8 2.84 6.1 3.58 -- 7.6 -- 4.52 -- 9.4 -- 5.69 -- 10.9 -- 7.06 -- 11.9 -- 8.81 -- Size TFE 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 TFE-R 5/64 1/8 1/4 3/8 1/2 5/8 3/4 1 1 1/4 -- -- -- -- Recovered Wall Thickness** After Heating (Nominal) TFE 0.23 0.23 0.25 0.25 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.38 0.38 0.38 0.38 0.38 TFE-R 0.23 0.25 0.30 0.30 0.38 0.38 0.38 0.38 0.38 -- -- -- -- -- **Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description*** Standard Clear (-X) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. In 1.2-meter [4-foot] lengths. 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. 3-114 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing Viton(R)/Viton(R)-HW/Viton(R)-E/Viton(R)-TW Heat-Shrinkable, Chemical-Resistant, High-Temperature Tubing Product Facts n High resistance to impact and abrasion n Resistance to a wide variety of fuels, lubricants, acids, and solvents at elevated temperatures n Flexibility at low temperatures without cracking Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range Raychem premium heatshrinkable tubing is fabricated from Viton(R) fluoroelastomers - a crosslinked material designed for a wide range of applications. It is available in three configurations. Viton(R)-E is the thickest wall version, Viton(R)-HW has a thinner wall. Viton(R) and Viton(R)-TW have the thinnest wall for lighter weight applications. Offering fluid resistance, Viton(R) tubing can be used in applications up to 200C [392F]. Minimum shrink temperature: 100C [212F] Viton(R), Viton(R)-HW, and Viton(R)-TW: -40C* to 200C [-40F to 392F] Series Viton(R) Viton(R)-TW Viton(R)-E Minimum full recovery temperature: 175C [347F] Viton(R)-E: -55C to 200C [-67F to 392F] Military AMS-DTL 23053/13** Raychem RT-1146 RK-6014/2 RK-6014 Def. Stan. 59-97 Issue 3 Type 4A VG 95343 Part 5 Type E VDE 0341/Pt9005 BS 4G-198 Part 3 12A MIL-PRF-46846 Type III, Class I Viton(R)-HW RT-1145 *Viton(R)-TW is rated for -5C when tested in accordance with RK-6014/2. **Formerly MIL-I-23053/13 and MIL-DTL-23053/13. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 3-115 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing Viton(R)/Viton(R)-HW/Viton(R)-E/Viton(R)-TW (Continued) Product Dimensions Size 1/8 3/16 1/4 3/8 1/2 5/8 3/4 7/8 1 1 1/4 1 1/2 2 Inside Diameter Maximum Recovered Minimum Expanded as Supplied After Heating 3.2 [0.125] 1.6 [0.062] 4.8 [0.187] 2.4 [0.093] 6.4 [0.250] 3.2 [0.125] 9.5 [0.375] 4.8 [0.187] 12.7 [0.500] 6.4 [0.250] 15.9 [0.625] 7.9 [0.312] 19.1 [0.750] 9.5 [0.375] 22.2 [0.875] 11.1 [0.437] 25.4 [1.000] 12.7 [0.500] 31.8 [1.250] 15.9 [0.625] 38.1 [1.500] 19.1 [0.750] 50.8 [2.000] 25.4 [1.000] Recovered Wall Thickness*** After Heating (Nominal) Viton(R)-E Viton(R)-HW Viton(R)/Viton(R)-TW 0.76 [0.030] -- 0.76 [0.030] 0.84 [0.033] -- 0.89 [0.035] 0.89 [0.035] 0.76 [0.030] 0.89 [0.035] 1.02 [0.040] 0.89 [0.035] 0.89 [0.035] 1.22 [0.048] 1.09 [0.043] 0.89 [0.035] -- 1.19 [0.047] 1.07 [0.042] 1.45 [0.057] 1.32 [0.057] 1.07 [0.042] -- 1.53 [0.060] 1.25 [0.049] 1.78 [0.070] 1.65 [0.065] 1.25 [0.049] -- 1.78 [0.070] 1.40 [0.055] 2.41 [0.095] 1.91 [0.075] 1.40 [0.055] 2.79 [0.110] 2.79 [0.110] 1.65 [0.065] ***Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard Black (-0) 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(R) 1/4-0). ****Europe only. For supply to MIL, Def Stan and BS add -MS, -DS or -BS to ordering description. VITON is a trademark of Dupont Dow Elastomers LLC. 3-116 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing XFFR Halogen-Free, Flame-Retardant, Heat-Shrinkable Tubing Product Facts n Emits minimal amounts of toxic or acid gases during combustion n Meets performance requirements of MIL-C-24640 and MIL-C-24643 cable jackets n Resists moisture, fungus, and weathering n Available in expansion ratios as high as 3:1 n XFFR has the following approvals: - ABS (American Bureau of Shipping) - DNV (Det Norske Veritas) - Lloyd's (Lloyd's Register of Shipping) Heat-Shrinkable Tubing Specifications/Approvals 3 Applications Installation Operating Temperature Range 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 SFTSFR1 tape, the tubing can also be used in applications requiring water sealing and protection from abrasion and corrosion. Minimum shrink temperature: 70C [158F] -55C to 105C [-67F to 221F] Series XFFR Available in: Minimum full recovery temperature: 121C [250F] Military MIL-C-24643 Industry NES 713 NES 711 Raychem RW-2016 Americas Europe Asia Pacific n n n 3-117 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing XFFR (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 7.62 [0.300] 2.54 [0.100] 10.16 [0.400] 3.81 [0.150] 19.05 [0.750] 5.59 [0.220] 27.94 [1.100] 9.52 [0.375] 38.10 [1.500] 12.70 [0.500] 50.80 [2.000] 19.05 [0.750] 76.20 [3.000] 31.75 [1.250] Size XFFR-03 XFFR-04 XFFR-07 XFFR-11 XFFR-15 XFFR-20 XFFR-30 Recovered Wall Thickness* After Heating (Nominal) 1.52 [0.060] 1.52 [0.060] 2.03 [0.080] 2.67 [0.105] 3.05 [0.120] 3.05 [0.120] 3.94 [0.155] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Part Numbering System Color Size selection Standard packaging Standard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. 1.2-meter [4-foot] or 7.5-meter [25-foot] lengths. XFFR - 03 X 4 / NM "NM" - no mark Length in feet (4 feet standard) Size Family No adhesive. 3-118 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing ZH-100 Flexible, Thin-Wall, LowFire-Hazard Tubing Product Facts n 2:1 shrink ratio Low smoke emissions n Flexible, flame-retardant n No added halogens n Low evolution of acid gases n 3 Heat-Shrinkable Tubing Specifications/Approvals Applications Installation Operating Temperature Range ZH-100 is a flexible, thin-wall, heat-shrinkable tubing designed for low-firehazard applications. ZH-100 contains no added halogens, and exhibits excellent fire safety characteristics combined with low evolution of acid gases, while retaining good mechanical and fluid resistance properties. Minimum shrink temperature: 80C [176F] -30C to 105C [-22F to 221F] Series ZH-100 Available in: Minimum full recovery temperature: 120C [248F] Military Def. Stan. 59-97 Issue 3 Type 8 Agency BR 1326A BS 3G-198 Part 3 Type 15 Raychem RW-2031 Americas Europe Asia Pacific n n n 3-119 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing ZH-100 (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 3.2 [0.125] 1.6 [0.062] 4.8 [0.187] 2.4 [0.093] 6.4 [0.250] 3.2 [0.125] 9.5 [0.375] 4.8 [0.187] 12.7 [0.500] 6.4 [0.250] 19.0 [0.750] 9.5 [0.375] 25.4 [1.000] 12.7 [0.500] 38.0 [1.500] 19.0 [0.750] 51.0 [2.000] 25.4 [1.000] Size 1/8 3/16 1/4 3/8 1/2 3/4 1 1 1/2 2 Recovered Wall Thickness* After Heating 0.50 0.10 [0.019 0.004] 0.50 .0.10 [0.019 0.004] 0.65 0.15 [0.026 0.006] 0.65 0.15 [0.026 0.006] 0.65 0.15 [0.026 0.006] 0.75 0.15 [0.030 0.006] 0.90 0.15 [0.035 0.006] 1.00 0.20 [0.039 0.008] 1.15 0.25 [0.045 0.010] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description** Standard Black (-0) Nonstandard White (-9), red (-2), blue (-6), yellow (-4), green (-5) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools. 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. 3-120 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing ZHTM Heat-Shrinkable, Flexible Tubing with Low Toxicity for Fire Safety Applications Product Facts n 2:1 shrink ratio n Low smoke emission n System 100 tubing 3 Heat-Shrinkable Tubing Applications A flexible, thick-wall, heatshrinkable tubing to be used in conjunction with -100 molded parts and Zerohal cable to form Raychem System 100. This material exhibits excellent fire safety characteristics combined with low smoke emission and low evolution of acid gases while retaining good mechanical and fluid-resistance Specifications/Approvals Series ZHTM Available in: Military Def. Stan. 59-97 Issue 3 Type 8 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. Agency BS 4G-198 Part 3 Type 15 VG 95343 Part 5 Type L VDE 0341/Pt 9005 Installation Minimum shrink temperature: 80C [176F] Minimum full recovery temperature: 121C [250F] Operating Temperature Range -30C to 105C [-22F to 221F] Industry BR 1326A Raychem RW-2058 Americas Europe Asia Pacific n n n 3-121 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Special Purpose Tubing ZHTM (Continued) Product Dimensions Inside Diameter Minimum Expanded Maximum Recovered After Heating as Supplied 3.0 [0.118] 1.5 [0.059] 5.0 [0.197] 2.5 [0.098] 8.0 [0.315] 4.0 [0.157] 12.0 [0.472] 6.0 [0.236] 18.0 [0.709] 9.0 [0.354] 24.0 [0.945] 12.0 [0.472] 40.0 [1.575] 20.0 [0.789] 50.0 [1.969] 30.0 [1.181] Size 3/1.5 5/2.5 8/4 12/6 18/9 24/12 40/20 50/30 Recovered Wall Thickness* After Heating 0.70 0.10 [0.028 0.004] 0.75 0.12 [0.030 0.005] 0.80 0.15 [0.031 0.006] 0.90 0.15 [0.035 0.006] 1.00 0.18 [0.039 0.007] 1.10 0.20 [0.043 0.008] 1.30 0.23 [0.051 0.009] 1.50 0.28 [0.059 0.011] *Wall thickness will be less if tubing recovery is restricted during shrinkage. Ordering Information Color Size selection Standard packaging Ordering description** Standard Black (-0) Always order the largest size that will shrink snugly over the component to be covered. Special order sizes are available upon request. On spools. 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. 3-122 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Table of Contents 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 Modified fluoroelastomer .............................................4-29, 4-30 -12 -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 End caps ..................................................................4-49, 4-50 Heat-shrinkable end caps .............................................4-51, 4-52 Boots 202A111 to 196 202C611 to 663 202D121 to 196 202D211 to 299 202D921 to 963 202F211 to 274 202G211 to 253 202G611 to 653 202K121 to 185 214A011 to 052 214A311 to 352 214P009 to 037 222A111 to 196 222D121 to 196 222D211 to 299 222D921 to 963 222F211 to 285 222K121 to 185 234A011 to 071 234A111 to 152 234A611 to 671 242W042 to 63 Straight boot .....................................................................4-53 Uniboot ...........................................................................4-54 Straight, lipped boot ............................................................4-55 Straight, lipped boot ............................................................4-56 Straight, lipped boot ............................................................4-57 Straight, lipped boot ............................................................4-58 Straight, lipped boot ............................................................4-59 Uniboot ...........................................................................4-60 Straight, lipped boot ............................................................4-61 D-subminiature, straight boot ................................................4-62 D-subminiature, straight boot ................................................4-63 D-subminiature, straight boot with jack screws ........................4-64 Right-angled boot ...............................................................4-65 Right-angled, lipped boot ...................................................4-66 Right-angled, lipped boot ...................................................4-67 Right-angled, lipped boot ...................................................4-68 Right-angled, lipped boot ...................................................4-69 Right-angled, lipped boot ...................................................4-70 D-subminiature, right-angled boot ..........................................4-71 D-subminiature, side-entry boot .............................................4-72 D-subminiature, 90 end-entry boot .......................................4-73 45 angled boot ..................................................................4-74 Feedthroughs 207W213 to 256 Two-part feedthrough .........................................................4-75 Transitions 301A011 to 048 301A511 to 514 322A112 to 158 342A012 to 058 362A014 to 114 381A301 to 304 382A012 to 046 382C312, 322 & 332 462A011 to 060 462A421 to 424 562A011 to 067 QFT SSB, T, F to 8S T transition ........................................................................4-76 Slimline T transition ............................................................4-77 T transition ........................................................................4-78 45 side-breakout transition ...................................................4-79 30 side-breakout transition ...................................................4-80 Slimline Y transition ............................................................4-81 Y transition ........................................................................4-82 Slimline Y transition ............................................................4-83 Transition, one to three cables................................................4-84 Slimline transition, one to three cables ....................................4-85 Transition, one to four cables ................................................4-86 Configurable heat-shrink transition .................................4-87, 4-88 Chem-X Heavy Duty Breakout Boots ..............................4-89, 4-90 Molded Parts Note: Users should independently evaluate the suitability of the product for their application. Before ordering, check with Tyco Electronics for most current data. Caps 101A011 to 094 SSC 4 4-1 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Table of Contents (Continued) Accessories 202W302 to 342 400W242 CES RayOLOn Kits shrinkHOoP XL Products Heat-shrink bobbins ...................................................4-91, 4-92 Heat-shrink positioning ring .........................................................4-93, 4-94 Heat-shrinkable cable entry seals ......................................................4-95 to 4-98 Roll-on sealing sleeve ................................................4-99, 4-100 Cable clamp heat-shrink grommet .............................................4-101 to 4-103 Conversion Table ...................................................4-104, 4-105 Overview 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 masstransit, military, and commercial marine applications, Raychem molded parts include: n Raychem SSC end caps, which provide optimum waterproofing and environmental protection for underwater, underground, or outdoor applications. The end caps are highly resistant to moisture, fungus, and weathering. n Raychem heat-shrinkable boots and transitions, which replace tapes, mold-inplace epoxies, and grease. These molded parts can be used for cable breakouts, transitions, and terminations. For example, they provide reliable sealing to specific altitudes on standard Navy 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: n Select the necessary shape. n Match the shape with the appropriate material. n Select a compatible adhesive, 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 require, including operation in low- and hightemperature environments; mechanical strength; resistance to fluids, flame, and mechanical abuse; environmental sealing; and strain relief. 4-2 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts General Information 4 Molded Parts Bulbous Molded Parts Modifications Raychem bulbous-shaped molded parts provide rugged mechanical and environmental protection, meet numerous specifications, and have been used successfully in military wire and cable harnesses for more than 30 years. Certain variations of the standard shapes, such as shorter leg lengths or specific over expansions, are possible. Modifications must be requested prior to your order, for feasibility. Most connector strain relief boots come in two versions: n n With an adapter lip molded into the "H" end, which locks into the groove on the backshell adapter (part number is identified with a "D" or "K"). Without the adapter lip (the boot may be installed directly on the rear of connector threads 12 mm [.472] long or longer). This part number is identified with an "A." Many other optional features are available, such as molding ports and drain holes. For other modifications and custom shapes, please contact Tyco Electronics. Molding Port Modifications (-00) Some specifications call for potting the molded shape with sealant to provide additional protection from moisture. 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 are also possible. Estimates are made upon request. 4-3 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts General Information (Continued) 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: n n n Lloyd's Register of Shipping Det Norske Veritas (DNV) American Bureau of Shipping (ABS) n DOD-STD-2003 n MIL-I-81765/1A 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. Slim-Line Molded Parts With their low profile, these flexible molded parts conform to cables better and create less bulk at transition points and connectors than bulbous molded parts. Raychem molded parts are available in a variety of slimline shapes, including straight and right-angle boots as well as transitions. A small family of parts can provide a wide variety of expansions (under expansion, over expansion, cutoff). Modifications are easily provided. 4-4 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Selection Tables Boots Family Description Application Lipped boots for use with a circular adapter Nonlipped boots for use directly on a circular connector 202D121 to 196 222D121 to 196 202K121 to 185 222K121 to 185 242W042 to 063 202A111 to 196 222A111 to 196 202D211 to 299 222D211 to 299 202F211 to 274 222F211 to 285 202G211 to 253 Lipped boots for use with a circular adapter 202D921 to 963 222D921 to 963 Lipped boots with compressible design for use with a circular adapter 202C611 to 663 202G611 to 653 Adapter boots for use with D-subminiature connectors 4 Molded Parts Low-profile lipped boots for use with a circular adapter Typical Shapes 214A011 to 052 234A011 to 071 214A311 to 352 234A111 to 152 234A611 to 671 4-5 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Selection Tables (Continued) Transitions Application Family Description Breakout Boots SSB, T, F, 6S, 85 "T" Transitions 301A011 to 048 301A511 to 514 322A112 to 158 45 Transitions 342A012 to 058 30 Transitions 362A014 to 114 "Y" Transitions 381A301 to 304 382A012 to 046 3:1 Transitions 462A011 to 060 462A421 to 424 4:1 Transitions 562A011 to 067 Typical Shapes Shape Selection: Other Products Application Family Description Feedthroughs 207W213 to 256 and CES D-Subminiatures 214P009 to 037 End Caps 101A011 to 094 and SSC Typical Shapes 4-6 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Part Numbering System 2 0 2D 1 21 - 3 - 01 / 42 - 0 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** 4 Size of Part in Family: From 11 (= smallest) to 99 (= largest) Molded Parts 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 Circular 0 = Straight 2 = 90 4 = 45 6 = 30 One opening Noncircular 0 = Straight 3 = 90 5 = 45 7 = 30 Number of openings in the part *See section 5 for details on adhesives. **See page 4-24 for details on materials. 4-7 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Visual Selection Guide Boots: Circular Connectors -- Lipped Lipped Boots for Use With an Adapter As supplied After recovery 202D121 through 196 202D211 through 299 202D921 through 963 202K121 through 185 222B012 through 063 222B112 and 123 222D121 through 196 222D211 through 299 222D921 through 963 222K121 202K121 through 185 242 A312 and 322 As supplied After recovery As supplied After recovery 4-8 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Visual Selection Guide (Continued) Boots: Circular Connectors -- Nonlipped Nonlipped Boots for Direct Attachment on Connectors As supplied After recovery 202A111 through 196 202A212 through 264 202A312 through 364 202A915 202A921 202B422 and 433 203A021 203A211 203A312 204A011 204A311 204A411 204A511 204A612 208A011 through 098 4 202A512 Molded Parts 202A011 through 096 As supplied After recovery As supplied After recovery As supplied After recovery 222A011 through 096 4-9 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Visual Selection Guide (Continued) Boots: Circular Connectors -- Nonlipped (Continued) Nonlipped Boots for Direct Attachment on Connectors As supplied After recovery 222A111 through 196 222A213 through 255 222A313 through 355 223A213 through 233 224A012 226A045 & 075 228A011 through 097 246A166 As supplied After recovery 242A142 243A012 & 022 As supplied After recovery 202B521 through 598 Boots: Circular Connectors-Slim-Line As supplied After recovery 202C611 through 633 202G621 through 653 202E334 through 346 202F211 through 274 202G211 through 253 222F211 through 285 4-10 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Visual Selection Guide (Continued) Boots: Rectangular Connectors As supplied After recovery 214A011 through 052 214A124 and 133 214A311 through 352 214A452 214A511 thru 552 214A613 214A814 214A923 214B623 214B713 234A011 through 071 234A111 through 152 234A313 through 333 234A413 through 434 234A611 through 671 234A711 through 752 234A911 through 971 234B011 through 052 4 Molded Parts 211A012 As supplied After recovery As supplied After recovery As supplied After recovery 4-11 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Visual Selection Guide (Continued) Transitions: Bulbous As supplied After recovery 301A011 through 048 302A012 through 037 302A214 322A012 through 037 322A112 through 158 As supplied After recovery 322A315 322A412 through 434 322A514 322B813 323A211 323A222 341A015 342A012 through 058 342A112 through 138 342A215 342A313 and 323 As supplied After recovery As supplied After recovery 343A014 through 027 362A014 through 114 4-12 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Visual Selection Guide (Continued) Transitions: Bulbous (Continued) As supplied After recovery 381A015 381A115 382A012 through 046 402A013 403A123 through 155 413A013 and 024 422A011 422A114 422A414 422A616 422A716 422A813 423A014 423A117 4 Molded Parts 363A018 and 020 As supplied After recovery As supplied After recovery As supplied After recovery 453A017 453A215 and 225 462A011 through 060 462A214 4-13 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Visual Selection Guide (Continued) Transitions: Bulbous (Continued) As supplied After recovery 502A516 502A812 through 845 522A013 561A017 562A011 through 067 602A012 602A022 602A114 622A014 703A155 704A011 and 012 902A014 As supplied After recovery 602A212 As supplied After recovery Transitions: Slim-Line As supplied After recovery 301A511 through 514 381A301 through 304 462A421 through 424 4-14 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Visual Selection Guide (Continued) Covers As supplied After recovery 102A951 102A961 102A962 102A992 102A993 102A994 202A817 220A012 through 023 234A211 234B111 and 122 254A015 4 102A981 Molded Parts 102A911 As supplied After recovery As supplied After recovery 301A212 301A222, 302A312 As supplied After recovery 302A734 401A112 and 402A212 4-15 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Visual Selection Guide (Continued) Covers (Continued) As supplied After recovery 401A212 and 403A312 401A414 501A112 601A012 402A222 403A016 501A012 and 502A212 As supplied After recovery Sleeves 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 As supplied After recovery 207W213 through 264 with A-type nut 207W213-x-01 through 264-x-01 with B-type nut 4-16 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Visual Selection Guide (Continued) Caps As supplied After recovery 101A011 thru 094 102A811 through 865 4 Molded Parts Miscellaneous 204A711 and 002A011 Riser and Plug (Not heat-shrinkable) 4-17 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Visual Selection Guide (Continued) Selected Molded Shapes Families As supplied After recovery 202A111 through 196 Nonlipped boot 202D121 through 196 Lipped boot As supplied After recovery 4-18 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Visual Selection Guide (Continued) Selected Molded Shapes Families (Continued) As supplied After recovery Nonlipped boot 202D211 through 299 Lipped boot 202D921 through 963 Lipped boot 202K121 through 185 Lipped boot 207W213 through 264 Feedthrough 214A011 through 052 Rectangular boot 222A213 through 255 90 boot nonlipped 4 Molded Parts 202A212 through 264 As supplied After recovery As supplied After recovery As supplied After recovery 222A111 through 196 90 boot nonlipped 4-19 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Visual Selection Guide (Continued) Selected Molded Shapes Families (Continued) As supplied After recovery 222A313 through 355 90 boot nonlipped 222D121 through 196 90 boot lipped 222D211 through 299 90 boot lipped 222D921 though 963 90 boot lipped 222K121 through 185 90 boot lipped 301A011 through 048 T transition As supplied After recovery As supplied After recovery 4-20 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Boot Adapter Selection Tables Table 1. Boots Boot Type Material Dash Number 50, 51 71 Uni-boot 55 55 Low-profile, 90 50, 51 71 202C611 202C621 202C632 202C642 202C653 202C663 202G621 202G632 202G642 202G653 -- 202F211 202F221 202F232 202F242 202F253 202F263 202F274 202G221 202G232 202G242 202G253 -- 222F211 222F221 222F232 222F242 222F253 222F263 222F274 222F285 Dimensions Cable Diameter Range 4.83-9.65 [.19-.38] 8.13-16.26 [.32-.64] 12.70-25.40 [.50-1.00] 17.53-35.05 [.69-1.38] 22.35-44.20 [.88-1.74] 22.86-55.63 [.90-2.19] 8.13-16.26 [.32-.64] 12.70-25.40 [.50-1.00] 17.53-35.05 [.69-1.38] 22.35-44.20 [.88-1.74] -- 6.60-15.75 [.26-.62] 7.62-19.30 [.30-.76] 8.89-22.86 [.35-.90] 10.16-27.18 [.40-1.07] 10.92-29.97 [.43-1.18] 12.70-36.83 [.50-1.45] 14.99-42.93 [.59-1.69] 7.62-19.30 [.30-.76] 8.89-22.86 [.35-.90] 10.16-27.18 [.40-1.07] 10.92-29.97 [.43-1.18] -- 6.60-15.75 [.26-.62] 7.62-20.83 [.30-.82] 8.89-22.86 [.35-.90] 10.16-27.18 [.40-1.07] 10.92-29.97 [.43-1.18] 12.70-36.83 [.50-1.45] 14.99-42.43 [.59-1.69] 17.53-61.21 [.69-2.41] Length 120.65 [4.75] 133.35 [5.25] 146.05 [5.75] 158.75 [6.25] 171.45 [6.75] 236.22 [9.30] 133.86 [5.27] 151.13 [5.95] 157.23 [6.19] 170.18 [6.70] -- 105.16 [4.14] 123.95 [4.88] 146.30 [5.76] 172.21 [6.78] 185.16 [7.29] 213.61 [8.41] 203.20 [8.00] 121.16 [4.77] 138.68 [5.46] 159.51 [6.28] 177.80 [7.00] -- 105.16 [4.14] 123.95 [4.88] 146.30 [5.76] 172.21 [6.78] 185.16 [7.29] 213.61 [8.41] 224.54 [8.84] 227.33 [8.95] Solid -- 12 14-16 18-20 22-32 24, 28, 31 12-14 16 18-20 22-32 16-24, 61 10 12-14 16 18-20 22 24-28 24 12-14 16 18-20 22-28 16-20 10 12-14 16 18-20 22 24-28 24 24-32 Fits Adapter Order Number Spin Entry Size Shielded Coupling -- 04 12--14 06-08 16-18 10-14 20 12-18 22-32 18-20 32, 36 -- 12-14 06-08 16-18 10-14 20 12-18 22-32 18-20 22-28, 61 -- 08-10 04-07 12-14 07-10 16-18 10-14 20 12-18 22 18-20 20 24-28 32 -- 12-14 07-10 16-18 10-14 20 14-18 22-24 16-20 20-24 -- 08-10 04-07 12-14 07-10 16-18 10-14 20 12-18 22 18, 20 24-28 20 32 -- 32-40 -- Tinel-Lock 04 04-07 10-16 12-18 16-20 -- 04-07 08-12 12-18 16-22 -- 04-07 05-08 08-12 12-16 16-18 18-20 -- 05-08 10-12 12-16 16-18 -- 04-07 05-10 08-12 12-16 16-18 18, 20 -- -- 4 Molded Parts Low-profile, Straight 50, 51 71 Part No. (continued on next page) 4-21 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Boot Adapter Selection Tables (Continued) Table 1. Boots (Continued) Dimensions Cable Diameter Length Range 6.60-15.75 [.26-.62] 105.92 [4.17] 202D211 7.62-19.30 [.30-.76] 121.16 [4.77] 202D221 8.89-22.86 [.35-.90] 138.68 [5.46] 202D232 159.51 [6.28] 202D242 10.16-27.18 [.40-1.07] 177.80 [7.00] 202D253 10.92-29.97 [.43-1.18] Low-profile, 3,4,25 Straight 203.20 [8.00] 202D263 12.70-36.83 [.50-1.45] 202D274 14.99-42.93 [.59-1.69] 203.20 [8.00] 202D285 18.29-55.88 [.72-2.20] 203.20 [8.00] 202D296 20.07-59.69 [.79-2.35] 203.20 [8.00] 202D299 23.37-72.39 [.92-2.85] 203.20 [8.00] 222D211 6.60-15.75 [.26-.62] 105.16 [4.14] 222D221 7.62-19.30 [.30-.76] 123.95 [4.88] 222D232 8.89-22.86 [.35-.90] 146.30 [5.76] 222D242 10.16-27.18 [.40-1.07] 172.21 [6.78] Low-profile, 222D253 10.92-29.97 [.43-1.18] 185.16 [7.29] 3,4,25 222D263 12.70-36.83 [.50-1.45] 213.61 [8.41] 90 224.54 [8.84] 222D274 14.99-42.93 [.59-1.69] 222D285 18.29-55.88 [.72-2.20] 227.33 [8.95] 233.43 [9.19] 222D296 20.07-59.69 [.79-2.35] 222D299 23.37-72.39 [.92-2.85] 203.20 [8.00] 202D121 6.10-19.05 [.24-.75] 38.10 [1.50] 202D132 7.11-23.37 [.28-.92] 54.86 [2.16] 202D142 7.62-25.15 [.30-.99] 66.80 [2.63] 202D153 8.89-30.48 [.35-1.20] 80.10 [3.15] 202D163 10.41-34.29 [.41-1.35] 103.63 [4.08] 202D174 10.41-34.29 [.41-1.35] 103.63 [4.08] Bulbous, 202D185 20.83-53.34 [.82-2.10] 165.10 [6.50] 3,4,25 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] 202K132 7.11-23.37 [.28-.92] 54.86 [2.16] 202K142 7.62-25.15 [.30-.99] 66.80 [2.63] 202K153 8.89-30.48 [.35-1.20] 80.10 [3.15] 202K163 10.41-34.29 [.41-1.35] 103.63 [4.08] 202K174 10.41-34.29 [.41-1.35] 103.63 [4.08] 202K185 20.83-53.34 [.82-2.10] 165.10 [6.50] 6.10-19.05 [.24-.75] 21.34 [0.84] 222D121 222D132 7.11-23.37 [.28-.92] 33.78 [1.33] 222D142 7.62-25.15 [.30-.99] 36.58 [1.44] Bulbous, 222D153 8.89-30.48 [.35-1.20] 43.69 [1.72] 3,4,25 90 222D163 10.41-34.29 [.41-1.35] 53.59 [2.11] 222D174 16.26-44.96 [.64-1.77] 77.98 [3.07] 222D185 20.83-53.34 [.82-2.10] 97.54 [3.84] 222D196 25.91-69.85 [1.02-2.75] 117.86 [4.64] 21.34 [0.84] 6.10-19.05 [.24-.75] 222K121 7.11-23.37 [.28-.92] 33.78 [1.33] 222K132 222K142 7.62-25.15 [.30-.99] 36.58 [1.44] 43.69 [1.72] 8.89-30.48 [.35-1.20] 222K153 53.59 [2.11] 222K163 10.41-34.29 [.41-1.35] 222K174 16.26-44.96 [.64-1.77] 77.98 [3.07] 222K185 20.83-53.34 [.82-2.10] 97.54 [3.84] Note: 202KXXX and 222KXXX parts Europe only. Boot Type Material Dash Number Part No. Solid 08 08-10 10-12 12-14 16-18 20-22 24 28 -- -- 08 08-10 10-12 12-14 16-18 20-22 24 28 -- -- -- 08 10 12-14 16-18 16-18 -- -- -- 08 10 12-14 16-18 16-18 -- 08 10 12-14 16-18 20-24 -- -- 08 10 12-14 16-18 20-24 -- Fits Adapter Order Number Spin Entry Size Shielded Coupling 08-10 06-07 08-10 08 10-12 10-12 12-14 12-14 16-18 16-18 20-22 18-20 28 22-24 32-34 28 40 -- 44 -- 08-10 06-07 08-10 08 10-12 10-12 12-14 12-14 16-18 16-18 20-22 18-20 22-24 28 32-34 28 40 -- 44 -- 08 04-05 10 06-07 12-14 09-10 16-18 11-14 20-22 15-16 20-22 15-16 -- 24 -- -- 08 04-05 10 06-07 12-14 09-10 16-18 11-14 20-22 15-16 20-22 15-16 -- 24 08 04-05 10 06-07 12-14 09-10 16-18 11-14 20-22 15-16 24 18-22 -- 24 -- -- 04-05 08 10 06-07 12-14 09-10 11-14 16-18 20-22 15-16 24 18-22 -- 24 Tinel-Lock 04-07 06-07 08-10 10-12 14-16 18-20 22-24 -- -- -- 04-07 06-08 08-10 10-12 14-16 18-20 22-24 -- -- 04-07 06-08 07-10 10-12 14-16 14-16 24 -- 04-07 06-08 07-10 10-12 14-16 14-16 24 04-07 05-08 08-10 10-14 14-18 18-22 24 -- 04-07 05-08 08-10 10-14 14-18 18-22 24 4-22 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Boot Adapter Selection Tables (Continued) Table 2. Shims Cable Diameter Range 3.81-4.83 [.15-.19] 6.35-8.13 [.25-.32] 9.65-12.70 [.38-.50] 3.30-9.65 [.13-.38] 14.48-17.53 [.57-.69] 9.91-14.48 [.39-.57] 3.30-9.65 [.13-.38] 19.30-22.35 [.76-.88] 9.91-19.30 [.39-.76] 3.30-9.65 [.13-.38] 17.53-22.86 [.69-.90] 17.53-22.86 [.69-.90] 5.08-6.60 [.20-.26] 5.08-6.60 [.20-.26] 5.84-7.62 [.23-.30] 5.84-7.62 [.23-.30] 5.92 [.233] 5.92 [.233] 6.86-8.89 [.27-.35] 6.86-8.89 [.27-.35] 7.87-10.16 [.31-.40] 3.30-7.87 [.13-.31] 8.38-10.92 [.33-.43] 3.30-8.38 [.13-.33] 9.65-12.70 [.38-.50] 3.30-9.65 [.13-.38] 11.43-14.99 [.45-.59] 9.91-11.43 [.39-.45] 3.30-9.65 [.13-.38] 13.46-17.53 [.53-.69] 9.91-13.46 [.39-.53] 3.30-9.65 [.13-.38] -- Shim Boot or Tubing Tubing Tubing Tubing 202E334 Tubing 202E346 202E344 Tubing 202E346 202E344 Tubing Tubing Tubing Tubing Tubing Tubing Tubing Tubing Tubing Tubing Tubing 202E334 Tubing 202E334 Tubing 202E334 Tubing 202E346 202E344 Tubing 202E346 202E344 Use tubing as a shim if necessary 4 Molded Parts Part No. 202C611 202C621 202C632 202C632 202C632 202C642 202C642 202C642 202C653 202C653 202C658 202C663 202D211/202F211 222D211/222F211 202D221/202F221 222D221/222F221 202D221/202F221 222D221/222F221 202D232/202F232 222D232/222F232 202D2421202F242 222D242/222F242 202D253/202F253 222D253/222F253 202D263/202F263 222D263/222F263 202D274/202F274 222D274/222F274 222D274/222F274 222D274/222F274 222D285/222F285 222D285/222F285 222D1XDU222D1XX 4-23 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials Material Selection Table Tyco Electronics offers Raychem products in a variety of materials to enable designers and material specifiers to obtain optimum performance. Applications Material* -3 Molded Part Material -3S Molded Part Material -4 Molded Part Material -6 Molded Part Material -8 Molded Part Material -12 Molded Part Material -25 Molded Part Material -25S Molded Part Material -50 Molded Part Material -51 Molded Part Material -55 Molded Part Material -71 Molded Part Material -100 Molded Part Material -100S Molded Part Material -125 Molded Part Material -130 Molded Part Material -146 Molded Part Material -152 Molded Part Material Characteristics 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. 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. 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. 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. 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. A high temperature, heat-shrinkable, flexible, flame retarded, fluoroelastomeric molding compound with excellent resistance to long term fluid immersion and heat exposure. A wide range of shapes are available in this material. -12 molded parts are recommended for use in System 200. 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. 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. 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. 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. A heat-shrinkable, flexible, flame retarded, fluid and high temperature resistant, modified fluoropolymer molding compound. A wide range of shapes is available. -55 molded parts are recommended for use in System 300. A heat-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. 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. A wide range of shapes are available in this material. -100 molded parts are recommended for use in System 100. 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 mechanical and fluid resistance properties. -100S molded parts are recommended for use in System 100. A heat-shrinkable, flame retarded, fluid and high temperature resistant, modified fluoropolymer molding compound. A range of shapes are available. -125 molded parts are recommended for use in System 300. Non flame-retarded molded material. Low shrink temperature. Flame retarded, ultra-high ratio heat-shrinkable material. Flame retarded, high ratio heat-shrinkable material. *Check with specific part page for applicable materials. 4-24 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -3 Semi-Rigid Modified Polyolefin Product Facts n Heat-shrinkable Semi-Rigid n Flame Retardant n Good resistance to fluids and heat n 4 Molded Parts Applications Installation Operating Temperature Range 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. A wide range of shapes are available in this material. The standard color is black. Raychem -3 molded parts will shrink on the application of heat above 125C [257F]. -55C to 135C [-67F to 275F] Available in: Recommended installation temperature: 150C [302F] Americas Europe Asia Pacific n n n 4-25 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -3 (Continued) Specifications/Approvals Raychem Military UL 224, File E85381 SAE-AS81765/1, Type I Def. Stan. 59-97 Issue 3 Type DA (Europe) BS-G-198-5-DA (Europe) RT-301 Product Characteristics Physical Thermal Electrical Water absorption Tensile strength Ultimate elongation 2% secant modulus Specific gravity Heat aging for 168 h at 175C [347F] Heat shock for 4 h at 225C [437F] Low-temperature flex at -55C [-67F] Flammability Electric strength -- Aviation fuel F40 Fluid resistance Lubricating oil O-149 Phosphate ester hydraulic fluid (DTD 900/4881A) Specification Requirements 10.5 MPa (min.) 250% (min.) 80-160 MPa 1.4 (max.) Ultimate elongation 150% (min.) No dripping, cracking, or flowing No cracking during mandrel bend Self-extinguishing 8 MV/m (min.) 0.5% (max.) Tensile strength 8.5 MPa (min.) Ultimate elongation 200% (min.) Tensile strength 8.5 MPa (min.) Ultimate elongation 200% (min.) Tensile strength 8.5 MPa (min.) Ultimate elongation 200% (min.) Test Method ISO 37; ASTM D 412 ISO 37; ASTM D 412 ASTM D 882 ISO 1183; ASTM D 792 ISO 188, ISO 37 ASTM D 2671 RK-6703, CL 2.7: RT-301 Sec. 4.3.4 RK-6703, CL 2.8: ASTM D 635 IEC 243 ISO 62 ISO 1817 and ISO 37 after immersion for 24 h at 23C [73F] ISO 1817 and ISO 37 after immersion for 24 h at 23C [73F] ISO 1817 and ISO 37 after immersion for 24 h at 23C [73F] 4-26 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -4 Flexible Polyolefin Product Facts n Heat-shrinkable Flexible n Flame Retardant n Good resistance to fluids and heat n 4 Molded Parts Applications Installation Operating Temperature Range 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. Raychem -4 molded parts will shrink on the application of heat above 100C [212F]. -55C to 135C [-67F to 275F] Recommended installation temperature: 150C [302F] A wide range of shapes are available in this material. The standard color is black. Available in: Americas Europe Asia Pacific n n n 4-27 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -4 (Continued) Specifications/Approvals Military UL 224, File E85381 SAE-AS81765/1, Type II Raychem RT-1304 Product Characteristics Physical Thermal Electrical Water absorption Fluid resistance Tensile strength Ultimate elongation Specific gravity Heat aging for 168 h at 175C [347F] Heat shock for 4 h at 225C [437F] Low-temperature flex at -55C [-67F] Flammability (burn time) Dielectric strength -- JP-4 fuel, aviation gasoline, water, hydraulic fluid Specification Requirements 1800 psi (min.) 400% (min.) 1.3 (max.) Ultimate elongation 300% (min.) No dripping, flowing, or cracking No cracking Average flame time: 120 s (max.) 350 V/mil (min.) 0.3% (max.) Tensile strength 8.5 MPa psi (min.) Ultimate elongation 200% (min.) Test Method ASTM D 412 ASTM D 412 ASTM D 792 RT 1304 Sec. 4.3.3 RT 1304 Sec. 4.3.5 RT 1304 Sec. 4.3.4 ASTM D 635 ASTM D 149 ASTM D 570 RT-1304 Sec. 4.3.3 4-28 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -12 Modified Fluoroelastomer Product Facts n Heat-shrinkable, flexible, fluid-resistant modified fluoro-elastomer n Excellent resistance to longterm fuel immersion 4 Molded Parts VITON is a trademark of Dupont Dow Elastomers LLC. Applications Installation Operating Temperature Range Raychem -12 molded parts with Viton(R) fluoroelastomers are designed to be used in conjunction with tubing made from Viton(R) fluoroelastomers or multiconductor 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 55C [-67F] to 200C [392F]. The standard color is black. Raychem -12 molded parts will shrink on the application of heat above 175C [347F]. -55C to 200C [-67F to 392F] Available in: Recommended installation temperature: 220C [428F] Americas Europe Asia Pacific n n n 4-29 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -12 (Continued) Specifications/Approvals Military SAE-AS81765/4 Def. Stan. 59-97 Issue 3 Type DD (Europe) BS-G-198-5-DD-P (Europe) Raychem RT-1312 -- -- Product Characteristics Physical Thermal Electrical Water absorption Tensile strength Ultimate elongation 2% secant modulus Specific gravity Heat aging for 168 h at 250C [482F] Heat shock for 4 h at 300C [572F] Low temperature flex at -55C [-67F] Flammability (burn time) Electric strength -- Aviation fuel F40 Fluid resistance Lubricating oil O-149 Hydraulic fluid H515 Specification Requirements 12.4 MPa (min.) 300% (min.) 70 MPa (max.) 1.95 (max.) Ultimate elongation 250% (min.) No dripping, cracking, or flowing No cracking 30 s (max.) 8 MV/m (min). 0.5% (max.) Tensile strength 11 MPa (min.) Ultimate elongation 200% (min.) Tensile strength 11 MPa (min.) Ultimate elongation 200% (min.) Tensile strength 11 MPa (min.) Ultimate elongation 200% (min.) Test Method ISO 37 ISO 37 ASTM D 882 ISO 1183 ISO 188, ISO 37 ASTM D 2671 ASTM D 2671 ASTM D 635 IEC 243 ISO 62 ISO 1817 after immersion for 24 h at 23C [73F] ISO 1817 after immersion for 24 h at 93C [200F] ISO 1817 after immersion for 24 h at 93C [200F] 4-30 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -25 Fluid-Resistant Modified Elastomer Product Facts n Heat-shrinkable, semi-rigid, chemical- and abrasionresistant molded shapes n Excellent resistance to hightemperature fluids n Resistance to long-term exposure at elevated temperatures 4 Molded Parts 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 a complete cable harness system capability. -25 parts have been specifically formulated and designed to provide optimum high-temperature fluid resistance and longterm heat resistance. This unique balance of properties makes -25 parts particularly suitable for sealing and strain relief at connector-cable terminations and cable-tocable transitions on military vehicle cables and harnesses. Available in a wide range of configurations, -25 parts will operate from -75C to 150C [-103F to 302F] for long periods. The standard color is black. Available in: Installation Operating Temperature Range Raychem -25 molded parts will shrink on the application of heat above 135C [275F]. -75C to 150C [-103F to 302F] Recommended installation temperature: 175C [347F] Americas Europe Asia Pacific n n n 4-31 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -25 (Continued) Specifications/Approvals Military VG95343 Parts 6, 7, 8 and 9 (Europe) Def Stan 59-97, Issue 3, Type DE (Europe) BSG-198-5-DE-P Raychem RT-1325 -- -- Product Characteristics Physical Thermal Electrical Fluid resistance Tensile strength Ultimate elongation Specific gravity Heat aging for 168 h at 150C [302F Heat shock for 4 h at 225C [437F] Low-temperature flex for 4 h at -70C [-94F] Flammability (burn time) Electric strength Aviation fuel JP-4 (MIL-T-5624) Hydraulic fluid (MIL-H-6083) Diesel fuel (VV-F-800 No 2) Automotive gasoline (MIL-G-3056) Specification Requirements 15 MPa (min.) 350% (min.) 1.5 (max.) Ultimate elongation 300% (min.) No dripping, cracking, or flowing No cracking during mandrel bend 120 s (max.) 8 MV/m Tensile strength 12 MPa (min.) Ultimate elongation 300% (min.) Tensile strength 12 MPa (min.) Ultimate elongation 300% (min.) Tensile strength 12 MPa (min.) Ultimate elongation 300% (min.) Tensile strength 12 MPa (min.) Ultimate elongation 300% (min.) Test Method ASTM D 412 ASTM D 412 ASTM D 792 ASTM D 412 ASTM D 2671 ASTM D 2671 ASTM D 635 ASTM D 149 ASTM D 412 after immersion for 24 h at 25C [77F] ASTM D 412 after immersion for 24 h at 25C [77F] ASTM D 412 after immersion for 24 h at 50C [122F] ASTM D 412 after immersion for 24 h at 25C [77F] 4-32 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -25S Fluid-Resistant Screened Elastomer Product Facts n n Fuel and heat resistance RFI, EMI protection 4 Molded Parts Applications Operating Temperature Range 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 highperformance harness system offering high levels of RFI and EMI protection. This -25 material provides optimum high-temperature fluid-resistance and longterm 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). -55C to 150C [-67F to 302F] Available in: Americas Europe Asia Pacific n n n 4-33 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -25S (Continued) Specifications/Approvals Military VG 95343 Pt. 20, Pt. 22 Raychem RK-6719 Product Characteristics Specification Requirements* Tensile strength: 12 MPa (min.) Ultimate elongation: 400% (min.) Metal adhesion: 15 N/cm (min.) Shielding effectiveness Tensile strength: 12 MPa (min.) Ultimate elongation: 400% (min.) Shielding effectiveness Tensile strength: 12 MPa (min.) Ultimate elongation: 400% (min.) Shielding effectiveness Initial values Heat shock (1/2 h at 200C [392F]) Thermal Heat aging (168 h at 160C [320F]) 3 thermal cycles of -75C to 150C [-103F to 302F] Immersion in the following fluids for 24 h: Lubricating oil (O-156, at 100C [212F]) Hydraulic fluid H515, at 50C [122F] Chemical Aviation fuel JP4 F40, at 23C [73F] Diesel fuel F54, at 23C [73F] 1, 1, 1, trichloroethane (1 h, at 23C [73F]) Screening effectiveness in dB at >30 MHz to 3 KHz to 30 MHz (min.) 100 MHz (min.) -- -- -- -- -- -- 75 70 -- -- -- -- 75 70 -- -- -- -- 75 70 Shielding effectiveness 75 70 Tensile strength: 10 MPa (min.) Ultimate elongation: 300% (min.) Shielding effectiveness Tensile strength: 10 MPa (min.) Ultimate elongation: 300% (min.) Shielding effectiveness Tensile strength: 10 MPa (min.) Ultimate elongation: 300% (min.) Shielding effectiveness Tensile strength: 10 MPa (min.) Ultimate elongation: 300% (min.) Shielding effectiveness Tensile strength: 10 MPa (min.) Ultimate elongation: 300% (min.) Shielding effectiveness -- -- 75 -- -- 75 -- -- 75 -- -- 75 -- -- 75 -- -- 70 -- -- 70 -- -- 70 -- -- 70 -- -- 70 *Values quoted are for the polymer/metal composite in all cases when terminated using epoxy adhesives. 4-34 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -50 Fluid-Resistant Modified Elastomer Product Facts n Excellent heat and fluid resistance n Low profile n Rugged n Lightweight 4 Molded Parts VITON is a trademark of Dupont Dow Elastomers LLC. Applications Installation Operating Temperature Range A high-performance blend of Viton(R) and other polymers, Raychem -50 offers excellent fluid and temperature resistance. It is suitable for use in most areas of military vehicle 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. Raychem -50 molded parts will shrink on the application of heat above 125C [257F]. -55C to 150C [-67F to 302F] Available in: Recommended installation temperature is 175C [347F] Americas Europe Asia Pacific n n n 4-35 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -50 (Continued) Specifications/Approvals Military SC-X-15111 (U.S.) Raychem RT-1313 Product Characteristics Physical Thermal Electrical Fluid resistance Tensile strength Ultimate elongation Specific gravity Heat aging for 168 h at 150C [302F] Heat shock for 4 h at 225C [437F] Low-temperature flex for 4 h at -70C [-94F] Flammability (burn time) Electric strength Aviation fuel JP-4 (MIL-T-5624) Hydraulic fluid (MIL-H-6083) Diesel fuel (VV-F-800 No 2) Automotive gasoline (MIL-G-3056) Specification Requirements 15 MPa (min.) 350% (min.) 1.5 (max.) Ultimate elongation 300% (min.) No dripping, cracking, or flowing No cracking during mandrel bend 120 s (max.) 8 MV/m Tensile strength 12 MPa (min.) Ultimate elongation 300% (min.) Tensile strength 12 MPa (min.) Ultimate elongation 300% (min.) Tensile strength 12 MPa (min.) Ultimate elongation 300% (min.) Tensile strength 12 MPa (min.) Ultimate elongation 300% (min.) Test Method ASTM D 412 ASTM D 412 ASTM D 792 ASTM D 412 ASTM D 2671 ASTM D 2671 ASTM D 635 ASTM D 149 ASTM D 412 after immersion for 24 h at 25C [77F] ASTM D 412 after immersion for 24 h at 25C [77F] ASTM D 412 after immersion for 24 h at 50C [122F] ASTM D 412 after immersion for 24 h at 25C [77F] 4-36 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -51 Chemical-Resistant Fluoroelastomer Product Facts n Excellent fuel resistance Low profile n Rugged n Lightweight n 4 Molded Parts Applications Installation Operating Temperature Range A high-performance elastomeric blend of polymers, Raychem -51 offers excellent fluid resistance. Raychem -51 molded parts will shrink on the application of heat above 125C [257F]. -55C to 135C [-67F to 275F] 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. Available in: Recommended installation temperature is 150C [302F] Americas Europe Asia Pacific n n n 4-37 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -51 (Continued) Specifications/Approvals Military SC-X-15112 (U.S.) Raychem RT-1321 Product Characteristics Physical Tensile strength Ultimate elongation Specific gravity Heat aging for 168 h at 121C [250F] Thermal Electrical Heat shock for 4 h at 200C [392F] Low-temperature flex for 4 h at -55C [-67F] Flammability (burn time) Dielectric strength Lubricating oil, diesel oil, water for 24 h at 25C [77F] Gasoline for 24 h at 25C [77F] Fluid resistance Isopropyl alcohol, cleaning fluid for 24 h at 25C 77F] Hydraulic fluid for 24 h at 71C [160F] Specification Requirements 1500 psi (min.) 300% (min.) 1.6 (max.) Tensile strength 1200 psi. (min.) Elongation 250% (min.) No dripping, flowing, or cracking No cracking 120 seconds, 1 inch (max.) 200 V/mil (min.) Tensile strength 1000 psi (min.) Elongation 225% (min.) Weight increase 10% (max.) Tensile strength 800 psi (min.) Elongation 225% (min.) Weight increase 25% (max.) Tensile strength 1400 psi (min.) Elongation 225% (min.) Weight increase 10% (max.) Tensile strength 1000 psi (min.) Elongation 225% (min.) Weight increase 25% (max.) Test Method ASTM D 412 ASTM D 412 ASTM D 792 RT-1321 Sec. 4.3.3 RT-1321 Sec. 4.3.3 RT-1321 Sec. 4.3.5 RT-1321 Sec. 4.3.4 ASTM D 635 ASTM D 149 RT-1321 Sec. 4.3.3 and 4.3.7 RT-1321 Sec. 4.3.3 and 4.3.7 RT-1321 Sec. 4.3.3 and 4.3.7 RT-1321 Sec. 4.3.3 and 4.3.7 4-38 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -55 Flexible Fluoropolymer Product Facts n Flame retardant Abrasion and cut through resistance n Flexible n High temperature resistance n High fluid resistance n Environmentally sealed n Applications A heat-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 recommended for use in System 300. Specifications/Approvals Operating Temperature Range -65C to 200C [-85f to 392F] Installation This specification covers the requirements for one type of flexible, electrical insulating molded component whose expanded dimensions will reduce to a predetermined size upon the application of heat in excess of 220C [428F]. 4 Molded Parts 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 fluoropolymer and features a one part epoxy adhesive in tape form. RT-1330 Product Characteristics Physical 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 4 hours at -65 2C [-85 4F] -- No cracking Section 4.3.4 Heat Shock 4 hours at 300C [572F] Heat Resistance 336 hours at 250C [482F] Followed by tests for: Tensile Strength Elongation -- No dripping, flowing or cracking Section 4.3.5 Available in: -- -- Section 4.3.6 psi (MPa) percent 2000 minimum (13.8) 150 minimum Section 4.3.3 ASTM D 2671 Americas Europe Asia Pacific n n n 4-39 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -55 (Continued) Product Characteristics (Continued) Electrical Dielectric Strength Volume Resistivity volts/mil ohm-cm 200 minimum 1011 minimum ASTM D 149 ASTM D 257 -- Noncorrosive Section 4.3.7 ASTM D 2671 Procedure A Chemical Corrosive Effect 16 hours at 200 3C [392 5F] Flammability Average Time of Burning Average Extent of Burning Fungus Resistance Water Absorption 24 hours at 23 3C [73 5F)] Fluid Resistance 24 hours at 23 3C [73 5F] in: Gasoline, Aviation Grade 100 (ASTM D 910) 1,1,1 Trichloroethane (MIL-T-81533) Coolanol 25 Followed by tests for: Tensile Strength Ultimate Elongation 24 hours at 50 3C [122 5F] 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 Ultimate Elongation 24 hours at 75 3C [167 5F] in: Hydraulic Fluid (MIL-H-5606) Skydrol(R) 500 Lubricating Oil (MIL-L-2104) Lubricating Oil (MIL-L-7808) Followed by tests for: Tensile Strength Ultimate Elongation Fluid Resistance 5 hours at 23 3C [73 5F] Tensile Strength Ultimate Elongation Nuclear Radiation Resistance Followed by tests for: Tensile Strength Ultimate Elongation seconds inches (mm) -- 15 maximum 0.5 maximum (12.5) Rating of 1 or less ASTM D 635 ASTM G 21 percent 0.5 maximum ASTM D 570 -- -- Section 4.3.8 psi (MPa) percent 3000 minimum (20.7) 150 minimum Section 4.3.3 ASTM D 2671 psi (MPa) percent -- 3000 minimum (20.7) 150 minimum -- Section 4.3.3 ASTM D 2671 Section 4.3.8 psi (MPa) percent -- 3000 minimum (20.7) 150 minimum -- Section 4,3.3 ASTM D 2671 Section 4.3.8 psi (MPa) Percent 3500 minimum (24.1) 150 minimum Section 4.3.3 ASTM D 2671 Section 4.3.9 psi (MPa) percent 3500 minimum (24.1) 150 minimum -- 4-40 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -71 Semirigid Modified Polyolefin Product Facts n n Flexible Flame-retardant 4 Molded Parts Applications Installation Operating Temperature Range 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 standard color is black. Raychem -71 molded parts will shrink on the application of heat above 100C [212F]. -55C to 135C -67F to 275F] Available in: Recommended installation temperature is 150C [302F] Americas Europe Asia Pacific n n n 4-41 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -71 (Continued) Specifications/Approvals Military SAE-AS81765/1, Type I Raychem RT-1316 Product Characteristics Physical Thermal Electrical Water absorption Fluid resistance Tensile strength Ultimate elongation Specific gravity Heat aging for 168 hr at 175C [347F] Heat shock for 4 h at 250C [482F] Low-temperature flex for 4 h at -55C [-67F] Flammability (burn time) Electric strength -- Aviation fuel JP-4 (MIL-T-5624) Lubricating oil O-149 (MIL-L-7808) Hydraulic fluid (MIL-H-5606) Skydrol(R) 500 Specification Requirements 10 MPa (min.) 250% (min.) 1.40 (max.) Ultimate elongation 200% (min.) No dripping, cracking, or flowing No cracking during mandrel bend 90 s (max.) 8 MV/m 0.5% (max.) Tensile strength 5 MPa (min.) Ultimate elongation 200% (min.) Tensile strength 5 MPa (min.) Ultimate elongation 200% (min.) Tensile strength 5 MPa (min.) Ultimate elongation 200% (min.) Tensile strength 5 MPa (min.) Ultimate elongation 200% (min.) Test Method ASTM D 412 ASTM D 412 ASTM D 792 ASTM D 412 ASTM D 2671 ASTM D 2671 ASTM D 635 ASTM D 149 ASTM D 570 ASTM D 412 after immersion for 24 h at 25C [77F] ASTM D 412 after immersion for 24 h at 25C [77F] ASTM D 412 after immersion for 24 h at 25C [77F] ASTM D 412 after immersion for 24 h at 25C [77F] 4-42 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -100 Low-Fire-Hazard Material Product Facts n Heat-shrinkable, semiflexible molded shapes for low fire hazard applications n Low-smoke index as defined by BS G 198 Part 5 n Low-toxicity index as defined by NES 713 n High-temperature index as defined by ISO 4589-3 4 Molded Parts Applications Raychem heat-shrinkable molded parts in -100 material form part of Raychem's System 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 fire is crucial. The material exhibits excellent fire safety characteristics combined with low-smoke and low-acid-gas emission while retaining good mechanical and fluidresistant properties. -100 parts with adhesive lining provide location, sealing, and strain relief of cableconnector terminations and cable-cable transitions on harnesses used where Available in: 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 a wide range of configurations, -100 parts will operate continuously from -30C to 105C [-22F to 221F]. The standard color is black. Operating Temperature Range -30C to 105C [-22F to 221F] Installation Raychem -100 molded parts will shrink on the application of heat above 120C [248F]. Recommended installation temperature: 150C [302F] Americas Europe Asia Pacific n n n 4-43 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -100 (Continued) Specifications/Approvals Military/NAVSEA Raychem RT-1323 RK-6717 -- -- -- 5617649 (U.S.) Def. Stan 59-97, Issue 3, Type DF (Europe) BSG 198 Part 5 Type DF (Europe) BR1326 listed Class C Product Characteristics Electrical Tensile strength Ultimate elongation 2% secant modulus Specific gravity Heat aging for 168 h at 150C [302F] Heat shock for 4 h at 225C [437F] Low-temperature flex at -30C [-22F] Limiting oxygen index Temperature index Flammability (burn time) Smoke index Toxicity index Electric strength Water absorption -- Physical Thermal Fire safety properties ISO 1817 Gasoline fuel Fluid resistance Lubricating oil O-149 Hydraulic fluid H515 Specification Requirements 8 MPa (min.) 200% (min.) 130 MPa (max.) 1.5 (max.) Ultimate elongation 100% (min.) No dripping, cracking, or flowing No cracking during mandrel bend 29 min. 250C [482F] (min.) 100 s (max.) 20 (max.) 5 (max.) per 100 g 15 MV/m (min.) 0.75% (max.) at 23C [73F] 3.5% (max.) at 70C [158F] Tensile strength 5 MPa (min.) Ultimate elongation 150% (min.) Tensile strength 5 MPa (min.) Ultimate elongation 150% (min.) Tensile strength 5 MPa (min.) Ultimate elongation 150% (min.) Test Method ISO 37 ISO 37 ASTM D 882 ISO 1183 ISO 188, ISO 37 ASTM D 2671 ASTM D 2671 ISO 4589-2 ISO 4589-3 ASTM D 635 BSG 198 Part 5 NES 713 IEC 243 ISO 62 ISO 1817 and ISO 37 after immersion for 24 h at 23C [73F] ISO 1817 and ISO 37 after immersion for 24 h at 50C [122F] ISO 1817 and ISO 37 after immersion for 24 h at 23C [73F] 4-44 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -100S Low-Fire-Hazard Screened Material Product Facts n Screened Zerohal material Low smoke index as defined by NES 711 n Low toxicity index as defined by NES 713 n High temperature index as defined by NES 715 n 4 Molded Parts 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. Available in: -100S is suitable for highperformance screen terminations in areas where Raychem Zerohal materials are required. Operating Temperature Range -30C to 105C [-22F to 221F] The standard color is black. Products made from these materials are normally used in an assembly (see section 7). Americas Europe Asia Pacific n n n 4-45 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -100S (Continued) Specifications/Approvals Military VG 95343 Pt. 20, Pt. 22 Raychem RK-6724 Product Characteristics Screening Effectiveness in dB at 3 KHz to >30 MHz to 100 MHz 30 MHz (min.) (min.) Specification Requirements* Initial values Heat shock (1/2 h at 200C [392F]) Thermal Heat aging (168 h at 150C [302F]) Immersion in the following fluids for 24 h: Phosphate ester hydraulic fluid DTD900/4881 at 23C [73F] Fluids Water at 23C [73F] Lubricating oil O-149 at 50C [122F] Transformer oil S-756 at 50C [122F] Tensile strength: 7 MPa (min.) Metal adhesion: 15 N/cm (min.) Shielding effectiveness Metal adhesion: 15 N/cm (min.) Shielding effectiveness Metal adhesion: 15 N/cm (min.) Shielding effectiveness Tensile strength: 5 MPa (min.) Shielding effectiveness Tensile strength: 5 MPa (min.) Shielding effectiveness Tensile strength: 5 MPa (min.) Shielding effectiveness Tensile strength: 5 MPa (min.) Shielding effectiveness 75 70 75 70 75 70 75 70 75 70 75 70 75 70 *Values quoted are for the polymer/metal composite in all cases when terminated using epoxy adhesives. (Refer to section 5.) 4-46 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -125 Flexible Fluoropolymer Product Facts n Flame retardant n Abrasion and cut through resistance n High temperature resistance n High fluid resistance n Environmentally sealed Applications Installation Operating Temperature Range A heat-shrinkable, flame retardant, fluid and high temperature resistant, modified fluoropolymer molding compound. A range of shapes is available. -125 molded parts are recommended for use in System 300. This specification covers the requirements for one type of electrically insulating molded component whose dimensions will reduce to a predetermined size upon the application of heat in excess of 160C 3C [320F 5F]. -55C to 175C [-67F to 347F] 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. 4 Molded Parts System 300 jacketing is based on a modified fluoropolymer and features a one part epoxy adhesive in tape form. Specifications/Approvals RT-1334 Product Characteristics Physical Elastic Memory Percent Tensile Strength Ultimate Elongation psi (MPa) Percent 275 minimum expansion 90 minimum retraction 4000 minimum (27.5) 300 minimum Secant Modulus psi (MPa) 100,000 maximum (689) Specific Gravity Low Temperature Flexibility 4 hours at -57 3C [-70 5F] Heat Shock 4 hours at 300 5C [572 9F] Heat Resistance 168 hours at 250 5C [482 9F] Followed by tests for: Tensile Strength Ultimate Elongation 2000 hours at 150 3C [302 5F] Followed by tests for: Tensile Strength Ultimate Elongation Available in: Section 4.3.2 -- 1.85 maximum Section 4.3.3 ASTM D 412 Section 4.3.4 ASTM D 882 ASTM D 792 -- No cracking Section 4.3.5 -- No dripping, flowing or cracking Section 4.3.6 -- -- Section 4.3.7.1 psi (MPa) Percent -- 3500 minimum (24.1) 250 minimum -- Section 4.3.3 Section 4.3.3 Section 4.3.7.2 psi (MPa) Percent 3500 minimum (24.1) 250 minimum Section 4.3.3 Section 4.3.3 Americas Europe Asia Pacific n n n 4-47 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Materials -125 (Continued) Product Characteristics (Continued) Electrical Dielectric Strength Volume Resistivity Volts/mil (kV/mm) ohm-cm 300 minimum (11.9) 1013 minimum ASTM D 149 ASTM D 257 Noncorrosive Section 4.3.8 ASTM D 2671 Procedure A 15 maximum 1 maximum (25) ASTM D 635 Chemical Corrosive Effect 16 hours at 175 3C [347 5F] Flammability Initial Average Time of Burning Average Extent of Burning After Fluid Immersion 24 hours at 23 3C [73 5F] Gasoline, Automotive, Combat MIL-G-3056 Fuel Oil, Diesel VV-F-800 DF-2 Turbine Fuel, Aviation, JP-4 MIL-T-5624 Average Time of Burning Average Extent of Burning Fungus Resistance Water Absorption 24 hours at 23 3C [73 5F] Fluid Resistance 24 hours at 23 3C [73 5F] Gasoline, Automotive, Combat MIL-G-3056 24 hours at 50 3C [122 5F] 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 3C [212 5F] Hydraulic Fluid, Synthetic MIL-H-46170 4 hours at 50 3C [122 5F] Cleaning Compound PC-437 5 hours at 23 3C [73 5F] Decontaminating Agent, DS-2 MIL-D-50030 Decontaminating Agent STB MIL-D-12468 Followed by tests for: Tensile Strength Ultimate Elongation Weight Increase Adhesive Compatibility Lap Shear Strength NSM to S-1264 to DCNS Nuclear Radiation Resistance Followed by tests for: Tensile Strength Ultimate Elongation -- Seconds Inches (mm) Section 4.3.10 Seconds Inches (mm) -- Percent -- 30 maximum 1 maximum (25) ASTM D 635 Rating of 1 or less ASTM G 21 0.5 maximum ASTM D 570 -- Section 4.3.9 psi (MPa) Percent Percent 3000 minimum (20.7) 250 minimum 3 maximum Section 4.3.3 Section 4.3.3 Section 4.3.9 psi (kPa) 100 minimum (689) Section 4.3.11 Section 4.3.12 psi (MPa) Percent 4000 (27.6) 250 Section 4.3.3 4-48 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Caps End Caps, 101A011 to 094 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. Applications Use for protecting cables and pipes or capping unused outlets in transitions. Provides an environmental seal when used with adhesive. As Supplied (a) H Dia. 4 H Dia. P After Unrestricted Recovery (b) H Dia. H Dia. P HW Product Dimensions Part No. 101A011 101A021 101A031 101A041 101A052 101A062 101A073 101A083 101A094 H Min. a 5.10 [.20] 7.40 [.29] 10.20 [.40] 15.20 [.60] 20.60 [.81] 25.40 [1.00] 39.40 [1.56] 50.80 [2.00] 83.80 [3.30] P Min. b 22.90 [.90] 25.40 [1.00] 30.50 [1.20] 40.60 [1.60] 61.00 [2.40] 68.80 [2.70] 91.40 [3.60] 101.60 [4.00] 114.30 [4.50] Max. b 2.00 [.08] 3.30 [.13] 4.80 [.18] 6.40 [.25] 9.40 [.37] 11.40 [.45] 18.00 [.71] 22.90 [.90] 38.10 [1.50] HW 20% b 1.02 [.04] 1.27 [.05] 1.52 [.06] 1.78 [.07] 2.03 [.08] 2.29 [.09] 2.54 [.10] 2.79 [.11] 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 n n n 4-49 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts HW Caps End Caps, 101A011 to 094 (Continued) Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 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. 4-50 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Caps SSC Heat-Shrinkable End Caps Product Facts n Self-sealing for waterproofing (sealantcoated parts only) n Electrical insulation to 1000 V n Abrasion-resistance n Mechanical protection n Easy installation, requiring no special skills n Operating temperature range of -40C to 85C [-40F to 185F] n Minimum shrink temperature of 121C [250F] 4 Molded Parts Applications These SSC heat-shrinkable end caps are made from a thermally 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 are available for underwater Available in: or underground applications with a pressure differential 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. Americas Europe Asia Pacific n n n 4-51 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Caps SSC (Continued) Specifications/Approvals Product Dimensions Type Raychem SSC-X and SSC-XTV SSC specification control drawing -- RT-1050-1 -- RW-2019 RW-2024 -- Caps have 1239 adhesive, Raychem Specification PPS 3012/70 Part No. SSC-1 SSC-2 SSC-3 SSC-4 SSC-5 SSC-5M1 SSC-6 SSC-7 Inner Diameter* As Supplied (min.) 10.00 [.390] 20.00 [.790] 35.00 [1.380] 55.00 [2.170] 75.00 [2.950] 75.00 [2.950] 100.00 [3.940] 120.00 [4.720] Part Length Recovered (max.) 4.00 [.160] 7.50 [.300] 15.00 [.590] 25.00 [.980] 32.00 [1.250] 32.00 [1.250] 45.00 [1.770] 70.00 [2.760] Military/Commercial PPS-3011/6 -- -- -- Wall Thickness (nom.) Recovered 10 % 33.50 [1.320] 55.30 [2.180] 89.90 [3.540] 143.20 [5.640] 150.10 [5.910] 79.25 [3.120] 162.50 [6.400] 145.00 [5.710] Recovered 20 % 2.00 [.080] 2.30 [.090] 3.00 [.120] 3.30 [.130] 3.30 [.130] 3.30 [.130] 4.00 [.160] 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. Ordering Information Military SSC-XTV SSC-X SSC-XU Sealing end cap with adhesive Sealing end cap with adhesive End cap, uncoated 4-52 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 202A111 to 196 Straight Boot P As Supplied (a) R JO Tan H Dia. J Dia. Tan H Dia. W After Unrestricted Recovery (b) P R JO Tan H Dia. J Dia. Tan 4 202A111 to 196 J Dia. H Dia. Molded Parts W Applications Use for mechanical protection and connector/cable strain relief. This family of boots has no lip, so that a boot can be installed directly onto the connector 202A111 to 196 accessory thread. Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions J H Part No. 202A111 202A121 202A132 202A142 202A153 202A163 202A174 202A185 202A196 Min. -3, -4, -25 a 16.5 [.65] 24.6 [.97] 28.4 [1.12] 31.0 [1.22] 36.1 [1.42] 42.7 [1.68] 51.8 [2.04] 66.0 [2.60] 86.4 [3.40] -12, -100 a 16.5 [.65] 22.6 [.89] 26.2 [1.03] 31.0 [1.22] 36.1 [1.42] 42.7 [1.68] 48.3 [1.90] 66.0 [2.60] 86.4 [3.40] Max. b 7.9 [.31] 9.9 [.39] 14.2 [.56] 17.8 [.70] 21.9 [.86] 27.4 [1.08] 35.3 [1.39] 43.7 [1.72] 57.2 [2.25] Min. -3, -4, -25 a 16.5 [.65] 24.6 [.97] 28.4 [1.12] 31.0 [1.22] 36.1 [1.42] 42.7 [1.68] 51.8 [2.04] 66.0 [2.60] 86.4 [3.40] -12, -100 a 11.9 [.47] 17.8 [.70] 20.3 [.80] 25.4 [1.00] 26.2 [1.03] 27.2 [1.07] 48.3 [1.90] 54.1 [2.13] 71.4 [2.81] Max. b P 10% b R 10% b JO Ref. b W 20% b 3.8 [.15] 5.3 [.21] 6.6 [.26] 7.4 [.29] 8.6 [.34] 9.4 [.37] 16.0 [.63] 19.6 [.77] 26.9 [1.06] 25.4 [1.00] 38.1 [1.50] 51.3 [2.02] 66.8 [2.63] 73.7 [2.90] 99.1 [3.90] 130.0 [5.13] 161.3 [6.35] 212.6 [8.37] 14.2 [.56] 21.8 [.86] 27.9 [1.10] 35.6 [1.40] 41.4 [1.63] 62.7 [2.47] 64.8 [2.55] 90.2 [3.55] 113.0 [4.45] 5.8 [.23] 9.1 [.36] 13.0 [.51] 17.8 [.70] 16.0 [.63] 18.0 [.71] 41.9 [1.65] 47.8 [1.88] 62.2 [2.45] 1.27 [.05] 1.52 [.06] 1.78 [.07] 1.78 [.07] 1.78 [.07] 2.03 [.08] 3.30 [.13] 3.81 [.15] 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. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-53 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots B (with 90 bend) 202C611 to 663 Uniboot S As Supplied (a) H Dia. K Dia. J Dia. H Dia. T P After Unrestricted Recovery (b) B (with 90 bend) S Tan H Dia. K Dia. J Dia. H Dia. J Dia. T Applications Use to provide abrasion protection for connectors. 202C611 to 663 The flexibility of design allows a variety of cable outlet angles. When installed on a spin-coupling adapter, cold reentry to the Materials Available 202C611 to 663 JO Material* -50 -51 -71 W Typ. P connector is possible by compressing the molded part. When used with adhesive it provides environmental sealing. Material Description Viton(R) polymer blend Elastomer polymer blend Flexible polyolefin Precoating No. N/A /164 /42 or /86 Adhesive Part No.** S-1125 S-1124 S-1017 or S-1048 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions H Part No. 202C611 202C621 202C632 202C642 202C653 202C663 Min. a -50, -51 14.2 [.56] 22.4 [.88] 34.0 [1.34] 44.2 [1.74] 21.2 [53.8] 22.5 [57.2] a -71 17.5 [.69] 26.4 [1.04] 38.1 [1.50] 47.8 [1.88] 54.9 [2.16] 77.2 [3.04] Max. b 6.9 [.27] 11.7 [.46] 17.5 [.69] 22.4 [.88] 27.9 [1.10] 40.6 [1.60] J Min. a -50, -51 a -71 11.2 [.44] 14.2 [.56] 17.8 [.70] 26.4 [1.04] 26.9 [1.06] 38.1 [1.50] 36.6 [1.44] 47.8 [1.88] 45.7 [1.80] 54.9 [2.16] 57.2 [2.25] 54.6 [2.15] Max. b 4.8 [.19] 8.1 [.32] 12.7 [.50] 17.5 [.69] 22.4 [.88] 22.9 [.90] K Max. b P 10% b 21.1 [.83] 26.7 [1.05] 32.8 [1.29] 37.8 [1.49] 42.9 [1.69] 62.2 [2.45] 120.7 [4.75] 133.4 [5.25] 146.1 [5.75] 158.8 [6.25] 171.5 [6.75] 236.2 [9.30] JO 10% b 17.5 [.69] 19.0 [.78] 22.4 [.88] 25.4 [1.00] 28.4 [1.12] 35.1 [1.38] S .03[0.76] b 1.52 [.06] 1.52 [.06] 1.78 [.07] 1.78 [.07] 1.78 [.07] 2.03 [.08] T .03[0.76] b 1.27 [.05] 1.27 [.05] 1.27 [.05] 1.27 [.05] 2.03 [.08] 2.03 [.08] W Min. b 0.33 [.013] 0.46 [.018] 0.51 [.020] 0.61 [.024] 0.61 [.024] 0.66 [.026] B Nom. b 62.5 [2.46] 67.8 [2.67] 73.4 [2.89] 78.2 [3.08] 82.8 [3.26] 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. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-54 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 202D121 to 196 Straight, Lipped Boot P As Supplied (a) R JO Tan J Dia. H Dia. H Dia. After Unrestricted Recovery (b) P R JO Tan 4 202D121 to 196 J Dia. H Dia. H Dia. J Dia. Molded Parts W Applications Use in conjunction with Raychem adapters to provide strain relief for harness systems using circular connectors. Boot is compatible 202D121 to 196 with all Raychem grooved adapters of appropriate shell size. Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions H Part No. 202D121 202D132 202D142 202D153 202D163 202D174 202D185 202D196 J Min. a Max. b 23.3 [.92] 28.4 [1.12] 31.0 [1.22] 36.0 [1.42] 42.7 [1.68] 51.8 [2.04] 66.0 [2.60] 81.7 [3.22] 10.5 [.41] 14.3 [.56] 17.8 [.70] 22.4 [.88] 28.2 [1.11] 35.1 [1.38] 44.5 [1.75] 57.6 [2.27] Min. -3, -4, -25 a 23.3 [.92] 28.4 [1.12] 31.0 [1.22] 36.0 [1.42] 42.7 [1.68] 51.8 [2.04] 66.0 [2.60] 81.7 [3.22] -12, -100 a 12.4 [.49] 14.7 [.58] 16.0 [.63] 18.5 [.73] 22.0 [.87] 35.3 [1.39] 45.7 [1.80] 57.1 [2.25] Max. b 5.6 [.22] 6.6 [.26] 7.2 [.28] 8.4 [.33] 9.9 [.39] 15.8 [.62] 20.4 [.80] 25.4 [1.00] P 10% b JO 10% b W 20% b 38.1 [1.50] 54.9 [2.16] 66.8 [2.63] 80.0 [3.15] 103.6 [4.08] 130.3 [5.13] 165.1 [6.50] 177.8 [7.00] 10.2 [.40] 16.5 [.65] 17.8 [.70] 20.8 [.82] 24.6 [.97] 39.6 [1.56] 48.3 [1.90] 47.8 [1.88] 1.78 [.07] 1.78 [.07] 2.03 [.08] 2.03 [.08] 2.29 [.09] 3.30 [.13] 4.06 [.16] 4.06 [.16] RR 10% b -- 21.6 [.85] 24.5 [.96] 29.7 [1.17] 36.7 [1.44] 53.8 [2.12] 65.6 [2.59] 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. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-55 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 202D211 to 299 Straight, Lipped Boot As Supplied (a) P JO U Tan J Dia. H Dia. H Dia. HW After Unrestricted Recovery (b) P JO U JW Tan J Dia. H Dia. H Dia. J Dia. 202D211 to 299 HW open-wire-bundle airborne Applications harnesses, or applications Use with circular connecwhere the long tail replaces tors and the appropriate Raychem backshell adapter cable jacketing removed during termination. to provide connector/cable to 299 strain relief. Boot is202D211 used on Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions J H Min. Part No. 202D211 202D221 202D232 202D242 202D253 202D263 202D274 202D285 202D296 202D299 Min. a Max. b 22.4 [.88] 25.7 [1.01] 29.5 [1.16] 34.0 [1.34] 37.3 [1.47] 43.7 [1.72] 50.0 [1.97] 62.7 [2.47] 69.3 [2.73] 81.8 [3.22] 11.4 [.45] 15.0 [.59] 18.8 [.74] 22.9 [.90] 29.5 [1.16] 34.0 [1.34] 41.2 [1.62] 47.0 [1.85] 59.7 [2.35] 67.1 [2.64] -3, -4, -25 a 22.4 [.88] 25.7 [1.01] 29.5 [1.16] 34.0 [1.34] 37.3 [1.47] 43.7 [1.72] 50.0 [1.97] 62.7 [2.47] 69.3 [2.73] 81.8 [3.22] -12, -100 a Max. b P 10% b JO 10% b 14.0 [.55] 16.0 [.63] 18.3 [.72] 21.3 [.84] 23.1 [.91] 27.2 [1.07] 31.5 [1.24] 39.1 [1.54] 43.2 [1.70] 51.1 [2.01] 6.4 [.25] 7.4 [.29] 8.4 [.33] 9.7 [.38] 10.4 [.41] 12.2 [.48] 14.2 [.56] 17.5 [.69] 19.6 [.77] 22.9 [.90] 105.9 [4.17] 121.2 [4.77] 138.7 [5.46] 159.5 [6.28] 177.8 [7.00] 203.2 [8.00] 203.2 [8.00] 203.2 [8.00] 203.2 [8.00] 203.2 [8.00] 86.4 [3.40] 98.6 [3.88] 112.8 [4.44] 130.8 [5.15] 142.2 [5.60] 163.1 [6.42] 157.7 [6.21] 153.2 [6.03] 143.3 [5.64] 138.4 [5.45] U 10% b HW 20% b 14.2 [.56] 15.0 [.59] 15.5 [.61] 15.7 [.62] 18.0 [.71] 19.8 [.78] 20.8 [.82] 23.4 [.92] 23.6 [.93] 31.2 [1.23] 1.52 [.06] 1.52 [.06] 1.78 [.07] 1.78 [.07] 2.0 [.08] 2.0 [.08] 2.3 [.09] 2.5 [.10] 2.5 [.10] 2.5 [.10] JW 20% b 1.14 [.045] 1.14 [.045] 1.14 [.045] 1.14 [.045] 1.14 [.045] 1.14 [.045] 1.40 [.055] 1.40 [.055] 1.40 [.055] 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. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-56 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 202D921 to 963 Straight, Lipped Boot As Supplied (a) Tan H Dia. J Dia. H Dia. HW After Unrestricted Recovery (b) P Tan 4 H Dia. J Dia. H Dia. J Dia. JO 202D921 to 963 Molded Parts JW HW Applications Use with circular connectors and the appropriate Raychem backshell adapter to provide connector/cable strain relief. Boot is used in applications where only a 202D921 to 963 small number of the available contacts are utilized, thus resulting in a high ratio between the adapter and cable diameters. Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions J H Part No. 202D921 202D932 202D953 202D963 Min. Min. a Max. b 19.3 [.76] 26.1 [1.03] 34.2 [1.35] 43.6 [1.72] 13.0 [.51] 19.1 [.75] 26.0 [1.02] 34.1 [1.34] -3, -4, -25 a 6.3 [.25] 7.6 [.30] 9.6 [.38] 11.4 [.45] -12, -100 a 4.5 [.18] 5.5 [.22] 6.6 [.26] 7.8 [.31] Max. b P 10% b JO 10% b HW 20% b JW 20% b 2.1 [.08] 2.6 [.10] 3.1 [.12] 3.6 [.14] 60.2 [2.37] 74.2 [2.92] 84.3 [3.32] 99.6 [3.92] 37.6 [1.48] 45.0 [1.77] 51.1 [2.01] 57.7 [2.27] 1.52 [.06] 1.78 [.07] 1.78 [.07] 1.78 [.07] 1.14 [.045] 1.14 [.045] 1.14 [.045] 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. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-57 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 202F211 to 274 Straight, Lipped Boot As Supplied (a) J Dia. H Dia. After Unrestricted Recovery (b) P Tan JO H Dia. HW J Dia. JW R Tan 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. Materials Available Material* -50 -51 -71 Material Description Flexible Viton(R) polymer blend Flexible elastomer polymer blend Flexible polyolefin Precoating No. N/A /164 /42 or /86 Adhesive Part No.** S-1125 S-1124 S-1017 or S-1048 Product Dimensions H J Part No. Min. a Max. b 202F211 202F221 202F232 202F242 202F253 202F263 202F274 23.9 [.94] 27.2 [1.07] 31.0 [1.22] 35.6 [1.40] 38.9 [1.53] 45.2 [1.78] 51.6 [2.03] 9.9 [.39] 13.2 [.52] 18.5 [.73] 22.1 [.87] 28.2 [1.11] 32.3 [1.27] 41.1 [1.62] Min. a 17.3 [.68] 20.8 [.82] 24.4 [.96] 28.7 [1.13] 31.5 [1.24] 38.4 [1.51] 45.5 [1.79] Max. b P 10% b JO 10% b HW 20% b JW 20% b 6.6 [.26] 7.6 [.30] 8.9 [.35] 10.2 [.40] 10.9 [.43] 12.7 [.50] 15.0 [.59] 105.9 [4.17] 121.2 [4.77] 138.7 [5.46] 159.5 [6.28] 177.8 [7.00] 203.2 [8.00] 203.2 [8.00] 86.4 [3.40] 98.6 [3.88] 112.8 [4.44] 130.8 [5.15] 142.2 [5.60] 163.1 [6.42] 157.7 [6.21] 1.5 [.06] 1.5 [.06] 1.8 [.07] 1.8 [.07] 1.8 [.07] 1.8 [.07] 1.8 [.07] 1.5 [.06] 1.5 [.06] 1.5 [.06] 1.5 [.06] 1.5 [.06] 1.5 [.06] 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. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-58 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 202G211 to 253 Straight, Low Profile Lipped Boot As Supplied (a) R Tan Tan Coating (see note 3) JO S T J Dia. H Dia. H Dia. HW P After Unrestricted Recovery (b) R Tan Tan Coating (see note 3) JO S 4 T H Dia. J Dia. Molded Parts J Dia. H Dia. JW HW P 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 entry size. When used with adhesive it provides environmental sealing. Materials Available Material Dash No. -55 Material Description Fluoroploymer Adhesive S-1255-04 Product Dimensions Part No. 202G211 202G221 202G232 202G242 202G253 J H Min. a 23.9 [.94] 27.2 [1.07] 31.0 [1.22] 31.7 [1.25] 38.9 [1.53] Max. b 9.9 [.39] 13.2 [.52] 18.5 [.73] 22.1 [.87] 28.2 [1.11] Min. a 23.9 [.94] 27.2 [1.07] 31.0 [1.22] 31.7 [1.25] 38.9 [1.53] Available in: Max. b 7.4 [.29] 8.4 [.33] 9.4 [.37] 10.7 [.42] 11.9 [.47] P 10% b 105.9 [4.17] 121.2 [4.77] 138.7 [5.46] 159.5 [6.28] 177.8 [7.00] R 10% b 11.7 [.46] 12.2 [.48] 12.2 [.48] 12.2 [.48] 10.6 [.42] S Ref. b 1.0 [.04] 1.0 [.04] 1.0 [.04] 1.0 [.04] 1.3 [.05] JO HW T Ref. 10% Ref. b b b 1.3 [.05] 86.4 [3.40] 1.0 [.04] 1.3 [.05] 87.4 [3.44] 1.0 [.04] 1.3 [.05] 104.4 [4.11] 1.0 [.04] 1.5 [.06] 124.5 [4.90] 1.0 [.04] 1.8 [.07] 143.5 [5.65] 1.3 [.05] Americas Europe Asia Pacific n n n JW Ref. b 0.7 [.03] 0.7 [.03] 0.7 [.03] 0.7 [.03] 1.0 [.04] 4-59 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots B (with 90 bend) 202G611 to 653 Uniboot As Supplied (a) .5010% HW J Dia. H Dia. K Dia. H Dia. T After Unrestricted Recovery (b) S P B (with 90 bend) .5010% JW HW J Dia. H Dia. J Dia. K Dia. H Dia. T S Tan JO P 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-entry to the connector is possible by Materials Available unscrewing the adapter and compressing the molded part. When used with adhesive it provides environmental sealing. Material Dash No. -55 Material Description Fluoroploymer Adhesive S-1255-04 Product Dimensions Part No. 202G611 202G621 202G632 202G642 202G653 H Min. a 14.2 [.56] 26.6 [1.05] 33.0 [1.30] 35.5 [1.40] 42.6 [1.68] Max. b 6.9 [.27] 11.7 [.46] 17.5 [.69] 22.3 [.88] 27.9 [1.10] J Min. Max. a b 11.2 [.44] 4.8 [.19] 26.6 [1.05] 8.1 [.32] 33.0 [1.30] 12.7 [.50] 35.5 [1.40] 17.5 [.69] 42.6 [1.68] 22.4 [.88] Available in: K Max. b P 10% b 21.1 [.83] 26.6 [1.05] 32.7 [1.29] 37.8 [1.49] 42.9 [1.69] 120.7 [4.75] 133.8 [5.27] 151.1 [5.95] 157.2 [6.19] 170.2 [6.70] JO 10% b 17.5 [.69] 19.9 [.78] 22.4 [.88] 25.4 [1.00] 28.4 [1.12] HW Ref. b JW Ref. b S Ref. b T Ref. b B Nom. b 1.0 [.04] 1.0 [.04] 1.0 [.04] 1.3 [.05] 1.3 [.05] 0.7 [.03] 0.7 [.03] 0.7 [.03] 1.0 [.04] 1.0 [.04] 1.0 [.04] 1.0 [.04] 1.0 [.04] 1.3 [.05] 1.3 [.05] 1.3 [.05] 1.3 [.05] 1.3 [.05] 1.3 [.05] 1.5 [.06] 62.5 [2.46] 67.8 [2.67] 73.4 [2.89] 78.2 [3.08] 82.8 [3.26] Americas Europe Asia Pacific n n n 4-60 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 202K121 to 185 P Straight, Lipped Boot R As Supplied (a) X U J Dia. H Dia. Ta H Dia. HW After Unrestricted Recovery (b) P R Y X U J Dia. H Dia. Slight taper Tan H Dia. 4 J Dia. Molded Parts J 202K121 to 185 JW HW 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. Applications Use in conjunction with Raychem adapters to pro185 vide strain202K121 relief fortoharness systems using circular connectors. Materials Available Material* -3 -4 -12 -25 -100 Boot is compatible with all Raychem grooved adapters of the appropriate shell size. Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions Part No. 202K121 202K132 202K142 202K153 202K163 202K174 202K185 H Min. Max. -3,-4,-12,-25 b a 24.0 [.95] 10.4 [.41] 30.0 [1.18] 14.2 [.56] 31.0 [1.22] 18.0 [.71] 36.0 [1.42] 22.4 [.88] 43.0[1.69] 28.2 [1.11] 60.0 [2.36] 35.1 [1.38] 66.0 [2.60] 44.5 [1.75] -3, -4, -25 a 24.0 [.95] 30.0 [1.18] 31.0 [1.22] 36.0 [1.42] 43.0 [1.69] 60.0 [2.36] 66.0 [2.60] J Min. -12 a 13.0 [.51] 14.0 [.55] 16.0 [.63] 19.0 [.75] 22.0 [.87] 35.0 [1.38] 38.0 [1.50] -100 a 14.0 [.55] 15.0 [.59] 18.0 [.71] 21.0 [.83] 25.0 [.98] 39.0 [1.54] 42.0 [1.65] Max. b P 10% b R 10% b U 10% b JO 10% b HW 20% b JW Min. b X 20% b Y 20% b 5.6 [.22] 5.9 [.23] 7.1 [.28] 8.4 [.33] 9.9 [.39] 15.7 [.62] 16.8 [.66] 38.0 [1.50] 55.0 [2.17] 67.0 [2.64] 80.0 [3.15] 99.0 [3.90] 130.0 [5.12] 170.0 [6.69] 21.0 [.83] 32.0 [1.26] 35.0 [1.38] 42.0 [1.65] 61.0 [2.40] 72.0 [2.83] 90.0 [3.54] 12.0 [.47] 12.0 [.47] 20.0 [.79] 20.0 [.79] 20.0 [.79] 20.0 [.79] 20.0 [.79] 8.5 [.33] 11.5 [.45] 17.0 [.67] 19.5 [.76] 21.0 [.82] 39.0 [1.53] 51.5 [2.02] 1.6 [.06] 1.8 [.07] 1.8 [.07] 2.0 [.08] 2.2 [.08] 3.3 [.13] 3.8 [.15] .41 [.016] .81 [.032] .81 [.032] .81 [.032] .81 [.032] 1.02 [.040] 1.63 [.064] 24.0 [.94] 24.0 [.94] 32.0 [1.26] 32.0 [1.26] 52.0 [2.05] 52.0 [2.05] 52.0 [2.05] 13.0 [.51] 18.0 [.71] 25.0 [.98] 30.0 [1.18] 30.0 [1.18] 50.0 [1.97] 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. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-61 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 214A011 to 052 D-Subminiature, Straight Boot As Supplied (a) K Dia. H J P J After Unrestricted Recovery (b) W X Typ. K Dia. H K Dia. 214A011 to 052 J P J X Typ. Applications Provides strain relief and to 052 on mechanical 214A011 protection D-subminiature connector terminations. Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions H Part No. 214A011 214A021 214A032 214A042 214A052 5% a 20.3 [.80] 28.2 [1.11] 42.2 [1.66] 58.7 [2.31] 57.9 [2.28] J 5% b 20.3 [.80] 28.2 [1.11] 42.2 [1.66] 58.7 [2.31] 57.9 [2.28] 5% a 10.7 [.42] 10.7 [.42] 10.7 [.42] 10.7 [.42] 13.7 [.54] K 5% b 10.7 [.42] 10.7 [.42] 10.7 [.42] 10.7 [.42] 13.7 [.54] Min. a 7.9 [.31] 10.2 [.40] 14.0 [.55] 17.3 [.68] 19.1 [.75] Max. b 4.1 [.16] 5.3 [.21] 8.1 [.32] 8.6 [.34] 10.7 [.42] P 10% b W 20% b X 20% b 33.3 [1.31] 38.9 [1.53] 45.0 [1.77] 53.3 [2.10] 61.0 [2.40] 1.0 [.04] 1.0 [.04] 1.0 [.04] 1.0 [.04] 1.0 [.04] 3.0 [.12] 3.0 [.12] 3.0 [.12] 3.0 [.12] 3.0 [.12] This Boot Fits Amphenol Cannon/ Cinch Series 17 DE-9 XX09X DA-15 XX15X DB-25 XX25X DC-37 XX37X 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. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-62 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 214A311 to 352 D-Subminiature, Straight Boot As Supplied (a) H&J H K Dia. J After Unrestricted Recovery (b) X Typ. W H&J H K Dia. 4 K Dia. R 214A311 to 352 Molded Parts J P X Typ. Applications Provides strain relief and 214A311 toprotection 352 mechanical on D-subminiature connector terminations. Materials Available Material* -3 -4 -25 Material Description Semirigid polyolefin Flexible polyolefin Fluid-resistant elastomer Precoating No. /42 or /86 /42 or /86 /42 or /86 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 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. Product Dimensions 214A311 214A321 214A332 214A342 214A352 5% a 16.0 [.63] 19.1 [.75] 29.2 [1.15] 34.3 [1.35] 37.6 [1.48] K J H Part No. 5% b 20.3 [.80] 28.2 [1.11] 42.2 [1.66] 58.7 [2.31] 57.9 [2.28] 5% a 16.0 [.63] 19.1 [.75] 29.2 [1.15] 34.3 [1.35] 37.6 [1.48] 5% b 10.7 [.42] 10.7 [.42] 10.7 [.42] 10.7 [.42] 13.7 [.54] Min. a 16.0 [.63] 19.1 [.75] 29.2 [1.15] 34.3 [1.35] 37.6 [1.48] Max. b 4.1 [.16] 5.3 [.21] 8.1 [.32] 8.6 [.34] 10.7 [.42] P 10% b R 10% b W 20% b X 20% b 33.3 [1.31] 38.9 [1.53] 45.0 [1.77] 53.3 [2.10] 61.0 [2.40] 19.1 [.75] 22.1 [.87] 25.4 [1.00] 28.4 [1.12] 31.8 [1.25] 1.02 [.04] 1.02 [.04] 1.02 [.04] 1.02 [.04] 1.02 [.04] 3.05 [.12] 3.05 [.12] 3.05 [.12] 3.05 [.12] 3.05 [.12] This Boot Cannon/ Cinch DE-9 DA-15 DB-25 DC-37 DD-50 Fits Amphenol Series 17 XX09X XX15X XX25X XX37X 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. Available in: Americas Europe Asia Pacific n n n 4-63 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 214P009 to 037 D-Subminiature, Straight Boot with Jack Screws As Supplied (a) 0.12 max. (end gap) K Dia. W P R X J H After Unrestricted Recovery (b) # 0.12 max. (end gap) K Dia. K Dia. W 214P009 to 037 P R S X H J T # 4-40 UNC Applications Provides strain relief and mechanical protection on D-subminiature connector terminations. 214P009 to 037 Materials Available Material* -111-0 -111-8 Material Description Semirigid polyolefin (black) Semirigid polyolefin (gray) *Contact Tyco Electronics for information on material properties. Product Dimensions Part No. H 5% b J 10% b 214P009-XXX 214P015-XXX 214P025-XXX 214P037-XXX 17.3 [.68] 25.2 [.99] 38.4 [1.51] 54.2 [2.13] 12.0 [.47] 12.0 [.47] 12.0 [.47] 12.0 [.47] K Min. a 9.0 [.35] 10.5 [.41] 12.0 [.47] 12.0 [.47] Max. b 3.8 [.15] 3.8 [.15] 5.1 [.20] 5.8 [.22] P 10% b R Ref. b S Nom. b T Nom. b X 20% b W 20% b Fits Connector Size 43.0 [1.69] 44.0 [1.73] 49.0 [1.87] 55.0 [2.16] 22.0 [.87] 23.0 [.90] 25.0 [.98] 25.0 [.98] 29.0 [1.14] 29.0 [1.14] 29.0 [1.14] 29.0 [1.14] 6.4 [.25] 6.4 [.25] 6.4 [.25] 6.4 [.25] 1.80 [.07] 2.03 [.08] 2.16 [.085] 2.26 [.089] 1.5 [.06] 1.5 [.06] 1.5 [.06] 1.5 [.06] 9 pin 15 pin 25 pin 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. Available in: Americas Europe Asia Pacific n n n 4-64 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 222A111 to 196 Right-Angled Boot As Supplied (a) P U J Dia. H Dia. R T JO H Dia. After Unrestricted Recovery (b) P U W 222A111 to 196 J Dia. H Dia. 4 J Dia. R Molded Parts T JO H Dia. Applications Use for mechanical protection and connector-cable 222A111 to 196 strain relief. This family of boots has no lip, so a boot can be installed directly onto the connector accessory thread. Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or/180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions J H Part No. 222A111 222A121 222A132 222A142 222A152 222A163 222A174 222A185 222A196 Min. a Max. b 17.8 [.70] 24.9 [.98] 30.0 [1.18] 32.5 [1.28] 36.1 [1.42] 43.9 [1.73] 53.1 [2.09] 67.6 [2.66] 87.6 [3.45] 7.9 [.31] 10.2 [.40] 14.2 [.56] 17.3 [.68] 21.8 [.86] 27.4 [1.08] 33.8 [1.33] 44.2 [1.74] 55.4 [2.18] -3, -4, -25 a 17.8 [.70] 24.9 [.98] 30.0 [1.18] 32.5 [1.28] 36.1 [1.42] 43.9 [1.73] 53.1 [2.09] 67.6 [2.66] 87.6 [3.45] Min. -100 a 10.9 [.43] 16.0 [.63] 21.1 [.83] 22.9 [.90] 27.4 [1.08] 28.4 [1.12] 48.3 [1.90] 58.4 [2.30] 68.8 [2.71] P Max. 10% -12 b b a 9.9 [.39] 3.8 [.15] 17.3 [.68] 18.0 [.71] 5.3 [.21] 21.3 [.84] 20.6 [.81] 6.4 [.25] 26.9 [1.06] 22.9 [.90] 6.9 [.27] 36.6 [1.44] 26.4 [1.04] 8.4 [.33] 43.7 [1.72] 27.4 [1.08] 9.4 [.37] 53.6 [2.11] 46.7 [1.84] 15.0 [.59] 75.7 [2.98] 54.4 [2.14] 20.3 [.80] 97.5 [3.84] 63.0 [2.48] 23.4 [.92] 128.0 [5.04] R 10% b T 10% b U 10% b JO 10% b W 20% b 20.1 [.79] 22.6 [.89] 26.7 [1.05] 30.5 [1.20] 35.1 [1.38] 43.9 [1.73] 52.8 [2.08] 66.0 [2.60] 79.2 [3.12] -- -- 19.1 [.75] 19.1 [.75] 19.1 [.75] 19.1 [.75] 25.4 [1.00] 25.4 [1.00] 25.4 [1.00] 11.4 [.45] 14.7 [.58] 17.8 [.70] 24.9 [.98] 30.0 [1.18] 34.0 [1.34] 53.3 [2.10] 71.1 [2.80] 87.6 [3.45] 4.3 [.17] 5.8 [.23] 7.1 [.28] 10.2 [.40] 12.7 [.50] 17.3 [.68] 32.0 [1.26] 40.6 [1.60] 56.4 [2.22] 1.02 [.04] 1.27 [.05] 1.52 [.06] 1.78 [.07] 1.78 [.07] 2.03 [.08] 3.30 [.13] 3.81 [.15] 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. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-65 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 222D121 to 196 Right-Angled, Lipped Boot As Supplied (a) P H Dia. J Dia. R K T W After Unrestricted Recovery (b) H P L H Dia. J Dia. J Dia. R JO K 222D121 to 196 Tan W H Applications Use in conjunction with Raychem adapters to provide strain relief for harness systems using circular connectors. Boot 222D121 to 196 is compatible with all Raychem grooved adapters of the appropriate shell size. Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions H Part No. 222D121 222D132 222D142 222D152 222D163 222D174 222D185 222D196 J Min. a Max. a 23.4 [.92] 28.4 [1.12] 31.0 [1.22] 36.0 [1.42] 42.7 [1.68] 51.8 [2.04] 66.0 [2.60] 81.8 [3.22] 10.4 [.41] 14.2 [.56] 17.8 [.70] 22.4 [.88] 28.2 [1.11] 35.1 [1.38] 44.5 [1.75] 60.5 [2.38] -3, -4, -25 b 23.4 [.92] 28.4 [1.12] 31.0 [1.22] 36.0 [1.42] 42.7 [1.68] 51.8 [2.04] 66.0 [2.60] 81.8 [3.22] Min. -100 b 14.0 [.55] 15.0 [.59] 18.0 [.71] 21.0 [.83] 25.0 [.98] 39.0 [1.54] 42.0 [1.65] 57.2 [2.25] P Max. 10% -12 b b b 12.4 [.49] 5.6 [.22] 21.3 [.84] 14.7 [.58] 6.6 [.26] 33.8 [1.33] 16.0 [.63] 7.1 [.28] 36.6 [1.44] 18.5 [.73] 8.4 [.33] 43.7 [1.72] 22.1 [.87] 9.9 [.39] 53.6 [2.11] 35.3 [1.39] 15.7 [.62] 78.0 [3.07] 45.7 [1.80] 20.3 [.80] 97.5 [3.84] 57.2 [2.25] 25.4 [1.00] 117.9 [4.64] R Ref. b JO 10% 22.6 [.89] 27.2 [1.07] 31.0 [1.22] 35.1 [1.38] 43.9 [1.73] 52.8 [2.08] 66.0 [2.60] 83.8 [3.30] 5.8 [.23] 15.5 [.65] 12.7 [.50] 14.5 [.57] 17.5 [.69] 33.5 [1.32] 40.1 [1.58] 38.1 [1.50] K 10% b W 20% 1.27 [.05] 15.2 [.60] 1.52 [.06] 19.1 [.75] 1.78 [.07] 19.1 [.75] 1.78 [.07] 19.1 [.75] 2.03 [.08] 19.3 [.76] 3.30 [.13] 25.4 [1.00] 3.81 [.15] 25.4 [1.00] 4.06 [.16] 25.4 [1.00] L 10% b 14.7 [.58] 24.9 [.98] 24.9 [.98] 30.0 [1.18] 33.0 [1.30] 53.8 [2.12] 71.1 [2.80] 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. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-66 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 222D211 to 299 Right-Angled, Lipped Boot P As Supplied (a) P H Dia. J Dia. R RR HW H Dia. After Unrestricted Recovery (b) JO Tan P JW P H Dia. J Dia. R J Dia. HW H Dia. RR JO 222D211 to 299 Tan 4 Molded Parts Applications Provides strain relief and mechanical protection 222D211 to 299 between cable and connector. Boot is usually used on open-wire-bundle airborne harnesses, or applications where the long tail replaces cable jacketing removed during termination. Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions H Part No. 222D211 222D221 222D232 222D242 222D253 222D263 222D274 222D285 222D296 222D299 Min. a Max. b 22.4 [.88] 25.7 [1.01] 29.5 [1.16] 34.0 [1.34] 37.3 [1.47] 43.7 [1.72] 50.0 [1.97] 62.7 [2.47] 69.3 [2.73] 81.8 [3.22] 11.4 [.45] 15.0 [.59] 18.8 [.74] 22.9 [.90] 29.5 [1.16] 34.0 [1.34] 41.1 [1.62] 47.0 [1.85] 59.7 [2.35] 67.1 [2.64] J Min. -3, -4, -25 -12, -100 a b 22.4 [.88] 14.0 [.55] 25.7 [1.01] 16.0 [.63] 29.5 [1.16] 18.3 [.72] 34.0 [1.34] 21.3 [.84] 37.3 [1.47] 23.1 [.91] 43.7 [1.72] 27.2 [1.07] 50.0 [1.97] 31.5 [1.24] 62.7 [2.47] 39.1 [1.54] 69.3 [2.73] 43.2 [1.70] 81.8 [3.22] 51.1 [2.01] Max. b P 10% b R Ref b JO 10% b PP 10% b RR 10% b 6.4 [.25] 7.4 [.29] 8.4 [.33] 9.7 [.38] 10.4 [.41] 12.2 [.48] 14.2 [.56] 17.5 [.69] 19.6 [.77] 22.9 [.90] 105.2 [4.14] 124.0 [4.88] 146.3 [5.76] 172.2 [6.78] 185.2 [7.29] 231.6 [8.41] 224.5 [8.84] 227.3 [8.95] 233.4 [9.19] 237.0 [9.33] 18.5 [.73] 19.8 [.78] 20.8 [.82] 21.8 [.86] 24.4 [.96] 27.4 [1.08] 29.5 [1.16] 33.3 [1.31] 35.1 [1.38] 44.5 [1.75] 87.6 [3.45] 99.1 [3.90] 114.3 [4.50] 132.6 [5.22] 143.8 [5.66] 169.2 [6.66] 173.2 [6.82] 168.1 [6.62] 157.2 [6.19] 151.1 [5.95] 6.9 [.27] 8.4 [.33] 10.4 [.41] 12.2 [.48] 15.5 [.61] 18.3 [.72] 21.1 [.83] 24.1 [.95] 30.0 [1.18] 33.3 [1.31] 12.4 [.49] 15.0 [.59] 15.5 [.61] 15.7 [.62] 17.8 [.70] 19.8 [.78] 20.8 [.82] 23.4 [.92] 23.6 [.93] 31.2 [1.23] HW 20% JW 20% 1.52 [.06] 1.14 [.045] 1.52 [.06] 1.14 [.045] 1.78 [.07] 1.14 [.045] 1.78 [.07] 1.14 [.045] 2.03 [.08] 1.14 [.045] 2.03 [.08] 1.14 [.045] 2.29 [.09] 1.40 [.055] 2.54 [.10] 1.40 [.055] 2.54 [.10] 1.40 [.055] 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. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-67 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 222D921 to 963 Right-Angled, Lipped Boot P As Supplied (a) U J Dia. R HW H H Dia. After Unrestricted Recovery (b) P U JW J Dia. R J Dia. HW H H Dia. JO 222D921 to 963 Applications Provides strain relief and mechanical protection between cabletoand 222D921 963 connector. It is used in applications where only a small number of the available contacts are utilized, resulting in a high ratio between the adapter and cable diameters. Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 Product Dimensions H Part No. 222D921 222D932 222D953 222D963 J Min. Min. a Max. b 19.3 [.76] 26.1 [1.03] 34.2 [1.35] 43.6 [1.72] 13.0 [.51] 19.1 [.75] 26.0 [1.02] 34.1 [1.34] -3, -4, -25 a 6.3 [.25] 7.6 [.30] 9.6 [.38] 11.4 [.45] -12, -100 a 4.5 [.18] 5.6 [.22] 6.6 [.26] 7.8 [.31] Max. b P 10% b R Ref. b U 10% b 2.1 [.08] 2.6 [.10] 3.0 [.12] 3.6 [.14] 44.5 [1.75] 67.3 [2.65] 81.3 [3.20] 115.6 [4.55] 16.3 [.64] 18.0 [.71] 18.8 [.74] 21.3 [.84] 5.6 [.22] 8.4 [.33] 11.4 [.45] 15.5 [.61] JO 10% b 21.8 [.86] 29.2 [1.15] 36.3 [1.39] 47.0 [1.85] HW 20% b JW 20% b 1.52 [.06] 1.78 [.07] 1.78 [.07] 1.78 [.07] 1.14 [.045] 1.14 [.045] 1.14 [.045] 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. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-68 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 222F211 to 285 P Right-Angled, Lipped Boot As Supplied (a) R H Dia. HW J Dia. H Dia. JO Tan After Unrestricted Recovery (b) P JW R H Dia. J Dia. HW J Dia. H Dia. JO 4 222F211 to 285 Tan Molded Parts Applications Use in conjunction with Raychem adapters to provide strain relief for harness 285 systems 222F211 using tocircular connectors. Boot is compatible with all Raychem grooved adapters of the appropriate shell size. Materials Available Material* -50 -51 -71 Material Description Viton(R) polymer blend Elastomer polymer blend Flexible polyolefin Precoating No. N/A /164 /42 or /86 Adhesive Part No.** S-1125 S-1124 S-1017 or S-1048 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions H Part No. 222F211 222F221 222F232 222F242 222F253 222F263 222F274 222F285 Min. a 23.9 [.94] 27.2 [1.07] 31.0 [1.22] 35.6 [1.40] 38.9 [1.53] 45.2 [1.78] 51.6 [2.03] 62.7 [2.47] J Max. b 9.9 [.39] 13.2 [.52] 18.5 [.73] 22.1 [.87] 28.2 [1.11] 32.3 [1.27] 41.1 [1.62] 42.9 [1.69] Min. a 17.3 [.68] 20.8 [.82] 24.4 [.96] 28.7 [1.13] 31.5 [1.24] 38.4 [1.51] 44.5 [1.75] 47.2 [1.86] Max. b 6.6 [.26] 7.6 [.30] 8.9 [.35] 10.2 [.40] 10.9 [.43] 12.7 [.50] 15.0 [.59] 17.5 [.69] P 10% b R 10% b JO 10% b 105.2 [4.14] 124.0 [4.88] 146.3 [5.76] 172.2 [6.78] 185.2 [7.29] 213.6 [8.41] 224.5 [8.84] 227.3 [8.95] 18.5 [.73] 19.8 [.78] 20.8 [.82] 21.8 [.86] 24.4 [.96] 27.4 [1.08] 29.5 [1.16] 33.3 [1.31] 87.6 [3.45] 99.1 [3.90] 114.3 [4.50] 132.6 [5.22] 143.8 [5.66] 169.2 [6.66] 173.2 [6.82] 168.1 [6.62] HW +.06 to -.03 b JW .03 b 1.52 [.06] 1.52 [.06] 1.78 [.07] 1.78 [.07] 1.78 [.07] 1.78 [.07] 1.78 [.07] 2.03 [.08] 1.52 [.06] 1.52 [.06] 1.52 [.06] 1.52 [.06] 1.52 [.06] 1.52 [.06] 1.78 [.07] 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. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-69 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 222K121 to 185 Right-Angled, Lipped Boot As Supplied (a) P H Dia. J Dia. R X HW H After Unrestricted Recovery (b) P Y Slight taper H Dia. JW J Dia. R J Dia. X 222K121 to 185 JO HW H For eyelet clip, order CS-1858 option. Applications Use in conjunction with Raychem adapters to provide strain relief for harness systems using circular 222K121 to 185is compatconnectors. Boot ible with all Raychem grooved adapters of the appropriate shell size. Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions Part No. 222K121 222K132 222K142 222K152 222K163 222K174 222K185 H Min. -100 -3, -4, -25 a a 24.0 [.95] 24.0 [.95] 30.0 [1.18] 30.0 [1.18] 31.0 [1.22] 31.0 [1.22] 36.0 [1.42] 36.0 [1.42] 43.0 [1.69] 43.0 [1.69] 60.0 [2.36] 52.0 [2.05] 66.0 [2.60] 66.0 [2.60] Max. b 10.4 [.41] 14.2 [.56] 18.0 [.71] 22.4 [.88] 28.2 [1.11] 35.1 [1.38] 44.5 [1.75] J Min. -100 -3, -4, -25 a a 24.0 [.95] 14.0 [.55] 30.0 [1.18] 15.0 [.59] 31.0 [1.22] 18.0 [.71] 36.0 [1.42] 21.0 [.83] 43.0 [1.69] 25.0 [.98] 60.0 [2.36] 39.0 [1.54] 66.0 [2.60] 42.0 [1.65] Max. b P 10% b R 10% b JO 10% b 5.6 [.22] 5.9 [.23] 7.1 [.28] 8.4 [.33] 9.9 [.39] 15.7 [.62] 16.8 [.66] 25.0 [.98] 32.0 [1.26] 39.0 [1.54] 46.0 [1.81] 55.0 [2.17] 80.0 [3.15] 108.0 [4.25] 25.0 [.98] 27.0 [1.06] 31.0 [1.22] 38.0 [1.50] 45.0 [1.77] 54.0 [2.13] 68.0 [2.68] 8.5 [.33] 8.5 [.33] 15.0 [.59] 18.0 [.63] 17.5 [.69] 32.0 [1.26] 48.0 [1.89] HW 20% b JW 20% b 1.3 [.05] .41 [.016] 1.5 [.06] .61 [.024] 1.8 [.07] .81 [.032] 1.8 [.07] .81 [.032] 2.0 [.08] .81 [.032] 3.3 [.13] 1.02 [.040] 3.8 [.15] 1.63 [.064] X 20% b Y 20% b 18.0 [.71] 18.0 [.71] 18.0 [.71] 25.0 [.98] 25.0 [.98] 25.0 [.98] 35.0 [1.38] 16.0 [.63] 20.0 [.79] 20.0 [.79] 25.0 [.98] 30.0 [1.18] 45.0 [1.77] 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. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-70 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 234A011 to 071 D-Subminiature, Right-Angled Boot As Supplied (a) K Dia. K Dia. P H W H J J After Unrestricted Recovery (b) K Dia. K Dia. 4 P R X W H J Molded Parts H 234A011 to 071 J Applications Provides strain relief and mechanical protection on D-subminiature connector terminations. 234A011 to 071 Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions H 234A011 234A021 234A032 234A042 234A052 234A061 234A071 J K 5% a 5% b 5% a 5% b Min. a Max. b P 10% b R 10% b W 20% b X 20% b 20.3 [.80] 28.2 [1.11] 42.2 [1.66] 58.7 [2.31] 57.9 [2.28] 20.3 [.80] 28.2 [1.11] 20.3 [.80] 28.2 [1.11] 42.2 [1.66] 58.7 [2.31] 57.9 [2.28] 20.3 [.80] 28.2 [1.11] 10.7 [.42] 10.7 [.42] 10.7 [.42] 10.7 [.42] 13.7 [.54] 10.7 [.42] 10.7 [.42] 10.7 [.42] 10.7 [.42] 10.7 [.42] 10.7 [.42] 13.7 [.54] 10.7 [.42] 10.7 [.42] 7.9 [.31] 10.2 [.40] 14.0 [.55] 17.3 [.68] 19.1 [.75] 7.9 [.31] 10.2 [.40] 4.1 [.16] 5.3 [.21] 7.4 [.29] 8.6 [.34] 10.7 [.42] 3.8 [.15] 5.1 [.20] 25.9 [1.02] 30.7 [1.21] 42.9 [1.69] 53.3 [2.10] 55.9 [2.20] 25.9 [1.02] 30.7 [1.21] 21.6 [.85] 24.6 [.97] 27.9 [1.10] 30.5 [1.20] 32.3 [1.27] 18.5 [.73] 19.8 [.78] 1.02 [.04] 1.02 [.04] 1.02 [.04] 1.02 [.04] 1.02 [.04] 1.02 [.04] 1.02 [.04] 3.05 [.12] 3.05 [.12] 3.05 [.12] 3.05 [.12] 3.05 [.12] 3.05 [.12] 3.05 [.12] Part No. This Boot Fits Cannon/ Cinch DE-9 DA-15 DB-25 DC-37 DD-50 DE-9 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. VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-71 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 234A111 to 152 J D-Subminiature, Side-Entry Boot As Supplied (a) H J P H K Dia. W After Unrestricted Recovery (b) X J H J 234A111 to 152 P H K Dia. R W K Dia. X Applications Provides strain relief and mechanical protection on D-subminiature connector 234A111 to 152 terminations. Materials Available Material* -3 -4 -25 Material Description Semirigid polyolefin Flexible polyolefin Fluid-resistant elastomer Precoating No. /42 or /86 /42 or /86 /42 or /86 or /225 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 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. Product Dimensions Part No. 234A111 234A121 234A132 234A142 234A152 H 5% a 20.3 [.80] 28.2 [1.11] 42.2 [1.66] 58.7 [2.31] 57.9 [2.28] J 5% b 20.3 [.80] 28.2 [1.11] 42.2 [1.66] 58.7 [2.31] 57.9 [2.28] 5% a 10.7 [.42] 10.7 [.42] 10.7 [.42] 10.7 [.42] 13.7 [.54] K 5% b 10.7 [.42] 10.7 [.42] 10.7 [.42] 10.7 [.42] 13.7 [.54] Min. a 7.9 [.31] 10.2 [.40] 14.0 [.55] 17.3 [.68] 19.1 [.75] Max. b 4.1 [.16] 5.3 [.21] 6.4 [.25] 7.9 [.31] 9.1 [.36] P 10% b R 10% b W 20% b X 20% b This Boot Fits Cannon/Cinch 27.9 [1.10] 35.1 [1.38] 47.5 [1.87] 59.7 [2.35] 63.2 [2.49] 18.5 [.73] 18.8 [.74] 20.1 [.79] 20.1 [.79] 26.4 [1.04] 1.02 [.04] 1.02 [.04] 1.02 [.04] 1.02 [.04] 1.02 [.04] 3.05 [.12] 3.05 [.12] 3.05 [.12] 3.05 [.12] 3.05 [.12] DE-9 DA-15 DB-25 DC-37 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. Available in: Americas Europe Asia Pacific n n n 4-72 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 K Dia. Boots 234A611 to 671 D-Subminiature, 90 End-Entry Boot As Supplied (a) K Dia. P K Dia. H&J H After Unrestricted Recovery (b) K Dia. P R 4 234A611 to 671 K Dia. H&J X W H Molded Parts J Applications Provides strain relief and 234A611 to 671 mechanical protection on D-subminiature connector terminations. Materials Available Material* -3 -4 -25 Material Description Semirigid polyolefin Flexible polyolefin Fluid-resistant elastomer Precoating No. /42 or /86 /42 or /86 /42 or /86 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 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. Product Dimensions Part No. 234A611 234A621 234A632 234A642 234A652 234A661 234A671 H 5% a 16.0 [.63] 19.1 [.75] 29.2 [1.15] 34.3 [1.35] 37.6 [1.48] 16.0 [.63] 19.1 [.75] J 5% b 20.3 [.80] 28.2 [1.11] 42.2 [1.66] 58.7 [2.31] 57.9 [2.28] 20.3 [.80] 28.2 [1.11] 5% a 16.0 [.63] 19.1 [.75] 29.2 [1.15] 34.3 [1.35] 37.6 [1.48] 16.0 [.63] 19.1 [.75] 5% b 10.7[.42] 10.7 [.42] 10.7 [.42] 10.7 [.42] 13.7 [.54] 10.7 [.42] 10.7 [.42] K Min. Max. a b 16.0 [.63] 4.1 [.16] 19.1 [.75] 5.3 [.21] 29.2 [1.15] 7.4 [.29] 34.3 [1.35] 8.6 [.34] 37.6 [1.48] 10.7 [.42] 16.0 [.63] 3.8 [.15] 19.1 [.75] 5.1 [.20] P 10% b R 10% b W 20% b X 20% b This Boot Fits Cannon/Cinch 25.9 [1.02] 30.7 [1.21] 42.9 [1.69] 53.3 [2.10] 55.9 [2.20] 25.9 [1.02] 30.7 [1.21] 21.6 [.85] 24.6 [.97] 27.9 [1.10] 30.5 [1.20] 32.3 [1.27] 18.5 [.73] 19.8 [.78] 1.02 [.04] 1.02 [.04] 1.02 [.04] 1.02 [.04] 1.02 [.04] 1.02 [.04] 1.02 [.04] 3.05 [.12] 3.05 [.12] 3.05 [.12] 3.05 [.12] 3.05 [.12] 3.05 [.12] 3.05 [.12] DE-9 DA-15 DB-25 DC-37 DD-50 DE-9 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. Available in: Americas Europe Asia Pacific n n n 4-73 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Boots 242W042 to 63 45 Angled Boot As Supplied (a) H Dia. J Dia. Applications Designed for use in the aggressive environments found adjacent to engines in automotive, aerospace and military applications, heat-shrinkable molded parts provide rugged protection, strain relief and a full 360environmental seal. The introduction of the 45 option means there is now a choice of three routes to the connector for closer positioning and greater design freedom. H Dia. J Dia. J Dia. After Unrestricted Recovery (b) JO P J Dia. W Typ. JO P W Typ. 135 S T 135 S U T H Dia. U H Dia. Compatibility Chart Material Dash Number -3 -4 -25 -130 -12 -100 Material Description Polyolefin, semirigid Polyolefin, flexible Elastomer, fluid-resistant Polyolefin, commercial flexible Viton(R) Polyolefin, Zerohal Precoating No. /42, /86 /42, /86 /42, /86, /225 /42, /86 N/A /180 Adhesive Part No. S-1017 or S-1048 S-1017 or S-1048 S-1017, S-1125 or S-1048 S-1017 or S-1048 S-1255-04 S-1030 Product Dimensions H Part No. 242W042 242W053 242W063 J Min. Min. a Max. b a -12, -100 a -3, -25 31.0 [1.22] 36.0 [1.42] 43.0 [1.69] 17.9 [.70] 22.1 [.87] 27.9 [1.10] 18.0 [.71] 21.0 [.83] 25.0 [.99] 31.0 [1.22] 36.0 [1.42] 43.0 [1.69] Max. b -12, -100, -3, -25 7.0 [.28] 8.4 [.33] 9.9 [.39] P 10% b S 10% b T 10% b U 10% b JO 10% b W 20% b 55.0 [2.17] 60.0 [2.36] 65.0 [2.56] 35.0 [1.38] 40.0 [1.58] 45.0 [1.77] 3.5 [.14] 3.5 [.14] 3.5 [.14] 2.0 [.08] 2.0 [.08] 2.0 [.08] 25.0 [.98] 30.0 [1.18] 35.0 [1.38] 1.8 [.07] 2.0 [.08] 2.2 [.09] As supplied dimensions are for uncoated parts, when coating is added, entry diameters will reduce by 1.5 [.06] max. Ordering Information 242W0XX-X/XX-0 Adhesive slash number (if required see Compatibility chart) Material dash number (see Compatibility chart) Base part number VITON is a trademark of Dupont Dow Elastomers LLC. Available in: Americas Europe Asia Pacific n n n 4-74 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Feedthroughs 207W213 to 256 Two-Part Feedthrough After Unrestricted Recovery (b) As Supplied (a) J Dia. S U Tan JO H M J Dia. J Dia. JW Slight taper B nut (-01 modification) A nut (standard) S U 4 Tan JO 207W213 to 256 S H J Dia. U Tan JO JW B nut (-01 modification) Molded Parts M Slight taper M H J Dia. A nut (standard) JW Applications Slight taper B nut (-01 modification) Use for strain relief and abrasion protection when cables pass through equipment boxes or panels. 207W213 to 256 A nut (standard) 207W213 to 256 Materials Available Material Dash Number Material Description Precoating No. -3 Semirigid polyolefin /42 or /86 -4 Flexible polyolefin /42 or /86 -12 Viton(R) N/A -25 Fluid-resistant elastomer /42 or /86 or /225 -100 Polyolefin, Zerohal /86 or /180 *For more information, please see the appropriate material page in this section. Adhesive Part No. S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 **For more information, please see section 5. Product Dimensions Part No. H Ref. b 207W213 207W223 207W234 207W245 207W256 11.9 [.47] 20.1 [.79] 30.1 [1.22] 45.0 [1.77] 68.1 [2.68] J Min. -3, -4, -12, Max. -100 -25 b a a 9.9 [.39] 8.5 [.33] 4.1 [.16] 18.0 [.71] 16.5 [.65] 7.1 [.28] 27.9 [1.10] 26.5 [1.04] 11.9 [.47] 41.9 [1.65] 40.5 [1.59] 18.0 [.71] 64.0 [2.52] 64.5 [2.54] 30.0 [1.18] JO Max. b M Thread b P 10% b 15.2 [.60] 19.3 [.76] 26.9 [1.06] 32.0 [1.26] 39.1 [1.54] 20.1 [.79] 30.0 [1.18] 41.9 [1.65] 55.9 [2.20] 80.0 [3.15] 62.0 [2.44] 71.9 [2.83] 87.1 [3.43] 102.1 [4.02] 121.9 [4.80] R 10% b 49.0 [1.93] 58.9 [2.32] 73.9 [2.91] 88.9 [3.50] 109.0 [4.29] S 10% b U 10% b JW 20% b Hole Dia. .51 [.02] 13.0 [.51] 16.0 [.63] 18.0 [.71] 18.0 [.71] 18.0 [.71] 9.9 [.39] 9.9 [.39] 9.9 [.39] 9.9 [.39] 9.9 [.39] 1.3 [.05] 1.8 [.07] 2.03 [.08] 3.05 [.12] 3.05 [.12] 23.9 [.94] 34.0 [1.34] 47.0 [1.85] 60.5 [2.38] 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. VITON is a trademark of Dupont Dow Elastomers LLC. 4-75 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Transitions 301A011 to 048 T Transition As Supplied (a) P K Dia. S J Dia. J Dia. H Dia. H After Unrestricted Recovery (b) P K Dia. W S J Dia. J Dia. K Dia. H Dia. 301A011 to 048 T H Dia. Applications Provides strain relief and 301A011 to 048 mechanical protection on cable harness assemblies. Materials Available Material Dash Number -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86, /180 Adhesive Part No. S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions Part No. 301A011 301A022 301A028 301A034 301A048 H, J & K Max. Min. a b 3.6 [.14] 6.6 [.26] 6.9 [.27] 13.2 [.52] 20.0 [0.79] 10.2 [.40] 26.9 [1.06] 13.5 [.53] 55.6 [2.19] 30.2 [1.19] P 10% b S 10% b T 10% b 29.7 [1.17] 58.7 [2.31] 90 [3.54] 120.1 [4.73] 246.4 [9.70] 15.1 [.59] 29.5 [1.16] 45 [1.77] 60.2 [2.37] 123.2 [4.85] -- 17.5 [.69] 30 [1.18] 35.6 [1.40] 70.9 [2.79] W 30% b 1.02 [.04] 1.52 [.06] 2.0 [.08] 2.29 [.09] 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. VITON is a trademark of Dupont Dow Elastomers LLC. 4-76 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Transitions 301A511 to 514 Slimline T Transition As Supplied (a) P H Dia. J Dia. HO Tan W H Dia. K Dia. K After Unrestricted Recovery (b) P H Dia. 4 J Dia. J Dia. HO Tan 301A511 to 514 Tan Molded Parts W H Dia. JO KO K Dia. K Applications Provides strain 301A511relief to 514 and mechanical protection on cable harness assemblies. Materials Available Material Dash Number -50 -51 -71 -125 Material Description Viton(R) polymer blend Elastomer polymer blend Flexible polyolefin Fluoropolymer Adhesive Part No. S-1125 S-1124 S-1017 or S-1048 S-1255-04 Precoating No. N/A /164 /42 or /86 N/A *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions H Part No. 301A511 301A512 301A513 301A514* VITON is a trademark of Dupont Dow Elastomers LLC. Min. a 19.8 [.78] 34.3 [1.35] 60.2 [2.37] 83.3 [3.28] Max. b 6.6 [.26] 11.4 [.45] 20.1 [.79] 33.3 [1.31] J&K Min. a 13.2 [.52] 22.9 [.90] 40.1 [1.58] 54.9 [2.16] Max. b 6.6 [.26] 11.4 [.45] 20.1 [.79] 33.3 [1.31] HO, JO, & KO 10% b W Nom. b P Nom. b 25.4 [1.00] 41.1 [1.62] 63.5 [2.50] 88.9 [3.50] 1.02 [.04] 1.27 [.05] 1.52 [.06] 1.78 [.07] 80.8 [3.18] 120.4 [4.74] 175.8 [6.92] 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. 4-77 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Transitions 322A112 to 158 T Transition P As Supplied (a) HW H Dia. H Dia. J Dia. K Dia. K K After Unrestricted Recovery (b) P HW H Dia. W H Dia. J Dia. J Dia. T 322A112 to 158 K Dia. KW K Dia. Applications Provides strain relief and mechanical protection on cable harness assemblies. 322A112 to 158 Materials Available Material Dash Number -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Modified elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No. S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions H&J Part No. 322A112 322A123 322A134 322A148 322A158 Min. a 13.2 [.52] 26.9 [1.06] 26.9 [1.06] 55.6 [2.19] 55.6 [2.19] K Max. b 5.8 [.23] 12.4 [.49] 12.7 [.50] 25.4 [1.00] 25.4 [1.00] Min. a 6.6 [.26] 6.6 [.26] 13.2 [.52] 13.2 [.52] 26.9 [1.06] Max. b 3.0 [.12] 3.0 [.12] 5.8 [.23] 5.8 [.23] 12.4 [.49] P 10% b 52.3 [2.06] 83.3 [3.28] 107.7 [4.24] 180.6 [7.11] 222.3 [8.75] T 10% b -- 10.7 [.42] 20.3 [.80] 25.4 [1.00] 38.1 [1.50] HW & W 20% b 1.52 [.06] 2.54 [.10] 2.54 [.10] 4.57 [.18] 4.57 [.18] KW 20% b 1.02 [.04] 1.02 [.04] 1.52 [.06] 1.52 [.06] 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. VITON is a trademark of Dupont Dow Elastomers LLC. 4-78 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Transitions 342A012 to 058 45 Side-Breakout Transition As Supplied (a) HW H Dia. T J Dia. H Dia. K Dia. After Unrestricted Recovery (b) P U HW 4 JW T 342A012 to 158 H Dia. J Dia. J Dia. Molded Parts H Dia. KW K K Dia. Applications Provides strain relief and 342A012 to 158 mechanical protection on cable harness assemblies. Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions Part No. 342A012 342A024 342A034 342A048 342A058 H&J Min. Max. a b 13.2 [.52] 6.9 [.27] 12.7 [.50] 26.9 [1.06] 13.7 [.54] 26.9 [1.06] 55.6 [2.19] 26.9 [1.06] 55.6 [2.19] 26.9 [1.06] K Min. a 6.6 [.26] 6.6 [.26] 13.2 [.52] 13.2 [.52] 26.9 [1.06] Max. b 3.6 [.14] 3.6 [.14] 6.1 [.24] 6.9 [.27] 13.7 [.54] P 10% b T 10% b U 10% b HW & JW 20% b KW 20% b 49.3 [1.94] 92.5 [3.64] 144.8 [5.70] 184.9 [7.28] 203.5 [8.01] 19.6 [.77] 31.8 [1.25] 50.8 [2.00] 63.5 [2.50] 66.0 [2.60] 19.6 [.77] 39.6 [1.56] 50.8 [2.00] 63.5 [2.50] 66.0 [2.60] 1.52 [.06] 2.54 [.10] 2.54 [.10] 4.57 [.18] 4.57 [.18] 1.02 [.04] 1.02 [.04] 1.52 [.06] 1.52 [.06] 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. VITON is a trademark of Dupont Dow Elastomers LLC. 4-79 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Transitions 362A014 to 114 30 Side-Breakout Transition As Supplied (a) P HW J Dia. H Dia. H Dia. K After Unrestricted Recovery (b) P HW S T JW J Dia. H Dia. H Dia. J Dia. 362A014 to 114 K KW K Dia. Applications Provides strain relief and mechanical protection on cable harness assemblies. 362A014 to 114 Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions H&J S P K 10% 10% Max. Min. Max. Min. a b b b b a 362A014 30.5 [1.20] 15.7 [.62] 20.3 [.80] 10.7 [.42] 82.6 [3.25] 31.8 [1.25] 362A024 35.6 [1.40] 18.3 [.72] 15.2 [.60] 8.6 [.34] 63.5 [2.50] 19.1 [.75] 362A114 35.6 [1.40] 18.8 [.74] 10.2 [.40] 5.3 [.21] 61.0 [2.40] 19.1 [.75] Part No. T 10% b 21.1 [.63] 22.4 [.88] 21.3 [.84] HW & JW 20% b KW 20% b 2.54 [.10] 1.78 [.07] 2.54 [.10] 1.52 [.06] 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. VITON is a trademark of Dupont Dow Elastomers LLC. 4-80 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 S T Transitions 381A301 to 304 Slimline Y Transition As Supplied (a) J Dia. P H Dia. H Dia. K Dia. W After Unrestricted Recovery (b) J R 4 381A301 to 304 J Dia. P K Dia. Molded Parts H Dia. H Dia. W S K Applications 381A301 to 304 Provides strain relief and mechanical protection on cable harness assemblies. Materials Available Material* -50 -51 -71 -125 Material Description Viton(R) polymer blend Elastomer polymer blend Flexible polyolefin Fluoropolymer Precoating No. N/A /164 /42 or /86 -- Adhesive Part No.** S-1125 S-1124 S-1017 or S-1048 S-1255-04 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions Part No. 381A301 381A302 381A303 381A304* VITON is a trademark of Dupont Dow Elastomers LLC. H Min. a 19.8 [.78] 34.3 [1.35] 60.2 [2.37] 83.3 [3.28] Max. b 6.6 [.26] 11.4 [.45] 20.1 [.79] 33.3 [1.31] J&K Max. Min. a b 6.6 [.26] 13.2 [.52] 22.9 [.90] 11.4 [.45] 40.1 [1.58] 20.1[.79] 54.9 [2.16] 33.3 [1.31] W Nom. b 1.0 [.04] 1.3 [.05] 1.5 [.06] 1.8 [.07] P Nom. b 40.6 [1.60] 63.0 [2.48] 94.7 [3.73] 133.9 [5.27] R&S Nom. b 40.6 [1.60] 63.0 [2.48] 94.7 [3.73] 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. 4-81 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Transitions 382A012 to 046 Y Transition As Supplied (a) S HW J Dia. H Dia. H Dia. K Dia. After Unrestricted Recovery (b) JW J Dia. S HW J Dia. T 382A012 to 046 H Dia. H Dia. KW K Dia. K Dia. Applications Provides strain relief and to 046 on mechanical382A012 protection cable harness assemblies. Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions H Part No. 382A012 382A023 382A034 382A046 Min. a 13.2 [.52] 26.9 [1.06] 38.6 [1.52] 55.6 [2.19] Max. b 6.1 [.24] 12.4 [.49] 18.0 [.71] 25.9 [1.02] J&K S 10% Min. Max. b a b 6.6 [.26] 3.3 [.13] 23.9 [.94] 13.2 [.52] 6.1 [.24] 53.3 [2.10] 26.9 [1.06] 12.4 [.49] 78.7 [3.10] 26.9 [1.06] 12.7 [.50] 111.8 [4.40] T 10% b HW 20% b JW & KW 20% b 15.5 [.61] 33.0 [1.30] 55.9 [2.20] 71.1 [2.80] 1.52 [.06] 2.54 [.10] 3.05 [.12] 4.57 [.18] 1.02 [.04] 1.52 [.06] 2.54 [.10] 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. VITON is a trademark of Dupont Dow Elastomers LLC. 4-82 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 T Transitions 382C312, 322 and 332 Slimline Y Transition As Supplied (a) After Unrestricted Recovery (b) R P Tan J Dia. J Dia. J Dia. JO Tan HO R Tan JO P Tan H Dia. H Dia. K Dia. HO W Typ.H Dia. W Typ. After Unrestricted Recovery (b) S Tan KO S R P J Dia. H Dia. K Dia. J Dia. JO Tan Tan K Dia. Tan KO 382C322, 382C332 HO 4 H Dia. K Dia. W Typ. Molded Parts S Tan KO K Dia. 382C312 Applications Provides strain relief and mechanical protection at two into one Y junctions in cable harness assemblies. Materials Available Material -50 -51 -71 -125 When used with adhesive it provides environmental sealing. These parts are based on the 382A3 range. They have the branched Material Description Viton(R) polymer blend Elastomer polymer blend Flexible polyolefin Fluoropolymer Product Dimensions H Part No. 382C312 Min. a 1.20 [30.5] Min. a .90 [22.9] Max. b .45 [11.4] Max. b .45 [11.4] H Part No. 382C322 Min. a .90 [22.9] H Part No. 382C332 VITON is a trademark of Dupont Dow Elastomers LLC. Min. a 1.00 [25.4] Precoating No. N/A /164 /42 or /86 N/A J Max. b .45 [11.4] K Max. b .45 [11.4] outlet(s) reduced in size to accommodate smaller cable diameters without the need for packing or shimming. Adhesive Part No. S-1125 S-1124 S-1017 or S-1048 S-1255-04 P, R & S Nom. b KO 15% b HO & JO 15% b W Nom b 2.48 [63.0] .85 [21.6] 1.62 [41.1] .04 [1.0] HO 15% b JO & KO 15% b W Nom. b 2.48 [63.0] 1.62 [41.1] .85 [21.6] .04 [1.0] P, R & S Nom. b HO 15% b JO & KO 15% b W Nom. b 2.48 [63.0] 1.62 [41.1] .85 [21.6] .04 [1.0] Min. a .60 [15.2] Max. b .30 [7.6] J&K Min. Max. a b .40 .20 [10.2] [5.1] P, R & S Nom. b J&K Min. Max. a b .60 .30 [15.2] [7.5] 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. 4-83 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Transitions 462A011 to 060 Transition, One to Three Cables P As Supplied (a) T HW J Dia. H Dia. K Dia. H Dia. L Dia. After Unrestricted Recovery (b) P J Dia. T U HW KW Typ. J Dia. H Dia. K Dia. K Dia. H Dia. L Dia. 462A011 to 060 L Dia. Applications Provides strain relief and mechanical protection on cable harness assemblies. 462A011 to 060 Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions H Part No. 462A011 462A023 462A034 462A046 462A060 Part No. 462A011 462A023 462A034 462A046 462A060 VITON is a trademark of Dupont Dow Elastomers LLC. J, K&L Min. a 13.2 [.52] 26.9 [1.06] 38.6 [1.52] 55.6 [2.19] 91.4 [3.60] Max. b 6.6 [.26] 13.2 [.52] 18.8 [.74] 25.4 [1.00] 54.6 [2.15] Min. a 6.6 [.26] 13.2 [.52] 19.3 [.76] 26.9 [1.06] 45.7 [1.80] Max. b 3.6 [.14] 6.9 [.27] 9.7 [.38] 12.4 [.49] 27.4 [1.08] T 10% b 30.5 [1.20] 57.2 [2.25] 88.9 [3.50] 121.9 [4.80] 254.0 [10.00] U 10% b 15.7 [.62] 33.0 [1.30] 45.7 [1.80] 71.1 [2.80] 127.0 [5.00] HW 20% b 1.52 [.06] 2.54 [.10] 3.05 [.12] 4.57 [.18] 7.11 [.28] KW 10% b 1.02 [.04] 1.52 [.06] 1.78 [.07] 3.05 [.12] 4.57 [.18] P 10% b 46.2 [1.82] 93.2 [3.67] 135.1 [5.32] 192.0 [7.56] 390.4 [15.37] 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. 4-84 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 U Transitions 462A421 to 424 P Slimline Transition, One to Three Cables As Supplied (a) K Dia. R H Dia. H Dia. J & L Dia. After Unrestricted Recovery (b) P J Dia. 4 S K Dia. R H Dia. Molded Parts H Dia. K Dia. J & L Dia. 462A421 to 424 W T L Dia. Applications Provides strain relief and mechanical protection on cable harness assemblies. 462A421 to 424 Materials Available Material* -50 -51 -71 Material Description Viton(R) polymer blend Elastomer polymer blend Flexible polyolefin Product Dimensions H Part No. Min. a 462A421* 19.8 [.78] 462A422* 34.3 [1.35] 462A423* 60.2 [2.37] 462A424* 99.8 [3.93] *-01 modification only Materials Available Material* -125 Max. b 6.6 [.26] 11.4 [.45] 20.1 [.79] 33.3 [1.31] Precoating No. N/A /164 /42 or /86 J, K & L Min. Max. b a 13.2 [.52] 6.6 [.26] 20.6 [.81] 11.4 [.45] 36.1 [1.42] 20.1 [.79] 54.9 [2.16] 33.3 [1.31] Material Description Fluoropolymer Adhesive Part No.** S-1125 S-1124 S-1017 or S-1048 W Nom. b P Nom. b R, S & T Nom. b 1.0 [.04] 1.3 [.05] 1.5 [.06] 1.8 [.07] 85.9 [3.38] 135.6 [5.34] 207.3 [8.16] 207.2 [8.16] 42.9 [1.69] 67.8 [2.67] 103.6 [4.08] 103.6 [4.08] Precoating No. -- Adhesive Part No.** 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 R, S & T P W Nom. Nom. Nom. Max. Min. Max. Min. b b b a b a b 85.9 [3.38] 42.9 [1.69] 1.0 [.04] 6.6 [.26] 13.2 [.52] 6.6 [.26] 462A421 19.8 [.78] 20.6 [.81] 11.4 [.45] 1.3 [.05] 135.6 [5.34] 67.8 [2.67] 11.4 [.45] 462A422 34.3 [1.35] 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. Part No. VITON is a trademark of Dupont Dow Elastomers LLC. 4-85 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Transitions 562A011 to 067 Transition, One to Four Cables As Supplied (a) K Dia. T HW J Dia. H Dia. H Dia. N Dia. L Dia. After Unrestricted Recovery (b) W K Dia. J Dia. T HW J Dia. U K Dia. H Dia. H Dia. 562A011 to 067 N Dia. L Dia. L Dia. N Dia. P Applications Provides strain relief and mechanical protection on cable harness assemblies. 562A011 to 067 Materials Available Material* -3 -4 -12 -25 -100 Material Description Semirigid polyolefin Flexible polyolefin Viton(R) Fluid-resistant elastomer Polyolefin, Zerohal Precoating No. /42 or /86 /42 or /86 N/A /42 or /86 or /225 /86 or /180 Adhesive Part No.** S-1017 or S-1048 S-1017 or S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1048 or S-1030 *For more information, please see the appropriate material page in this section. **For more information, please see section 5. Product Dimensions H Part No. 562A011 562A022 562A032 562A043 562A054 562A067 Min. a 13.2 [.52] 19.3 [.76] 19.3 [.76] 26.9 [1.06] 38.6 [1.52] 55.6 [2.19] Max. b 6.9 [.27] 9.7 [.38] 9.7 [.38] 13.0 [.51] 18.5 [.73] 26.7 [1.05] J, K, L & N Min. Max. a b 6.6 [.26] 3.4 [.14] 9.4 [.37] 5.3 [.21] 13.2 [.52] 6.9 [.27] 13.2 [.52] 6.9 [.27] 9.7 [.38] 19.3 [.76] 26.9 [1.06] 13.0 [.51] P 10% b 24.1 [.95] 35.6 [1.40] 49.3 [1.94] 49.3 [1.94] 71.9 [2.83] 101.6 [4.00] T 10% b 43.9 [1.73] 43.2 [1.70] 50.5 [1.99] 65.8 [2.59] 95.3 [3.75] 135.1 [5.32] U 10% b 18.0 [.71] 23.1 [.91] 25.4 [1.00] 33.5 [1.32] 46.5 [1.83] 65.5 [2.58] HW 20% b 1.52 [.06] 1.78 [.07] 1.78 [.07] 2.54 [.10] 3.05 [.12] 4.57 [.18] W 20% b 1.02 [.04] 1.02 [.04] 1.52 [.06] 1.52 [.06] 1.78 [.07] 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. VITON is a trademark of Dupont Dow Elastomers LLC. 4-86 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 U Transitions QFT Configurable Heat-Shrink Transition Product Facts n Configurable heat-shrink transition n Low cost commercial polyolefin n 80C [176F] shrink temperature n High shrink ratio n Specially engineered easy-to-use crimp tool 4 Molded Parts H Dia. J Dia. Expanded Recovered P JO H Dia. J Dia. HW J Dia. H Dia. JW them to be employed as 1:2, 1:3, and even 1:4 tranQFT heat-shrinkable transitions form a watertight seal P sitions. With their high shrink ratio and crimps the configprotecting cable splices JO from corrosion and mechan- urable QFT product line can accommodate almost all of ical abuseHW while providing J Dia. H Dia. excellent electrical insulating your transition needs with sizes. only 3 product JW properties. QFT products use special crimps that allow Operating Temperature Range Specifications/Approvals Raychem RW 2008 RT1050/1 Molded Part Adhesive Temperature Ratings Operating temperature range Minimum recovery temperature Maximum storage temperature -20C to 70C [-4F to 158F] (125C [257F] without sealant) 55C [131F] 40C [104F] Applications Dimensions Table QFT1 QFT2 QFT3 H Max. Min. 31.0 [1.22] 9.0 [.35] 43.0 [1.69] 14.0 [.55] 57.0 [2.24] 24.0 [.95] J Min. 31.0 [1.22] 43.0 [1.69] 57.0 [2.24] Max. 4.4 [.17] 7.0 [.28] 12.0 [.47] -20C to 70C [-4F to 158F] P +/- 10% JO +/- 10% HW +/- 20% JW +/- 20% 60.0 [2.36] 75.0 [2.95] 90.0 [3.53] 12.0 [.47] 18.0 [.71] 25.0 [.98] 1.5 [.06] 1.8 [.07] 1.8 [.07] 1.0 [.039] 1.0 [.039] 1.0 [.039] 4-87 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Transitions QFT (Continued) Typical QFT Performance Physical Electrical Chemical Part Numbering System Property Tensile strength Ultimate elongation Longitudinal change Specific gravity Heat aging 168 hours at 120C [248F] Heat shock 4 hours at 105C Dielectric strength Fluid resistance 1 Engine Oil Hydraulic Fluid Tensile Strength Ultimate Elongation Fluid resistance 2 Automotive gasoline Diesel fuel Cleaning fluid Antifreeze Engine cleaning fluid Tensile strength Ultimate elongation Performance 10 MPa (1500psi) minimum 250% minimum 0 to 20% maximum 1.4 maximum Minimum 200% ultimate elongation Tensile Strength 10 MPa min. Test method ISO 37 ISO 37 ISO 1183 ISO 1183 ISO 188 ISO 37 No cracking, dripping or flowing ASTM D 2671 8MV/m minimum (24 +/- 2h immersion at 23C+/- 2C) (SAE 20W/50) IEC 243-1 ISO 1817 -- 10 MPa minimum 200% minimum (30 +/- 3m immersion at 23C+/- 2C) (BS 4040) (BS 2869) (TL 6850-07) (Ethylene Glycol/Water 50/50 v/v) (Gunk) 10 MPa minimum 200% minimum ISO 37 -- ISO 1817 -- -- -- -- ISO 37 -- QFT3 - 130/42 - 0* Color Adhesive Material Size Product name *Available in bulk pack, part number QFT3-130/42-0-B500 (US and UK). Ordering Information Color Standard Code Standard Packaging Crimp tool Bulk pack QFT-Crimp-Tool-Manual (069172-000) Black (-0) 0 10 pieces per bag, 30 clips 500 pieces per box and 500 clips per bag (clips ordered separately) - contact Tyco Electronics for details -- 4-88 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Transitions SSB, D, T, F to 8S Heavy Duty Breakout Boots Product Facts n Watertight Easy installation, requiring no special skills n Compatibility with polyethylene, PVC, lead, steel, aluminum, standard Navy cable jackets, and copper wire and cable n Four configurations and twelve sizes n Minimum shrink temperature of 121C [250F] n Type approval by: - ABS (American Bureau of Shipping) - DNV (Det Norske Veritas) - Lloyd's (Lloyd's Register of Shipping) n 4 Molded Parts Applications These flame-retardant heatshrinkable 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 are made of a rugged, thermally stabilized, modified polyolefin and factory- coated with a thermoplastic adhesive sealant. As a result, they offer excellent water sealing, mechanical abrasion-protection, corrosion-resistance, weatherproofing, and electrical insulation. The transitions replace tapes, epoxies, and grease in applications involving cable breakouts, transitions, and terminations. 4-89 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Transitions SSB, D, T, F to 8S (Continued) Specifications/Approvals Commercial RW-2024 Product Dimensions Description SSB-1202 FR SSB-2002 FR D3-9 FR D14-30 FR D50-100 FR D200-400 FR T3-9 FR T14-23 FR T14-50 FR T42-100 FR T150-300 FR T400 FR T500-600 FR F3-9 FR F-23 FR F42-60 FR F75-100 FR F133-200 FR F150-400 FR 6S100-200 FR 8S23-75 FR 8S14-50 FR 8S42-100 FR Military MIL-STD-2003 MIL-I-81765/1A Number of Legs 2 2 2 2 2 2 3 3 3 3 3 3 3 4 4 4 4 4 4 6 8 8 8 ID Base Min. Exp. Max. Rec. 40.64[1.60] 11.43 [0.45] 50.8[2.00] 35.56[1.40] 20.32[0.80] 9.39[0.37] 30.48[1.2] 15.24[0.6] 48.26[1.9] 22.86[0.9] 76.2[3] 38.1[1.5] 22.86[0.9] 9.14[0.36] 30.48[1.2] 17.78[0.70] 38.1[1.5] 12.7[0.5] 43.18[1.7] 22.86[0.9] 60.96[2.4] 35.56[1.4] 81.28[3.2] 50.8[2] 124.46[4.90] 58.93[2.32] 22.86[0.9] 10.92[0.43] 31.75[1.25] 20.32[0.8] 44.45[1.75] 25.4[1] 59.69[2.35] 25.4[1] 67.31[2.65] 35.56[1.4] 133.35[5.25] 76.2[3] 60.96[2.4] 36.83[1.45] 35.56[1.4] 21.59[0.85] 57.15[2.25] 21.59[0.85] 63.50[2.50] 21.59[0.85] ID legs Min. Exp. Min. Rec. 13.97[0.55] 3.81[0.15] 19.05[0.75] 8.89[0.35] 8.38[0.33] 2.79[0.11] 12.7[0.5] 4.32[0.17] 19.05[0.75] 7.62[0.3] 36.83[1.45] 12.7[0.5] 8.38[0.33] 2.29[0.09] 12.70[0.5] 4.57[0.18] 4.06[0.16] 16.51[0.65] 20.32[0.8] 4.83[0.19] 30.48[1.25] 12.70[0.5] 35.56[1.4] 17.78[0.7] 50.8[2] 22.86[0.9] 7.11[0.28] 2.79[0.11] 12.7[0.5] 5.08[0.2] 20.32[0.8] 8.13[0.32] 25.4[1] 8.89[0.35] 30.48[1.2] 10.92[0.43] 34.29[1.35] 13.97[0.55] 20.32[0.8] 8.89[0.35] 10.16[0.4] 3.3[0.13] 14.22[0.56] 3.3[0.13] 22.1[0.87] 3.3[0.13] Leg 36.83[1.45] 69.85[2.75] 17.78[0.7] 25.4[1] 30.48[1.2] 38.1[1.5] 19.05[0.75] 25.4[1] 30.48[1.2] 30.48[1.25] 40.6[1.6] 40.6[1.6] 50.8[2] 19.05[0.75] 27.94[1.1] 30.48[1.25] 43.18[1.7] 38.1[1.5] 76.2[3] 69.85[2.75] 30.48[1.25] 30.48[1.25] 30.48[1.25] Length Body 62.23[2.45] 88.90[3.50] 50.8[2] 63.5[2.5] 76.2[3] 88.9[3.5] 50.80[2.0] 60.96[2.40] 76.2[2.3] 57.15[2.25] 88.90[3.50] 88.9[3.5] 187.96[7.40] 50.8[2] 63.50[2.50] 63.50[2.50] 165.1[6.5] 91.44[3.6] 152.4[6] 86.36[3.4] 50.8[2] 50.8[2] 50.8[2] 4-90 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Accessories 202W302 to 342 Heat-Shrink Bobbins Product Facts n Fast installation Temperature range of -40C to 105C [-40F to 221F] n Fits range of diameters n Low cost, high volume installation n Shrinks onto hose/pipe/ wire harnesses n Good mechanical, thermal and chemical properties n Good abrasion resistance n Excellent location, cushioning and protection of cable or hoses from P clips and wire ties n Stays in place when heated. n Suits most hoses/pipes/wire harnesses n No expensive tooling required n Engine area solution n 4 Molded Parts H As Supplied (a) After Unrestricted Recovery (b) T P R W H Dia. H S J T H P W R H Dia. J S Square expanded = -130 material T Circular expanded = -12 and -25 material -3, -4 P R W H Dia. S 4-91 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Accessories 202W302 to 342 (Continued) Materials Available Material -3 -4 -12 -25 -130 Material Description Polyolefin, semi-rigid Polyolefin, flexible Viton(R) Fluid resistant elastomer Flexible polyolefin Precoating No. /42, /86 /42, /86 N/A /86 or /225 /42, /86 Adhesive Part No. S-1017, S-1048 S-1017, S-1048 S-1255-04 S-1017 or S-1048 or S-1125 S-1017 Product Dimensions H Part No. 202W302 202W312 202W321 202W331 202W342 Min. a Max. b 29.0 [1.142] 9.5 [.374] 39.0 [1.535] 12.7 [.500] 10.0 [.394] 3.0 [.118] 19.0 [.748] 6.4 [.252] 54.0 [2.126] 18.0 [.709] J Min. a P 10% b R 10% b S 10% b T 10% b W 20% b 29.0 [1.142] 39.0 [1.535] 10.0 [.394] 19.0 [.748] 54.0 [2.126] 35.0 [1.378] 35.0 [1.378] 29.0 [1.142] 29.0 [1.142] 35.0 [1.378] 25.0 [.984] 25.0 [.984] 23.0 [.906] 24.0 [.945] 25.0 [.984] 5.0 [.197] 5.0 [.197] 3.0 [.118] 2.5 [.098] 5.0 [.197] 3.0 [.118] 3.0 [.118] 3.0 [.118] 2.0 [.079] 3.0 [.118] 1.5 [.059] 2.0 [.079] 1.5 [.059] 1.5 [.059] 2.0 [.079] Recommended Hose Sizes Max. Min. 11.0 [.433] 14.0 [.551] 4.0 [.157] 8.0 [.315] 20.0 [.787] 25.0 [.984] 34.0 [1.339] 8.0 [.315] 17.0 [.669] 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. VITON is a trademark of Dupont Dow Elastomers LLC. 4-92 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Accessories 400W242 Heat-Shrink Positioning Ring Product Facts n Easy to install Close fit to hose/pipe n Fits range of diameters due to high expansion n Low cost, high volume installation n Shrinks onto hose/pipe n Minimum distance between substrates n Good mechanical, thermal and chemical properties n Push on fit to hose/pipe n Stays in place when installed n No expensive tooling required n Positions where needed n Keeps hoses/pipes together, optimizing space n Under body solution n Engine area solution n Twinning two hoses/pipes rationalizes part descriptions n Hose/pipe can be orientated correctly for ease of fitting to vehicle n 4 Molded Parts As Supplied (a) Y Z Z Y Z Y H Dia. H Dia. H Dia. -130 -3, -4, -25, -100 H Dia. H Dia. W W After Unrestricted Recovery (b) V V P H Dia. P W V J Dia. J Dia. K P K J Dia. K 4-93 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Accessories 400W242 (Continued) Materials Available Material -3 -4 -25 -100 Material Description Polyolefin, semi-rigid Polyolefin, flexible Elastomer, fluid resistant Polyolefin, Zerohal -130 Flexible polyolefin Precoating no. /42, /86 /42, /86 /86, /225 -100-CS1972 (S1030 tape supplied in bag) /42, /86 Adhesive part no. S-1017 or S-1048 S-1017 or S-1048 S-1017 or S-1048 S-1030 S-1017 As supplied dimensions are for uncoated parts, when coating is added, entry diameters will reduce by 1.5 [.06] max. Part Numbering System 400W242 -**/**-0 Adhesive Slash Number (if required see compatibility chart) Material Dash Number (see compatibility chart) Base Part Number Product Dimensions Part No. 400W242 H J K P V W Y* Z* Max. 1.2 1.7 0.45 1 2 2 Min. Max. b b b b b a a a b 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. 4-94 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Accessories CES Heat-Shrinkable Cable Entry Seals Product Facts n Comes in many sizes and configurations n Seals multicable openings n SAE-AS81765/1 Type 1 n Seals per U.S. Coast Guard HQ 3774 in wet, dry, and corrosive locations 4 nylon nut, an O-ring, and a heat-shrinkable molded area. The CES for threadedhole applications is a onepart assembly that combines a tapered national pipe thread (NPT) in rigid plastic nylon with a heat-shrinkable molded area. CESs are available in two basic types: standard and threaded. The standard CES for thin-wall enclosures consists of a three-part assembly -- a rigid plastic All CESs are available with the molded area configured with one opening for a single wire or cable entry or with two, three, or four legs Standard cable entry seal installation instructions Cable entry seal number 1 2 3 4 5 Torque in-pounds Nm 1.7-2.3 15-20 15-20 1.7-2.3 2.3-2.8 20-25 40-45 4.5-5.1 45-50 5.1-5.7 Threaded cable entry seal installation instructions Note: Surfaces to be sealed should be clean and free of burrs, pits, or deep scratches. 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 Insert cable through expanded opening and make necessary connections (see note following Step 4 in the next section). Step 1 Apply a thread sealant to the threaded end and then screw threaded cable entry seal into pretapped hole or pipe fitting. Step 2 Tighten by applying wrench to hexagonal nut. Step 3 Insert cable through expanded opening and make necessary connection (see Note). Step 4 Shrink expanded nose by applying 121C-135C [250F-275F] of heat from a heat gun with circular reflector, 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 component shrink tighter. Note If armored cable is used, the factory-applied sealant will not fill Molded Parts Raychem Heat-Shrinkable Cable-Entry Seals (CESs) provide a watertight, fume-tight seal where cables enter connection boxes, bulkheads, or other enclosures. Applications of equal size to seal multiple 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 wire and cable jackets. When armored cable is being sealed it may be necessary to use additional sealants, such as G.E. RTV 112 or Dow Corning RTV 732, to form the water seal. Step 5 Shrink expanded nose by applying 121C-135C [250F-275F] of heat from a heat gun with circular reflector, or a 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 component shrink tighter. *Follow the safety precautions of the manufacturer of the heater. the interstices of the armor. The armor must be cut back so that the part is 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. 4-95 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Accessories CES (Continued) Standard CES Temperature Temperature rating Minimum shrink temperature -55C to 90C [-67F to 194F] 121C [250F] Specifications Type Molded heat-shrink nose Adhesive Raychem RT-301 RW-2019 Product Dimensions Part No. No. of Legs CES-1 CES-2 CES-3 CES-4 CES-4S* CES-5 1 1 1 1 1 1 Overall Nom. Recommended Length 69.85 [2.75] 69.85 [2.75] 95.25 [3.75] 114.30 [4.50] 114.30 [4.50] 177.80 [7.00] Min. Expanded I.D. Nose 12.70 [0.50] 19.05 [0.75] 28.45 [1.12] 40.64 [1.60] 50.80 [2.00] 69.85 [2.75] Flame retardant polyolefin Hot melt adhesive Max. Recovered I.D. Nose 4.32 [0.17] 6.35 [0.25] 12.70 [0.50] 19.05 [0.75] 19.05 [0.75] 36.32 [1.43] Max. I.D. of Part Drill Size 19.05 [0.75] 19.05 [0.75] 27.94 [1.10] 39.62 [1.56] 53.34 [2.10] 73.66 [2.90] 25.40 [1.00] 25.40 [1.00] 35.05 [1.38] 50.80 [2.00] 59.94 [2.36] 88.90 [3.50] Max. O.D. of Nut 35.81 [1.410] 35.81 [1.410] 48.31 [1.902] 69.09 [2.720] 85.09 [3.350] 103.38 [4.070] *Part configuration may be different than depicted in figure. Contact Tyco Electronics for specification. Breakout CES Product Dimensions Part No. No. of Legs Overall Nom. Recommended Length CES-2-D1A CES-2-T1 CES-2-T1B CES-2-F1A CES-2-F1 CES-3-D1 CES-3-T1 CES-3-F1 CES-4-D3 CES-4-T1 CES-4-F1 CES-5-T4 CES-5-F4 2 3 3 4 4 2 3 4 2 3 4 3 4 69.85 [2.75] 69.85 [2.75] 88.90 [3.50] 69.85 [2.75] 88.90 [3.50] 88.90 [3.50] 88.90 [3.50] 88.90 [3.50] 101.60 [4.00] 101.60 [4.00] 101.60 [4.00] 127.00 [5.00] 127.00 [5.00] Min. Expanded I.D. (Each Leg) 15.24 [0.60] 10.16 [0.40] 15.24 [0.60] 10.16 [0.40] 15.24 [0.60] 15.24 [0.60] 15.24 [0.60] 15.24 [0.60] 22.86 [0.90] 22.86 [0.90] 22.86 [0.90] 31.75 [1.25] 31.75 [1.25] Max. Recovered I.D. (Each Leg) 2.79 [0.11] 2.79 [0.11] 4.32 [0.17] 2.79 [0.11] 4.32 [0.17] 4.32 [0.17] 4.32 [0.17] 4.32 [0.17] 7.62 [0.30] 7.62 [0.30] 7.62 [0.30] 12.70 [0.50] 12.70 [0.50] Max. I.D. of Part Drill Size Max. O.D. of Nut 19.05 [0.75] 19.05 [0.75] 19.05 [0.75] 19.05 [0.75] 19.05 [0.75] 27.94 [1.10] 27.94 [1.10] 27.94 [1.10] 40.64 [1.60] 40.64 [1.60] 40.64 [1.60] 73.66 [2.90] 73.66 [2.90] 25.40 [1.00] 25.40 [1.00] 25.40 [1.00] 25.40 [1.00] 25.40 [1.00] 35.05 [1.38] 35.05 [1.38] 35.05 [1.38] 50.80 [2.00] 50.80 [2.00] 50.80 [2.00] 63.50 [2.50] 63.50 [2.50] 35.81 [1.41] 35.81 [1.41] 35.81 [1.41] 35.81 [1.41] 35.81 [1.41] 48.26 [1.90] 48.26 [1.90] 48.26 [1.90] 69.09 [2.72] 69.09 [2.72] 69.09 [2.72] 103.38 [4.07] 103.38 [4.07] 4-96 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Accessories CES (Continued) Threaded CES Min. Max. Overall Nom. Recommended Expanded Recovered Length I.D. Nose I.D. Nose CES-2-A50 83.82 [3.30] 19.05 [0.75] 6.35 [0.25] 83.82 [3.30] 19.05 [0.75] 6.35 [0.25] CES-2-A75 83.82 [3.30] 19.05 [0.75] 6.35 [0.25] CES-2-A100 111.00 [4.37] 28.45 [1.12] 12.70 [0.50] CES-3-A100 117.35 [4.62] 28.45 [1.12] 12.70 [0.50] CES-3-A150 127.00 [5.00] 50.80 [2.00] 19.05 [0.75] CES-4A-A150* 152.40 [6.00] 69.85 [2.75] 25.40 [1.00] CES-5-A250* * Not illustrated - refer to Specification Control Drawing for details. Part No. National Adapter I.D. 12.70 [0.50] 19.05 [0.75] 19.05 [0.75] 25.40 [1.00] 27.94 [1.10] 35.56 [1.40] 60.96 [2.40] Pipe Thread Size 1/2-14 3/4-14 1-11 1/2 1-11 1/2 1 1/2-11 1/2 1 1/2-11 1/2 2 1/2-10 4 Molded Parts Threaded Breakout CES Product Dimensions Part No. No. of Legs Overall Nom. Recommended Length CES-2A-T1 CES-2A-F1 CES-2A-D1 CES-2A-T2 CES-2A-F2 CES-3A-D1 CES-2A-T3 CES-3A-F1 CES-3A-D2 CES-3A-T2 CES-3A-F2 CES-4A-D3 CES-4A-T3 CES-4A-F3 3 4 2 3 4 2 3 4 2 3 4 2 3 4 95.25 [3.75] 95.25 [3.75] 95.25 [3.75] 95.25 [3.75] 95.25 [3.75] 95.25 [3.75] 95.25 [3.75] 95.25 [3.75] 95.25 [3.75] 95.25 [3.75] 95.25 [3.75] 95.25 [3.75] 95.25 [3.75] 95.25 [3.75] Min. Expanded I.D. (Each Leg) 10.16 [0.4] 10.16 [0.4] 15.24 [0.6] 10.16 [0.4] 10.16 [0.4] 15.24 [0.6] 15.24 [0.6] 15.24 [0.6] 15.24 [0.6] 15.24 [0.6] 15.24 [0.6] 22.86 [0.9] 22.86 [0.9] 22.86 [0.9] Max. Recovered I.D. (Each Leg) 2.79 [0.11] 2.79 [0.11] 2.79 [0.11] 2.79 [0.11] 2.79 [0.11] 4.32 [0.17] 4.32 [0.17] 4.32 [0.17] 4.32 [0.17] 4.32 [0.17] 4.32 [0.17] 7.62 [0.30] 7.62 [0.30] 7.62 [0.30] Max. I.D. of Part Pipe Thread Size (NPT) 12.70 [0.50] 12.70 [0.50] 19.05 [0.75] 19.05 [0.75] 19.05 [0.75] 25.40 [1.00] 25.40 [1.00] 25.40 [1.00] 27.94 [1.10] 27.94 [1.10] 27.94 [1.10] 37.34 [1.47] 37.34 [1.47] 37.34 [1.47] 1/2-14 1/2-14 3/4-14 3/4-14 3/4-14 1-11 1/2 1-11 1/2 1-11 1/2 1 1/2-11 1/2 1 1/2-11 1/2 1 1/2-11 1/2 1 1/2-11 1/2 1 1/2-11 1/2 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. 4-97 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Accessories CES (Continued) Right-Angle Threaded CES A A C C D D B B Part No. CES-2R-A50 CES-2R-A75 CES-3R-A100 CES-3R-A150 C Min. Exp. ID 12.70 [0.50] 18.03 [0.71] 27.94 [1.10] 40.64 [1.60] B ID Min 12.70 [0.50] 19.05 [0.75] 25.40 [1.00] 27.94 [1.10] Max. Rec. ID 7.11 [0.28] 8.38 [0.33] 9.65 [0.38] 15.75 [0.62] Length A D 35.56 [1.4] 25.40 [1.00] 43.18 [1.7] 27.94 [1.10] 53.34 [2.1] 33.78 [1.33] 78.74 [3.1] 39.62 [1.56] NPT Size 1/2-14 3/4-14 1-11 1/2 1 1/2-11 1/2 Right-Angle Breakout CES A A C C D D B B Part No. CES-1R CES-2R CES-3R CES-4R C Min. Exp. ID 12.70 [0.50] 18.03 [0.71] 27.94 [1.10] 40.64 [1.60] Max. Rec. ID 7.11 [0.28] 8.38 [0.33] 9.65 [0.38] 15.75 [0.62] B ID Min 12.70 [0.50] 19.05 [0.75] 27.94 [1.10] 40.64 [1.60] Length D A 35.56 [1.4] 42.67 [1.68] 43.18 [1.7] 44.96 [1.77] 53.34 [2.1] 58.42 [2.30] 78.74 [3.1] 71.12 [2.80] Drill Size 25.40 [1.00] 25.40 [1.00] 34.80 [1.37] 50.80 [2.00] 4-98 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Accessories RayOLOn Kits Roll-On Sealing Sleeve Product Facts n A Raychem heatless sealing solution n Re-useable sealing solution n Roll-on to seal, roll-off to re-enter n Enhanced sealing with gel strips n Protection of connectors and splices against corrosion n Available in many conveniently packaged kits 4 RayOLOn re-useable roll-on sealing sleeves are a family of products designed to protect connectors, electrical cable splices, and other cylindrical substrates from harsh environmental elements like salt spray and water moisture. RayOLOn sleeves are a part of Raychem's "heatless" sealing products that require no 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 substrate requires servicing, the sleeve can be rolled off to provide access to the Specifications and Approvals Raychem Temperature Ratings Continuous operating temperature range Short term temperature exposure Minimum installation Sleeve Dimensions Inches (millimeters) Molded Parts Applications component under the sleeve. After the service is completed, the sleeve can be rolled on the part again to provide the protection. This operation may be done many times throughout the life of the sleeve providing time and material cost savings. Operating Temperature Range -40C to 70C [-40F to 158F] RW 3031 Base Part No. Available Kits LNCL-11-125 LNCL-11-205 LNCL-12-140 LNCL-12-240 LNCL-13-155 LNCL-13-305 LNCL-14-185 LNCL-14-355 LNCL-15-185 LNCL-15-260 LNCL-15-450 GK GK GK, CK-N GK, CK-N GK, TK-8 GK GK, TK-7 GK GK, TK-1, TK-5, TK-6 GK, SS GK, SS -40C to 70C [-40F to 158F] -63C to 90C [-81F to 194F] -25C [-13F] Dimensions (Reference) Diameter Lengths 4.92 [125] 0.51 [13.0] 8.07 [205] 0.51 [13.0] 0.56 [14.2] 5.51 [140] 0.56 [14.2] 9.45 [240] 0.75 [19.0] 6.10 [155] 0.75 [19.0] 12.00 [305] 1.02 [25.9] 7.28 [185] 1.02 [25.9] 14.00 [355] 1.45 [36.8] 7.28 [185] 10.2 [260] 1.45 [36.8] 17.72 [450] 1.45 [36.8] Recommended Use Range Connection Length 0.22 - 0.68 [6 - 17] 0.22 - 0.68 [6 - 17] 0.48 - 0.90 [12 - 23] 0.48 - 0.90 [12 - 23] 0.69 - 1.20 [18 - 30] 0.69 - 1.20 [18 - 30] 0.96 -1.50 [25 - 38] 0.96 -1.50 [25 - 38] 1.40 - 2.00 [36 - 46] 1.40 - 2.00 [36 - 46] 1.40 - 2.00 [36 - 46] 3.00 [75] 6.00 [150] 4.00 [100] 7.00 [175] 4.00 [100] 9.00 [225] 5.00 [125] 10.0 [250] 5.00 [125] 7.50 [190] 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 4-99 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Accessories RayOLOn Kits (Continued) Typical RayOLOn Roll-On Sealing Sleeve Properties Physical/ Chemical Electrical Property Tensile strength Ultimate elongation Density Water absorption 24 hours at 23C [73F] Flammability Dielectric strength Volume resistivity Performance 8.3 MPa (1200 psi) minimum 100 % minimum 1.1 g/cm3 maximum Test method ASTM D 2671 ASTM D 412 ASTM D 792 0.5 % maximum ASTM D 570 40 mm/min maximum 90 kV/cm (225 V/mil) minimum 1x1012 -cm ASTM D 635 ASTM D 149 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. Part Numbering System LNCL - XX - XXX - XX - XX Configuration Designator (blank if not required) Kit Designator Length of Sleeve Diameter Size Designator Product Family Name Kits GK--General kit: CK--Connector sealing kit: TK--Panel boot sealing kit: SS--Ship-or-shore kit: Roll-on sleeve, gel strip, cable tie, core tube, installation instruction Roll-on sleeve, cable tie, connector flange cover, gel strip, installation instruction Roll-on sleeve, ferrule, gel strip, cable tie, installation Instruction 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. 4-100 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Accessories shrinkHOoP Cable Clamp Heat-Shrink Grommet Product Facts n Less assembly time Superior strain-relief n Fewer errors -- less rework n Rework made easier n No build-up taping or feeding wire through grommet n Typical installation in just 10-20 seconds n Re-expandable I.D. allows wire addition to a cable bundle n 4 Molded Parts Applications shrinkHOoP grommet (URHR) is an ultra high ratio heat-shrinkable-strain-relief grommet that can be placed over the cable assembly after the connector 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, grommet, or tape/grommet combination). The high ratio conformity of shrinkHOoP grommets will match most typical cable configurations from single conductor to the high density multiple conductor arrangements. Operating Temperature Range -55C to 135C [-67F to 275F] 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 grommet reheated (shrinking it down again), positioned, and clamped in place. 4-101 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Accessories shrinkHOoP (Continued) Specifications/Approvals RW Y X L Y X X1 L Product Dimensions Inches (millimeters) Part No. URHR-1 URHR-2 URHR-3 URHR-4 URHR-5 I.D. Expanded (X1) min. 1 [25] 1.23 [31] 1.44 [37] 1.85 [47] 2 [51] Typical shrinkHOoP Grommet Performance Physical I.D. 1 X Recovered (X) max. .08 [2.1] .10 [2.6] .14 [3.6] 0.18 [4.7] 0.20 [5.1] O.D. (Y) Ref. Length (L) Ref. Wt. (gm) Ref. 0.25 [6] 0.375 [10] 0.5 [13] 0.562 [14] 0.812 [21] 0.5 [13] 0.5 [13] 0.5 [13] 0.75 [19] 0.75 [19] 0.75 Property Tensile strength Ultimate elongation Specific gravity Water absorption Flammability Corrosion resistance Low temperature flex 4 hours at - 55+/-1C [67+/-2F] Heat resistance 168 hrs at 175+/-1C [347+/-2F] Heat shock 4 hrs at 225+/-2C [437+/-5F] Elastic Memory Electrical -- Dielectric strength Volume resistivity -- Chemical Fluid Resistance Flammability* Notes 1 1.5 a) Recovered length will allow for 1.91 [0.075] either side of the collar, minimum in most cases. 3.5 5 Performance 1500 psi (10.3 Mpa) 250% minimum 1.4 maximum 0.5 % maximum Pass Pass Test Method ASTM D-412 ASTM D-412 ASTM D-792 ASTM D-570 A ASTM D-635 ASTM D-2671 A Pass ASTM D-2671 C 200% ultimate elongation, minimum 1200 psi (8.3 Mpa) tensile strength, minimum No cracking, dripping or flowing 275% minimum expansion to 4 inch (10 cm) of a fully recovered test specimen, and 93% recovery of expanded specimen after oven conditioning for 1 minute at 150+/-2C[302 +/- 4F] 200 v/mil (7880 v/mm) minimum 10 14 ohm-cm minimum 200% ultimate Elongation, minimum 1200 psi (8.3 Mpa) tensile strength, minimum Avg. flame time = 30 sec. max Avg. burn length = 3 in. max. Avg. flame time from drippings = 3 sec. max ASTM D-2671 ASTM D 2671 -- ASTM D-876 ASTM D-257 ASTM F-146 FAR part 25, Appendix F, part 1 (a), section 3 *applies to sizes 2, 3, and 4 only 4-102 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Accessories shrinkHOoP (Continued) Selection chart 10, 12 (11, 13) Connector Size 14, 16 (15, 17) 18, 20 (19, 21) 22, 24, 28* MIL-C-5015 MS3451, 52, 56, 59 MS3450 1 2 2 3 3 4 4 5 5 * MIL-C-26500** MS24266 MS24264, 265 1 2 2 3 3 4 4 5 5 * MIL-C-26482 MS3120, 21, 22, 26 MS3470, 71, 74, 75, 76 MS3124, MS3472 1 1 2 2 2 3 3 3 4 4 4 5 5 5 * MIL-C-83723 Series I M83723/01 & 02, 05 & 06 07 & 08, 13 & 14, 23 & 24 M83723/03 & 04 1 1 2 2 2 3 3 3 4 4 4 5 5 5 * MIL-C-83723 Series II M83723/17 & 18, 23 & 24 M83723/12 & 20, 21 & 22 1 2 2 3 3 4 4 5 5 * MIL-C-83723 Series III M83723/71 & 72 thru 97 & 98 M83723/66, 67, 68 & 69 1 2 2 3 3 4 4 5 5 * MIL-C-38999 Series I MS27469 MS27466, 68, 96, 27505, 27656 1 2 2 3 3 4 4 5 5 * MIL-C-38999 Series II MS27472, 97, 98, 27508, 27513 MS27473, 84, 27474 1 2 2 3 3 4 4 5 5 * MIL-C-38999 Series III 38999/26 38999/20, 24 1 3 2 4 3 5 4 5 5 * Boeing BACC45, F, M, N, P, R, S, T BACC 63X -- -- 2 3 3 4 4 5 5 * Boeing DC39, 31, 34, 35, 50-57 DC32, 33, 36, 37, 60, 61, 62, 63 1 2 2 3 3 4 4 5 5 * 4 Molded Parts 8 (9) Connector Series * Consult Tyco Electronics for availability of larger sizes. ** Note: cable support clamp I.D. may effect the size of shrinkHOoP grommet selected. 4-103 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 XL Products Ordering Information Tyco Electronics Corporation has acquired XL Technologies. Use the information in the following table to convert the XL part number into the new Tyco Electronics Raychem product description. Description XL Part No. 080EK025 080EK025-woA 137EK050 137EK050-woA 1-8117-2A 1-8117-3A 1-8117-4A 200EK075 200EK075-woA 20432242 2-8115-2A 2-8115-2AOE 2-8115-2B 2-8115-3A 2-8115-3B 2-8115-4A 2-8115-4B 2-8117-2A 2-8117-2AOE 2-8117-3A 2-8117-4A 2-8118-3A 2S-8115-2A 2S-8115-3A 2S-8115-4A 380EK150 380EK150woA 3-8115-2B 3-8115-3B 3-8115-4B 3-8118-4B 3A-8117-2B 3A-8117-3B 3A-8117-4B 4-8115-2C 4-8115-3C 4-8115-4C 4-8117-2B 4-8117-3B 4-8117-4B 4A-8117-2C 4A-8117-3C 4A-8117-4C 52451-2X12A 5-8115-3D 8114-1 1/2/14 8114-1-49R 8114-2 8114-2-50R 8114-2S 8114-2V 8114-2VL 8114-3 8114-3-51R 8114-3L 8114-3S 8114-4 8114-4-54R 8114-4N 8114-4S Convert to Description SSC-2/239 SSC-2/U SSC-3/239 SSC-3/U CES-2A-D1 CES-2A-T1 CES-2A-F1 SSC-4/239 SSC-4/U CES-4/HR-3 CES-2-D1A CES-2-D1A CES-2-D1 CES-2-T1 CES-2-T1B CES-2-F1A CES-2-F1 CES-2A-D1 CES-2A-D1 CES-2A-T2 CES-2A-F2 CES-2-T1 CES-2-D1A CES-2-T1 CES-2-F1A SSC-6/239 SSC-6/U CES-3-D1 CES-3-T1 CES-3-F1 CES-3-F1 CES-3A-D1 CES-2A-T3 CES-3A-F1 CES-4-D3 CES-4-T1 CES-4-F1 CES-3A-D2 CES-3A-T2 CES-3A-F2 CES-4A-D3 CES-4A-T3 CES-4A-F3 91385-2/12 CES-5-T4 CES-1 CES-1-2 CES-1R CES-2 CES-2R CES-2 CES-2V CES-2V CES-3 CES-3R CES-3L CES-3S CES-4 CES-4R CES-4 CES-4S Description XL Part No. 8114-4S/C 8114-5 8116-1 8116-1-49R 8116-1A 8116-2 8116-2-50R 8116-3 8116-3-51R 8116-3A 8116-4 8116-4-52R 8116-4A 8116-5 8118-2 91342-1 91342-12 91342-2 91342-23 91342-3X2.5 91342-3 91342-34 91342-4 91343-1 91343-2 91343-2A 91343-3 91343-4 91343-5 91343-5678 91343-6 91343-910 91344-1 91344-1213 91344-1415 91344-1617 91344-2 91344-3 91344-4 91344-5 91344-6 91346-3 91346-30 91346-31 91346-32 91347-30 91347-31 91347-32 91348-1 91348-2 91348-3 91348-30 91348-31 91348-32 91349-30 91349-31 91349-32 91350-30 91350-31 91350-32 91351-30 Convert to Description CES-4S CES-5 CES-2-A50 CES-2R-A50 CES-2-A50 CES-2-A75 CES-2R-A75 CES2-A100 CES-3R-A100 CES-3-A100 CES-3-A150 CES-3R-A150 CES-4A-A150 CES-5-A250 CES-2 D3-9 FR D3-30 FR D14-30 FR D14-100 FR D50-200 FR D50-100 FR D50-400 FR D200-400 FR T3-9 FR T14-23 FR T14-50 FR T42-100 FR T150-300 FR T-400 FR T3-100 FR T500-600 FR T150-400 FR F3-9 FR F3-23 FR F42-100 FR F75-200 FR F-23 FR F42-60 FR F75-100 FR F133-200 FR F150-400 FR 6S100-200 FR 202A111-3-0 202A111-3/42-0 202A111-3/86-0 202A121-3-0 202A121-3/42-0 202A121-3/86-0 8S23-75 FR 8S14-50 FR 8S42-100 FR 202A132-3-0 202A132-3/42-0 202A132-3/86-0 202A142-3-0 202A142-3/42-0 202A142-3/86-0 202A153-3-0 202A153-3/42-0 202A153-3/86-0 202A163-3-0 4-104 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 XL Products Ordering Information (Continued) Convert to Description 202A163-3/42-0 202A163-3/86-0 202A174-3-0 202A174-3/42-0 202A174-3/86-0 202A185-3-0 202A185-3/42-0 202A185-3/86-0 202A196-3-0 202A196-3/42-0 202A196-3/86-0 202D921-3/-0 202D921-3/42-0 202D921-3/86-0 202A921-3/-0 202A921-3/42-0 202D121-3/-0 202D121-3/42-0 202D121-3/86-0 202D132-3/-0 202D132-3/42-0 202132-3/-86-0 202D142-3/-0 202D142-3/42-0 202D142-3/86-0 202D153-3-0 202D153-3/42-0 202D153-3/86-0 202D163-3-0 202D163-3/42-0 202D163-3/86-0 202D174-3-0 202D174-3/42-0 202D174-3/86-0 202D185-3-0 202D185-3/42-0 202D185-3/86-0 202D196-3-0 202D196-3/42-0 202D196-3/86-0 202D211-3-0 202D211-3/42-0 202D211-3/86-0 202D221-3-0 202D221-3/42-0 202D221-3/86-0 202D232-3-0 202D232-3/42-0 202D232-3/86-0 202D242-3-0 202D242-3/42-0 202D242-3/86-0 202D253-3-0 202D253-3/42-0 Description XL Part No. 913L70-32 913L87-30 913L87-31 913L87-32 913R48-30 913R48-31 913R48-32 913R49-30 913R49-31 913R49-32 913R50-30 913R50-31 913R50-32 913R51-30 913R51-31 913R51-32 913R52-30 913R52-31 913R52-32 913RL48-30 913RL48-31 913RL48-32 913RL49-30 913RL49-31 913RL49-32 913RL50-30 913RL50-31 913RL50-32 913RL51-30 913RL51-31 913RL51-32 913RL52-30 913RL52-31 913RL52-32 913Y95-30 913Y95-31 913Y95-32 913Y96-30 913Y96-31 913Y96-32 HHW-1.3/6A HHW-13/6A HHW-15/12 HHW-15/6 HHW-15/9 HHW-20/9 HRSR-1 HRSR-2 HRSR-3 HRSR-4 HRSR-5 XHTA XHTU XMTA Convert to Description 202D253-3/86-0 202D921-3-0 202D921-3/42-0 202D921-3/86-0 222A132-3-0 222A132-3/42-0 222A132-3/86-0 222A142-3-0 222A142-3/42-0 222A142-3/86-0 222A152-3-0 222A152-3/42-0 222A152-3/86-0 222A163-3-0 222A163-3/42-0 222A163-3/86-0 222A174-3-0 222A174-3/42-0 222A174-3/86-0 222D132-3-0 222D132-3/42-0 222D132-3/86-0 222D142-3-0 222D142-3/42-0 222D142-3/86-0 222D152-3-0 222D152-3/42-0 222D152-3/86-0 222D163-3-0 222D163-3/42-0 222D163-3/86-0 222D174-3-0 222D174-3/42-0 222D174-3/86-0 381A301-71/-0 381A301-71/42-0 381A301-71/86-0 381A302-71/-0 381A302-71/42-0 381A302-71/86-0 SST-6-13FR/97-0 SST-6-13FR/97-0 SST-12-15FR/97-0 SST-6-15FR/97-0 SST-9-15FR/97-0 SST-9-20FR/97-0 URHR-1 URHR-2 URHR-3 URHR-4 URHR-5 RHW RHW RPRD 4 Molded Parts Description XL Part No. 91351-31 91351-32 91352-30 91352-31 91352-32 91353-30 91353-31 91353-32 91354-30 91354-31 91354-32 913L87-30 913L87-31 913L87-32 91387-30 91387-31 913L47-30 913L47-31 913L47-32 913L48-30 913L48-31 913L48-32 913L49-30 913L49-31 913L49-32 913L50-30 913L50-31 913L50-32 913L51-30 913L51-31 913L51-32 913L52-30 913L52-31 913L52-32 913L53-30 913L53-31 913L53-32 913L54-30 913L54-31 913L54-32 913L66-30 913L66-31 913L66-32 913L67-30 913L67-31 913L67-32 913L68-30 913L68-31 913L68-32 913L69-30 913L69-31 913L69-32 913L70-30 913L70-31 4-105 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Molded Parts Engineering Notes 4-106 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adhesives Table of Contents Tyco Electronics manufacturers Raychem adhesives and sealants to accommodate a wide range of applications, materials, and environmental conditions. 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 Raychem adhesives include both thermosets and thermoplastics. 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 a mastic-type sealant for water holdout applications. The sealants adhere to nonoily substrates and can be removed where reentry is necessary. 5 Adhesives Selection Guide To determine 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. Note: Users should independently evaluate the suitability of the product for their application. Before ordering, check with Tyco Electronics for most current data. 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 application requires. To use the Selection Table, follow these four steps: 1. Under "Substrate Category," find the product material and product name/part number for the Raychem part. 4. See the Adhesive/ Sealant Product Characteristics Table to verify the characteristics of the adhesive/sealant you selected. 2. Across the top of the table, find the part's product type and dash number. 3. At the intersection of the substrate category (product material/name/part number) and the product type (by designated dash number) you will find the part number for the most compatible adhesive for the Raychem part. 5-1 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adhesives Adhesive/Sealant Product Characteristics Tables Product Type Precoat Designation Thermosets S-1006 -- S-1009 -- S-1255-04 -- S-1125 Type Operating Temperature Range Product Designation Available Form/ Packaging -55C to 135C [-67F to 275F] S-1009 Kit 8 S-1006 Kit A 50-ml dual syringe Ten 3-gram packs Epoxy/ polyamide two-part paste Epoxy/ polymercaptan two-part paste One-part epoxy tape adhesive -55C to 135C [-67F to 275F] S-1009 Kit A S-1009 Kit 8 Ten 3-gram packs 50-ml dual syringe -55C to 200C [-67F to 392F] S-1255-04 Tape [3/4 in. x .020 x 100 ft.] -- Epoxy/polyamide two-part paste -55C to 150C [-67F to 302F] /225 Precoated latent-curing epoxy/polyamide -75C to 150C [-103F to 302F] S-1125 Kit 1 S-1125 Kit 2 S-1125 Kit 3 S-1125 Kit 4 S-1125 Kit 5 S-1125 Kit 8 Precoat only on -25 molded parts Five 10-gram packs Two 10-gram packs One 100-gram pack Five 10-gram packs One 10-gram pack 50-ml dual syringe -- Thermoplastics S-1017 /42 Hot-melt/ polyamide -20C to 60C*** [-4F to 140F] S-1017 Tape [1 in. x .010 in. x 50 ft.] S-1030 /180 Hot-melt/ polyolefin -80C to 80C [-112F to 176F] S-1030 Tape [3/4 in. x .010 in. x 33 ft.] S-1048 /86 Hot-melt, high performance -55C to 120C [-67F to 248F] S-1048 Tape [1 in. x .026 in. x 100 ft.] S-1124 /164 Hot-melt/ elastomeric polymer Hot-melt/ polyamide adhesive -55C to 105C [-67F to 221F] S-1124 -20C to 90C] [-4F to 194F] S-1297 Tape [1 in. x .010 in. x 10 ft.] Hot-melt grey butyl sealant Hot-melt grey butyl sealant -40C to 90C [-40F to 194F] -40C to 90C [-40F to 194F] S-1278-01 S-1278-02 S-1305-01 Tape [1 in. x .062 in. x 25 ft.] Tape [33/4 in. x .125 in. x 10 ft.] Tape [1 in. x.062 in. x25 ft.] S-1297 /97 Sealants S-1278 -- S-1305 -- Tape [3/4 in. x .018 in.x 10 ft.] *Shelf life from date of manufacture. **For specific adhesion properties, see product specification sheets. ***Passes cold bend at -40C [-40F] per RT-4204. ****Only S-1006 Kit A conforms to MIL-A-46864. 5-2 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adhesives Adhesive/Sealant Product Characteristics Tables (Continued) Pot Life at 23C [73.4F] Curing Conditions Shelf life* at or below 25C [77F] Specifications** Comments 1h 96 h at 20C [68F] min. or 1 hr at 120C [248F] 2 years 1 year Kit 8 RT-1006 RK-6612 MIL-A-46864**** General purpose harnessing adhesive. Not used on Viton(R) fluoroelastomers, silicone or Kynar(R); 20-minute pot life 20 min. 24 h at 20C [68F] min. or 1 hr at 95C [203F] 2 years 1 year Kit 8 RT-1009 45 min at 120C [248F] 2 h at 155C [311F] min. or 15 min at 240C [464F] 1 year RT-1014 General purpose harnessing adhesive Not used on Viton(R) fluoroelastomers or silicone; 20-minute pot life One-part epoxy tape used with Viton(R) fluoroelastomer harness systems. Heat cure required (2 hours at 155C [311F]) 24 h at 20C min. or 1 hr at 85C [185F] 18 months 1 year Kit 8 RT-1011 RK-6619 VG-95343 Good fluid-resistant epoxy used with System 25 36 months VG-95343 Precoated epoxy system for System 25 90 min. Cure during installation of molded parts RK-6630 120C [248F] Unlimited RT-1050/1 -- 120C [248F] Unlimited RT-1050/6 RK-6017 -- 160C [320F] Unlimited RT-1050/3 RK-6626 -- 135C [275F] Unlimited RT-1050/13 -- 120C [248F] Unlimited RW-2019 -- 110C [230F] Unlimited RW-2020 -- 110C [230F] Unlimited RW-2021 5 General purpose harnessing adhesive Standard precoated adhesive for -3 and -4 molded parts Good low-temperature flexibility Available as a preinstalled tape for molded parts Requires high temperature to achieve bonding. Highest service temperature for hot melt Requires reflowing in an oven at 150C [302F] for 90 minutes. Designed to bond to -51 molded parts. General purpose harnessing adhesive Standard precoated adhesive in Sigmaform molded parts, CES and CSGA cable entry seals, and SST-FR heat-shrinkable tubing Adhesives -- General purpose sealant and cable breakout area filler 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 -40C [-40F] per RT-4204. ****Only S-1006 Kit A conforms to MIL-A-46864. VITON is a trademark of Dupont Dow Elastomers LLC 5-3 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adhesives Adhesive/Sealant Selection Table Substrate Category Product Name Examples Polyolefin RNF-100 Versafit CRN BSTS SST HR Kynar(R) Fluoropolymer RT555 HCTE CONVOLEX Vinyl PVC DR-25 NT Elastomer NT-FR SFR SRFR Viton(R) VPB Zerohal XFFR ZHTM Molded Part Material Dash Number -3 S-1006 S-1009 S-1017 S-1030 S-1048 S-1297 S-1009 S-1048 S-1125 -- -- -- S-1006 S-1009 S-1017 -- S-1006 S-1009 S-1017 -- -- -- -- -- -- -- -- -4 S-1006 S-1009 S-1017 S-1030 S-1048 S-1297 S-1009 S-1048 S-1125 -- -- -- S-1006 S-1009 S-1017 -- S-1006 S-1009 S-1017 -- -- -- -- -- -- -- -- -6 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- * * -- -- -- -- -- -8 -- -- -- -- -- -- S-1009 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -12 -- -- -- -- -- -- -- -- -- S-1255 S-1255 S-1125 -- -- -- -- -- -- -- -- -- -- S-1255 -- -- -- -- -25 -50 -51 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- S-1125 -- -- -- -- -- -- -- -- -- -- -- S-1125 -- -- -- -- -- -- -- -- -- -- -- -- -- -- S-1125 S-1125 S-1125 -- -- S-1124 -- -- -- -- -- -- S-1125 -- S-1124 -- -- -- -- -- -- -- -- -- -- S-1125 -- -- S-1255 -- -- -- -- -- -- -- -55 -- -- -- -- -- -- -- -- -- S-1255 S-1255 S-1125 -- -- -- -- -- -- -- -- -- -- S-1255 -- -- -- -- -71 S-1006 S-1009 S-1017 S-1030 S-1048 S-1297 S-1009 S-1048 S-1125 -- -- -- S-1006 S-1009 S-1017 -- S-1006 S-1009 S-1017 -- -- -- -- -- -- -- -- -100 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- S-1030 S-1030 -125 -130 -- S-1006 -- S-1009 -- S-1017 -- -- -- -- -- -- S-1009 -- S-1048 -- S-1125 -- S-1255 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- S-1255 -- -- -- -- -- -- -- -- -- *GE RTV 108 used with SFR SRFR and -6 (silicone) molded parts. VITON is a trademark of Dupont Dow Elastomers LLC 5-4 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adhesives 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 jackets, 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 a minute or two to allow complete evaporation of the solvent. 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 solvent. The cloth or paper should not be saturated with the solvent. Allow the part to stand for a minute or two to allow complete evaporation of the solvent. Note: n Avoid contamination of the prepared surface. If using primer, apply it according to the manufacturer's instructions and allow it to dry. n Epoxy adhesives may cause skin and eye irritation. Be sure to observe the handling instructions. n When using hot-melt adhesives on substrates with high heat-sink capacity (such as connector backshells), preheat the substrate until it is hot to touch, then apply the adhesive tape and shrink the molded part in place. The use of cleaning solvent is described in the preparation of various components for adhesive bonding. Please observe the solvent manufacturer's safety recommendations. 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 off loose particles with a tissue 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 properly 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. 5 Adhesives Molded Parts, Cable Jackets, and Tubing Materials Caution: 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: 2 hours at 155C [311F] S-1124: 90 minutes at 150C [302F] 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 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). 5-5 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adhesives 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 positioned, 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 procedure on each leg of the transition. 7. Continue heating each end of the transition until the part is fully recovered 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. Thermosets Transition Connector Boot 1. Thoroughly mix the two parts according to the instructions provided with the kit. 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. 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. 8. Follow the curing conditions outlined in this guide. 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: 2 hours at 155C [311F] S-1124: 90 minutes at 150C [302F] 5-6 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 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. 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. 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. 5 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. Adhesives 3. Position the boot on the adapter and cable. Apply heat starting at the connector end. Transition 5. Follow the curing conditions specified for "thermosets" in the "Adhesive/Sealant Product Characteristics Table" on pages 5-2 and 5-3. 6. With a clean cloth, remove excess adhesive from all areas immediately. 7. Follow the curing conditions outlined in this guide. 5-7 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adhesives Engineering Notes 5-8 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapters Table of Contents 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 a variety of Raychem adapters for applications in many industries, including aerospace, marine, and mass transit. These adapters are: n n n n Available in many configurations to match applications Easy to install Ideal for high-reliability applications Kitted for customer convenience. In this section we present Raychem spin-coupling adapters and Tinel-Lock adapters. Tinel-Lock adapters are ideal for lightweight aerospace applications requiring repeated highto-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. 6 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, shapememory-alloy shieldtermination device available in many sizes to accommodate various entry sizes and shield configurations. 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 (Pattern 105) Spin-Coupling Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-74 Tinel-Lock Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-75, 6-76 6-1 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Fundamentals Definitions Introduction 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 a variety of Raychem adapters for applications in many industries, including aerospace, marine, and mass transit. Connector These adapters are: n n n n Shell Size Available in many configurations to match applications Easy to install Ideal for high-reliability applications Kitted 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. Adapter Entry Size Heat-shrinkable Molded Boot Adapter Type Adapter Family Shell Size 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 heatshrinkable molded part. Tyco Electronics offers several families (or series) of Raychem adapter products. Each Raychem adapter part number begins with an alphanumeric prefix denoting the Raychem product family. 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. Entry Size Raychem Adapter Code A numerical code is used to identify connectors with similar adapter interfaces. This code is used to determine the adapter family and part number. Entry size is the diameter of the hole through which the cable enters into the adapter. For example, the 08 entry is 12.7 [0.5]. Entry sizes are specified on braided and Tinel-Lock adapters only. 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. Ring Designator This is a two-letter code that is part of each Tinel-Lock adapter part number. It specifies the size of the Tinel-Lock ring suited to specific types of cable braid. Order Number This is a two-digit number that specifies the size of the adapter that will mate to the corresponding shell size of a connector. 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. 6-2 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Fundamentals Types of Adapters Adhesive Molded Part Adapter Adhesive Cable Jacket Solid Adapters (Fixed) Adapter Cable Braid ElectroMagnetic Force Ring Sealing Adhesive Molded Part Cable Braid Sealing Adhesive SolderSleeve Device Cable Jacket Sealing Adhesive Molded Part The four principal adapter types are: n Solid (fixed) n Spin-Coupling n Braided n Tinel-Lock Solid Adapters (Fixed) Solid adapters are designed for use where no access is required; for example, when potting is necessary or a lower space profile is needed. Spin-Coupling Adapters 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-part components 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 are used for environmental protection and strain relief of unscreened cable terminations. Cable repairs can be made without damaging the boot. 6 Braided Adapters Adapters 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. Cable Jacket Adapter Braided Adapters Adapter Types Sealing Adhesive 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 wire and has a handling characteristic that enables it to be pulled down onto a wide range of cable diameters. This allows a standard 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 configurations are available. 6-3 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Fundamentals Types of Adapters (Continued) Adapter Adhesive Molded part Tinel-Lock Ring Cable Braid Adhesive Cable Jacket Tinel-Lock Adapters Tinel-Lock Adapters Roll-back Repair with Adapters This termination system consists of a modified spin-coupling adapter with a Tinel-Lock ring. The Tinel-Lock ring is made from a special shape memory metal that shrinks uniformly when heated (see Application Tooling, section 10). More than 85 percent of cable repairs are made within 75 [3.0] of the connectors--usually because of a broken pin or wire. By reheating the heatshrinkable 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. The Tinel-Lock ring is used to terminate copper cable braid directly onto the rear of the adapter. The adapter entry size and ring designator must be selected to suit the cable diameter and braid type. The resulting 360 termination withstands severe shock, vibration, temperature cycling, and corrosion. Straight, 45, and 90 configurations are available. 6-4 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Fundamentals Adapter Selection Process Step-by-Step Selection Process Selecting an adapter for your application involves a five-step process: 1. From the connector number, determine: n Order number (shell size) n Material n Plating 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. 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 6 Select Raychem Adapter Code Adapters Select Raychem Adapter Family n Choose configuration n n Determine entry size n n Choose Tinel-Lock ring depending on braid (AI or BI?) n Select options n Select molded part Solid or Spin-Coupling Shielded Tinel Choose configuration Determine entry size (based on cable diameter) n Select options n Select molded part n Select options n Select molded part 6-5 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Raychem Adapter Code Table A. Raychem Adapter Code by Military Part Number 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 manufacturer'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 Military Part No. D38999/20 D38999/24 D38999/26 D38999/40 D38999/42 D38999/44 D38999/46 D38999/47 M28840/10 M28840/11 M28840/14 M28840/16 M81511/01 M81511/03 M81511/05 M81511/06 M81511/21 M81511/23 M81511/25 M81511/26 M81511/31 M81511/32 M81511/33 M81511/34 M81511/35 M81511/36 M81511/37 M81511/38 M81511/41 M81511/45 M81511/46 M81511/49 M81511/51 M81511/53 M81511/55 M81511/56 M83723/01 M83723/02 M83723/03 M83723/04 M83723/05 M83723/06 M83723/07 M83723/08 M83723/13 M83723/14 M83723/17 M83723/18 M83723/19 M83723/20 M83723/23 M83723/24 M83723/36 M83723/37 M83723/38 M83723/39 M83723/40 M83723/41 M83723/42 M83723/43 M83723/48 Connector Specification MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-28840 MIL-C-28840 MIL-C-28840 MIL-C-28840 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-81511 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 Series/Class Series III: Class C, F, K, W Series III: Class C, F, K, W Series III: Class C, F, K, W Series IV: Class C, F, W Series IV: Class C, F, W Series IV: Class C, F, W Series IV: Class F, W Series IV: Class C, W Class D, DS Class D, DS Class D, DS Class D, DS Series 2: Class A, E, F Series 2: Class A, E, F Series 2: Class A, E, F Series 2: Class A, E, F Series 1: Class A, E, F Series 1: Class A, E, F Series 1: Class A, E, F Series 1: Class A, E, F Series 2: Class C, P, T Series 2: Class C, P, T Series 2: Class C, P, T Series 2: Class C, P, T Series 1: Class C, P, T Series 1: Class C, P, T Series 1: Class C, P, T Series 1: Class C, P, T Series 3: Class A, E, F Series 3: Class A, E, F Series 3: Class A, E, F Series 3: Class A, E, F Series 4: Class A, E, F Series 4: Class A, E, F Series 4: Class A, E, F Series 4: Class A, E, F Series I: Class A, G, R Series I: Class A, G, R Series I: Class A, G, R Series I: Class A, G, R Series I: Class A, G, R Series I: Class A, G, R Series I: Class A, G, R Series I: Class A, G, R Series I: Class A, G, R Series I: Class A, G, R Series II: Class A, G, R Series II: Class A, G, R Series II: Class A, G, R Series II: Class A, G, R Series II: Class A, G, R Series II: Class A, G, R Series I: Class A, G, R Series I: Class A, G, R Series I: Class A, G, R Series I: Class A, G, R Series I: Class A, G, R Series I: Class A, G, R Series I: Class G, R Series I: Class G, R Series I: Class G, R Raychem Adapter Code 40 40 40 40 40 Contact Tyco Electronics 40 40 30 30 30 30 61 61 61 61 61 61 61 61 61 61 61 61 61 61 61 61 61 61 61 61 61 61 61 61 54 54 54 54 54 54 54 54 54 54 19 19 19 19 19 19 54 54 54 54 54 54 54 54 54 6-6 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Raychem Adapter Code (Continued) Table A. Raychem Adapter Code by Military Part Number (Continued) Connector Specification MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-83723 MIL-C-22992 MIL-C-22992 MIL-C-22992 MIL-C-22992 MIL-C-22992 MIL-C-22992 MS24264 MIL-C-26500 (AL) MS24264 MIL-C-26500 (SST) MS24265 MIL-C-26500 (AL) MS24265 MIL-C-26500 (SST) MS24266 MIL-C-26500 (SST) MS24266 MIL-C-26500 (AL) MS27466 MS27467 MS27468 MS27469 MS27472 MS27473 MS27474 MS27475 MS27479 MS27480 MS27481 MS27482 MS27484 MS27497 MS27515 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 Series/Class Series I: Class G, R Series II: Class K Series II: Class K Series III: Class H Series III: Class A, G, R Series III: Class A, G, R Series III: Class A, G, R Series III: Class A, G, R Series III: Class A, G, R Series III: Class A, G, R Series III: Class A, G, R Series III: Class A, G, R Series III: Class A, G, R Series III: Class A, G, R Series III: Class G, R Series III: Class G, R Series III: Class A, G, K, R, S Series III: Class A, G, K, R, S Series III: Class A, G, K, R, S Series III: Class A, G, K, R, S Series III: Class A, G, K, R Series III: Class A, G, K, R Series III: Class G, R, W Series III: Class G, R, W Series III: Class A, G, K, R Series III: Class A, G, K, R Series III: Class S Series III: Class S Class C, J, R Class C, J, R Class C, J, R Class C, R Class C, J, R Class C, R Class F, G, R Type B&T aluminum shell Class E Type B&T stainless steel shell Class F, G, R Type B&T aluminum shell Class E Type B&T stainless steel shell Class E Type B&T stainless steel shell Class F, G, R Type B&T aluminum shell Series I: Class E, P, T Series I: Class E, P, T Series I: Class E, P, T Series I: Class Y Series II: Class T Series II: Class E, P, T Series II: Class T Series II: Class Y Series II: Class T Series II: Class E, T Series II: Class T Series II: Class Y Series II: Class E, T Series II: Class T Series I: Class E Raychem Adapter Code 54 19 19 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 32 32 32 32 32 32 6 Adapters Military Part No. M83723/49 M83723/52 M83723/53 M83723/65 M83723/66 M83723/67 M83723/68 M83723/69 M83723/71 M83723/72 M83723/73 M83723/74 M83723/75 M83723/76 M83723/77 M83723/78 M83723/82 M83723/83 M83723/84 M83723/85 M83723/86 M83723/87 M83723/91 M83723/92 M83723/95 M83723/96 M83723/97 M83723/98 MS17343 MS17344 MS17345 MS17346 MS17347 MS17348 51 52 51 52 52 51 41 41 41 Contact Tyco Electronics 41 41 41 Contact Tyco Electronics 41 41 41 Contact Tyco Electronics 41 41 Contact Tyco Electronics 6-7 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Raychem Adapter Code (Continued) Table A. Raychem Adapter Code by Military Part Number (Continued) Military Part No. MS27613 MS27614 MS27615 MS27652 MS27653 MS27654 MS27656 MS27661 MS27665 MS3100 MS3101 MS3106 MS3107 MS3108 MS3110 MS3111 MS3114 MS3116 MS3120 MS3121 MS3124 MS3126 MS3128 MS3130 MS3132 MS3134 MS3137 MS3138 MS3140 MS3144 MS3147 MS3148 MS3400 MS3401 MS3404 MS3406 MS3408 MS3409 MS3412 MS3424 MS3445 MS3446 MS3450 MS3451 MS3454 MS3456 MS3459 MS3464 MS3467 MS3468 MS3470 MS3471 MS3472 Connector Specification MIL-C-26500 (SST) MIL-C-26500 (SST) MIL-C-26500 (SST) MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-5015 MIL-C-5015 MIL-C-5015 MIL-C-5015 MIL-C-5015 MIL-C-26482 MIL-C-26482 MIL-C-26482 MIL-C-26482 MIL-C-26482 MIL-C-26482 MIL-C-26482 MIL-C-26482 MIL-C-26482 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-5015 MIL-C-5015 MIL-C-5015 MIL-C-5015 MIL-C-5015 MIL-C-5015 MIL-C-5015 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-5015 MIL-C-5015 MIL-C-5015 MIL-C-5015 MIL-C-5015 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-26482 MIL-C-26482 MIL-C-26482 MS3474 MS3475 MS3476 NAS1599 NAS1641 NAS1642 NAS1643 MIL-C-26482 MIL-C-26482 MIL-C-26482 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-81703 Raychem Adapter Code Class K Type B&T stainless steel shell 52 Class K Type B&T stainless steel shell 52 Class K Type B&T stainless steel shell 52 Series I: Class E, T 41 Series I: Class E, T 41 Series I: Class E, T Contact Tyco Electronics Series I: Class E, T 41 Series I 41 Series I 41 Class A, E, F, R less endbell; solder contact 18 Class A, E, F, R less endbell; solder contact 18 Class A, E, F, R less endbell; solder contact 18 Class A, E, F, R less endbell; solder contact 18 Solder contact with endbell 15 Series 1: Class E, F, J, P 21 Series 1: Class E, F, J, P 21 Series 1: Class E, F, P 241 Series 1: Class E, F, J, P 21 Series 1: Class E, F, J, P 21 Series 1: Class E, F, J, P 21 Series 1: Class E, F, P 241 Series 1: Class E, F, J, P 21 21 Series 1: Class E, F, J, P Series 1: Class E, P, J 71 Series 1: Class E 71 Series 1: Class E, P, J 71 Series 1: Class E, P, J 71 Series 1: Class E, P, J 71 Series 1: Class E, J 71 Series 1: Class E, J 71 Series 1: Class E, J 71 Series 1: Class E, J 71 Class D, L, U, W crimp contact 54 Class D, L, U, W crimp contact 54 Class D, L, U, W crimp contact 54 Class D, L, U, W crimp contact 54 Class D, L, U, W crimp contact 54 Crimp contact 54 Class D, L, U, W crimp contact less endbell 54 Series 3: Class E, L 54 Series 2: Class E 71 Series 3: Class E, L 54 Class D, L, U, W crimp contact 54 Class D, L, U, W crimp contact 54 Class D, L, U, W crimp contact 54 Class D, L, U, W crimp contact 54 Class L, W crimp contact 54 Series 3: Class E, L 54 Series 3: Class E, L 54 54 Series 3: Class E, L Series 2: Class A, L 54 Series 2: Class A, L 54 54 Series 2: Class A, L Series/Class Series 2: Class A, L Series 2: Class A, L Series 2: Class A, L Series 3: Series 3: Series 3: Series 3: 54 54 54 54 54 54 54 Code 24 connectors have an internal accessory thread. 1 6-8 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Raychem Adapter Code (Continued) Table A. Raychem Adapter Code by Military Part Number (Continued) Military Part No. NAS1650 NAS1651 NAS1652 NAS1653 NAS1692 NAS1693 NAS1694 NAS1699 NAS1700 NAS1701 NAS1702 Connector Specification MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-81703 Series/Class Series 3: Series 3: Series 3: Series 3: Series 3: Series 3: Series 3: Series 3: Series 3: Series 3: Series 3: Raychem Adapter Code 54 54 54 54 54 54 54 54 54 54 54 6 Adapters 6-9 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Raychem Adapter Code (Continued) Table B. Raychem Adapter Code by Manufacturer's Prefix Manufacturer's Prefix 10-214 10-475 10-720 118 149 162GB 164GB 165 172 179 182 246 251 2PPN 2PPN-07 2PSN 2PSN-07 348 381 418 45/PT 450 451 460 48 486 518 5MS 602 602GB 62AB-14 62GB 650 652 652 674 675 679 69 71 711 801 837 83723 83730 845 847 850 851 8520 8525 8526 853 857 89 Manufacturer6 Bendix Bendix Bendix Amphenol Deutsch Amphenol Amphenol Amphenol Amphenol Amphenol Amphenol Amphenol Cannon Plessey Plessey Plessey Plessey Amphenol Deutsch Amphenol Socapex Deutsch Socapex Deutsch Amphenol Amphenol Amphenol FKI2 Amphenol Amphenol Amphenol Amphenol Schaltbau Amphenol UMD Schaltbau Schaltbau Schaltbau Amphenol Bendix Amphenol Amphenol Deutsch Souriau Deutsch Souriau Souriau Souriau Souriau Souriau Souriau Souriau Souriau Souriau Souriau Connector Specification MIL-C-5015 40M38277 MIL-C-5015 MIL-C-26482 MIL-C-81703 MIL-C-26482 BS9522 F0023 None MIL-C-5015 MIL-C-5015 None MIL-C-5015 MIL-C-26482 MIL-C-26482 MIL-C-26482 BS9522 F0017 MIL-C-26482 MIL-C-81511 40M39569 MIL-C-38999 MIL-C-26482 MIL-C-26482 PRL 54125 MIL-C-26482 MIL-C-26500 MIL-C-26482 MIL-C-83723 Def. Stan. 59-35 Def. Stan. 59-56 Def. Stan. 59-56 MIL-C-26482 Def. Stan. 59-35 VG 95329 LN 29504 PRL 54125 VG 95328 VG 95328 VG 95329 MIL-C-5015 MIL-C-5015 BS9522 F0042 None MIL-C-83723 MIL-C-83723 MIL-C-83723 NFL 54120 NFL 54120 MIL-C-26482 MIL-C-26482 MIL-C-26482 NAS 1599 PAN 6432-1 MIL-C-83723 LN 29728 NFL 54140 Series/Class MS3100 Class A, E, R -- MS3100 Class A, E, R Series 2 Series 1 Series 1 -- -- -- -- -- MS3100 Class E, F, R Series 1 Series 1 Series 1 Patt 105 Series 1 Series 1 and 2 -- Series I and II Series 1 Series 1 -- Series 1 Alum Class F, G, R Series 2 Series III Patt 121A Patt 602 Patt 602 Series 1 Patt 105 -- -- -- -- -- -- MS3100 Class E, F, R MS3100 Class A, E, R -- -- Series III Series III Series III -- -- Series 1 Series 1 Series 2 -- -- Series III -- -- Raychem Adapter Code 18 41 18 54 71 76, 774 Contact Tyco Electronics Contact Tyco Electronics Contact Tyco Electronics Contact Tyco Electronics Contact Tyco Electronics 18 21 21 243 76, 774 243 61 54 41 21 21 21 or 243 21 51 54 54 75 54 54 Contact Tyco Electronics 76, 774 61 54 21 or 243 Contact Tyco Electronics Contact Tyco Electronics 61 18 18 54 54 54 54 54 Contact Tyco Electronics Contact Tyco Electronics 21 21 54 54 54 54 54 54 FKI was previously Thorn. Code 24 connectors have an internal accessory thread. Code 77 braided version. 2 3 4 6-10 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Raychem Adapter Code (Continued) Table B. Raychem Adapter Code by Manufacturer's Prefix (Continued) Manufacturer6 Souriau Souriau Souriau Souriau Souriau Deutsch Bendix Matrix Deutsch Amphenol Matrix Deutsch Deutsch AB Elec AB Elec AB Elec AB Elec Deutsch Deutsch Deutsch Deutsch Pyle Bendix G&H Tech TRW Burndy Pyle Deutsch Pyle TRW Cannon Cannon Cannon Cannon VEAM TRW Burndy Plessey Cannon Cannon Cannon Cannon Cannon Deutsch Deutsch Deutsch Deutsch Deutsch Deutsch Deutsch Deutsch Deutsch Cannon Deutsch Deutsch Connector Specification MIL-C-5015 MIL-C-5015 MIL-C-38999 VG 96912 MIL-C-38999 MIL-C-81511 MIL-C-26482 MIL-C-5015 LN 29500 MIL-C-5015 MIL-C-5015 MIL-C-81511 Not known Def. Stan. 59-35 Def. Stan. 59-35 BS9522 F0032 MIL-C-38999 MIL-C-81703 MIL-C-83723 MIL-C-26482 MIL-C-81511 MIL-C-83723 MIL-C-26482 MIL-C-38999 MIL-C-38999 MIL-C-26482 MIL-C-83723 MIL-C-26482 MIL-C-83723 MIL-C-26500 VG 95234 MIL-C-5015 MIL-C-5015 MIL-C-5015 VG 95234 MIL-C-83723 MIL-C-38999 MIL-C-38999 MIL-C-83723 MIL-C-5015 MIL-C-83723 None MIL-C-22992 MIL-C-81703 None MIL-C-81703 MIL-C-81703 MIL-C-81703 MIL-C-26482 VG 95328 MIL-C-83723 MIL-C-81703 None MIL-C-38999 Series/Class Class K Class K Series I Series 1 Series II Series 3 and 4 Series 2 MS3400 Class L, U, W -- MS3100 Class A MS3400 Series 3 -- Patt 105 Patt 105 -- Series I and II -- Series I Series 2 Series 4 Series III Series I Series IV Series IV Series 1 Series III Series 1 Series III Aluminum -- MS3100 class E, F, R MS3100 Class A Class K -- Series III Series II Series II Series II MS3400 Class L, U, W Series II -- Class C, J, R Series 3 -- -- Series 3 Series 2 Series 2 -- Series III Series 1 -- -- Series III Raychem Adapter Code Contact Tyco Electronics Contact Tyco Electronics 41 47 41 61 54 54 Contact Tyco Electronics 18 54 61 71 76, 774 76, 774 78 41 71 54 54 61 54 21 40 40 21 54 21 54 51 58 18 18 Contact Tyco Electronics 64***, 66**, 78* 54 41 41 19 54 19 31 32 54 71 Contact Tyco Electronics 54 71 54 Contact Tyco Electronics 54 71 Contact Tyco Electronics 71 40 6 Adapters Manufacturer's Prefix 891 892 8LT 8ST 8T 9-815 91-483 944 951 97 981 A815 AA70 AB05 AB06 ABB ABJ ADS AFD AFD5 B815 BE BG BL BL BT BT BTK BY1 C48 CA (Bayonet) CA3101 CA3101 CA3101KE CIR CN0930 CT CT CV-R CV34 CVA CWL CWLD D817 DA DBAD DBAS DD DFE DKM DL DM DPX DS DTS * AB connectors only ** VEAM standard ***VEAM panel mount 4 Code 77 braided version. 6-11 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Raychem Adapter Code (Continued) Table B. Raychem Adapter Code by Manufacturer's Prefix (Continued) Manufacturer's Prefix EA EB EEG ES ESC004 ET FC FDBA FF FH FPK FP5K FYL G GC-E GTA HAN HD HTMAS HTMF HTMS JT JT JT JT-R JT-R KFS KJ KJA KJJ KJJL KJL KPSE KPT KV-R L LJT LJT LL3 LL5/6 LMB LPT LS LTT M-T M723 MB1 MB3 MB9 MD MDR MF MK12 MK18 MK38 Manufacturer6 Pyle Pyle Pyle Pyle Various Pyle Flight Deutsch Flight Flight Pyle Pyle Pyle Burndy General Hughes Deutsch SAE Cannon Cannon AB Elec Amphenol Bendix/FKI Socapex FKI2 Teldix Cannon Cannon Cannon Cannon Cannon Cannon Cannon Cannon Cannon Burndy Bendix Socapex Deutsch Deutsch Litton-Veam Deutsch Pyle FKI2 Burndy Matrix Matrix Matrix Matrix Matrix Deutsch Cannon Plessey Plessey Plessey Connector Specification None NAS 1599 MIL-C-83723 None MIL-C-5015 NAS 1599 MIL-C-5015 LN 29504 MIL-C-5015 MIL-C-83723 MIL-C-26500 MIL-C-26500 MIL-C-26500 None MIL-C-26482 MIL-C-28840 MIL-C-5015 MIL-C-28840 MIL-C-5015 MIL-C-83723 MVEE 695 MIL-C-38999 MIL-C-38999 MIL-C-38999 PAN 6433-1 PAN 6433-1 MIL-C-28840 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-26482 MIL-C-26482 NAS 1599 MIL-C-26482 MIL-C-38999 MIL-C-38999 MIL-C-81511 BS9540 F0001 Def. Stan. 59-35 MIL-C-26482 None BS9522 F0029 MIL-C-26482 MIL-C-83723 MIL-C-26482 MIL-C-83723 MIL-C-38999 MIL-C-26482 None MIL-C-83723 Def. Stan. 59-35 Def. Stan. 59-35 MIL-C-38999 Series/Class -- -- Series I -- Class K -- Rev E only -- MS3400 Class D, L, U, W Series III Class K Class K Class K -- Series 1 -- MS3100 Class E, KE -- Class K Series III: Class K -- Series II Series II Series II -- -- -- Series II Series III Series II Series I Series I Series 1 Series 1 -- Series 1 Series I Series I -- Patt 602 Patt 121A Series 1 -- Patt 616 Series 1 Series II Series 2 Series III Series I and II Series 2 -- Series III Patt 603 Patt 608 Series I Raychem Adapter Code 54 54 54 54 Contact Tyco Electronics 54 Contact Tyco Electronics 54 54 54 52 Contact Tyco Electronics 52 21 21 30 Contact Tyco Electronics 30 Contact Tyco Electronics 54 75 41 41 41 41 41 30 41 40 Contact Tyco Electronics Contact Tyco Electronics 41 21 21 54 21 41 41 61 Contact Tyco Electronics 75 21 54 41 21 19 54 54 41 54 71 54 76, 774 795 41 FKI was previously Thorn. Code 77 braided version. 5 Free connectors only. 2 4 6-12 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Raychem Adapter Code (Continued) Table B. Raychem Adapter Code by Manufacturer's Prefix (Continued) Manufacturer6 Plessey Plessey Plessey Matrix Matrix Matrix Matrix Plessey AB Elec Socapex Teldix Bendix Teldix Socapex Teldix Bendix FKI2 FKI2 FKI2 FKI2 FKI2 FKI2 FKI2 FKI2 FKI2 FKI2 FKI2 Bendix Cannon Cannon Cannon Cannon Bendix AB Elec Bendix Bendix Raychem Deutsch Deutsch Deutsch Deutsch Deutsch Deutsch SAE Bendix AB Elec AB Elec AB Bendix SICEM Bendix Bendix Various Various Deutsch Connector Specification MIL-C-38999 DEF 5325-2 Def. Stan. 59-35 MIL-C-38999 MIL-C-83723 MIL-C-83723 MIL-C-38999 NFL 54 125 Def. Stan. 59-35 MIL-C-26482 MIL-C-26482 None VG 95328 MIL-C-26482 MIL-C-26482 MIL-C-26482 MIL-C-26482 BS9522 F0017 BS9522 N0001 BS9522 F0017 BS9522 N0001 BS9522 F0017 BS9522 N0001 BS9522 F0017 BS9522 N0001 BS9522 F0017 BS9522 N0001 MIL-C-26482 MIL-C-26482 MIL-C-26482 -- Def. Stan. 59-56 None -- None MIL-C-22992 MIS-20065 Def. Stan. 59-56 PAN 6432-2 PAN 6432-1 PAN 6432-2 None None MIL-C-5015 MIL-C-5015 Def. Stan. 59-35 Def. Stan. 59-35 BS9522 F0030 MIL-C-5015 VG 95234 MIL-C-5015 MIL-C-5015 PAN 6433-2 PAN 6433-2 MIL-C-26482 Series/Class Series II Patt 104 Patt 105 Series IV Series III Series III Series III -- Patt 104 Series 1 Series 1 -- -- Series 1 Series 1 Series 1 Series 1 Patt 105 Patt 603 Patt 105 Patt 603 Patt 105 Patt 603 Patt 105 Patt 603 Patt 105 Patt 603 Series 2 Series 2 Series 2 -- Patt 602 -- -- -- Class C, J, R -- Patt 602 -- -- -- -- -- MS3400 Class E Patt 104 Patt 104 -- MS3100 Class A -- MS3100 Class E MS3100 Class E -- -- Series 1 Raychem Adapter Code 41 Contact Tyco Electronics 76, 774 40 54 54 40 76 or 243, 774 Contact Tyco Electronics 76, 774 76, 774 22 Contact Tyco Electronics 76, 774 76, 774 243 243 76, 774 76, 774 76, 774 76, 774 76, 774 76, 774 76, 774 76, 774 76, 774 76, 774 54 54 54 54 54 32 78 31 32 54 54 54 54 54 71 71 54 18 Contact Tyco Electronics Contact Tyco Electronics 75 18 Contact Tyco Electronics 18 18 47 Contact Tyco Electronics 76, 774 6 Adapters Manufacturer's Prefix MK25 MK7 MK8 ML94 MQ3 MT3 MT93 P5 PAT104D PT PT PT-CE PT-G PT-SE PT-SE PT07 PT07SE PT33 PT33SE PT44 PT44SE PT55 PT55SE PT77 PT77SE PTG55 PTG55SE PTS-DR PV7 PVJ PVW PVX QDP QRP QWL QWLD RD1 RR RR20 RR50 RR70 RSM RTK SA SB SB-104 SB-M4 SB-MS SC SCB SF SG SJT SJT07 SLPT FKI was previously Thorn. Code 24 connectors have an internal accessory thread. Code 77 braided version. 2 3 4 6-13 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Raychem Adapter Code (Continued) Table B. Raychem Adapter Code by Manufacturer's Prefix (Continued) Manufacturer's Prefix SM SPT SPT SPT07 STK STT STT07 T31 TRIM TRIO TT TV TV-O-R TVP TVPS TVS Tri-Start VPT VTT ZZY/ZZW ZZY/ZZW Manufacturer6 Bendix Bendix Socapex Various Deutsch FKI2 FKI2 Pyle Burndy FKI2 FKI2/Bendix Bendix FKI2/Bendix FKI2/Bendix FKI2/Bendix Bendix VEAM FKI2 Pyle Pyle Connector Specification MIL-C-5015 MIL-C-26482 MIL-C-26482 MIL-C-26482 None BS9522 F0012 BS9522 F0012 MIL-C-38999 None BS9522 N0003 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-38999 MIL-C-26482 MIL-C-38999 MIL-C-26500 MIL-C-26500 Series/Class MS3100 Class A, E, R Series 1 Series 1 Series 1 -- Patt 615 Patt 615 Series III -- Patt 614 Series III Series III and IV Series III Series III Series III Series III and IV Series 1 Series III Class R, G (AL) Class E (SST) Raychem Adapter Code 18 76, 774 76, 774 243 71 47 Contact Tyco Electronics 40 Contact Tyco Electronics 41 40 40 40 Contact Tyco Electronics Contact Tyco Electronics 40 21 40 51 52 May be a number or letter depending upon connector style. FKI was previously Thorn. 3 Code 24 connectors have an internal accessory thread. 4 Code 77 braided version. 5 Free connectors only. 6 Some 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. 1 2 6-14 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Raychem Adapter Code (Continued) Table C. Raychem Adapter Code by Connector Specification Series/Class -- -- G0001 G0002 G0003 Patt 615 Patt 104 Patt 105 Patt 608 -- Patt 616 Patt 121A Patt 121B -- Patt 603 Patt 614 Patt 602 -- -- -- -- Class C, J, R Series 1 Series 2 Aluminum, Class F, G, R Stainless steel, Class E, K Class D Series I and II Series III and IV MS3400 MS3100 5MS Series 1, 2, 3, and 4 Series 1, 2 Series 3 Series II Series I and III -- -- -- -- -- 5MS -- -- -- -- -- -- -- -- -- -- -- Series 2 Series 1 Raychem Adapter Code 41 54 41 41 40 47 Contact Tyco Electronics 76 792 Contact Tyco Electronics 41 75 78 54 76 41 54 21 54 54 47 32 21, 241 54 51 52 30 41 40 54 18, 15 (with endbell) 75 61 71 54 19 54 32 54 41 40 54 75 54 Contact Tyco Electronics 54 54 54 41 47 21, 241 64***, 66**, 78* Contact Tyco Electronics 61 41 47 6 Adapters Connector Specification 40M38277 40M39569 BS9520 BS9520 BS9520 BS9522 F0012 BS9522 F0014 BS9522 F0017 BS9522 F0020 BS9522 F0023 BS9522 F0029 BS9522 F0030 BS9522 F0032 BS9522 F0042 BS9522 N0001 BS9522 N0003 BS9540 F0001 LN 29500 LN 29504 LN 29728 LN 29729 MIL-C-22992 MIL-C-26482 MIL-C-26482 MIL-C-26500 MIL-C-26500 MIL-C-28840 MIL-C-38999 MIL-C-38999 MIL-C-5015 MIL-C-5015 MIL-C-5015 MIL-C-81511 MIL-C-81703 MIL-C-81703 MIL-C-83723 MIL-C-83723 MIL-C-85049/59 MIL-C-85049/60 MIL-C-85049/62 MIL-C-85049/69 MIS-20065 MVEE NAS 1599 NFL 54120 NFL 54140 PAN 6432-1 PAN 6432-2 PAN 6433-1 PAN 6433-2 PRL 54125 VG 95234 VG 95328 VG 95329 VG 96912 VG 96912 Code 24 connectors have an internal accessory thread. Free connectors only. 1 2 * AB connectors only ** VEAM standard ***VEAM panel mount 6-15 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Raychem Adapter Family Selecting the Raychem Adapter Family 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 prefix for that family you can then build the part number for your Raychem adapter. Table D. Identification of Adapter Family Prefix by Raychem Adapter Code Raychem Connector Code 15 18 19 21 24 30 32 40 41 47 51 52 54 61 71 75 76 77 78 79 80 81 Boot Adapter Solid (Fixed) Spin-Coupling 210M5 202M5 218M5 218M6 201M7 201M4 203M6 203M9 208M5 208M6 211M8 211M9 -- 204M3 209M3 209M4 202M1 202M2 202M8 202M7 207M4 205M5 208M3 209M6 201M9 201M1 202M4 202M3 203M5 202M9 228M5 228M7 225M5 225M6 228M6 228M8 225M4 225M3 -- 229M3 215M4 213M5 214M3 214M4 Straight 219M0 218M7 -- 206M0 216M0 211M5 207M3 208M7 204M0 210M0 207M0 208M0 203M0 205M0 217M0 227M0 -- 228M0 225M0 229M1 213M6 214M5 Shielded Adapter 45 219M1 218M8 -- 206M1 216M1 211M6 212M4 208M8 204M1 210M1 207M1 208M1 203M1 205M1 217M1 227M1 -- 228M1 225M1 229M2 213M7 214M6 90 219M2 218M9 -- 206M2zx 206M5 211M7 212M5 208M9 204M2 210M2 207M2 208M2 203M2 205M2 217M2 227M2 -- 228M2 225M2 229M0 213M8 214M7 Tinel-Lock Adapter Straight, 45, and 90 TXR 15 TXR 18 -- TXR 21 -- TXR 30 TXR 32 TXR 40 TXR 41 TXR 47 TXR 51 TXR 52 TXR 54 TXR 61 TXR 71 TXR 75 TXR 76 -- TXR 78 TXR 79 TXR 80 TXR 81 Band-Strap Adapter* -- BND 18 -- BND 21 -- -- BND 32 BND 40 BND 41 BND 47 -- -- BND 54 -- -- -- -- -- -- -- -- -- 6-16 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Raychem Part Number Having Selected the Right Adapter Type and Raychem Adapter Family, You Can Now Construct a Part Number for the Adapter. 1. Start with the alphanumeric prefix you selected in Table 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 several or all of the following: n Order number n Manufacturer's prefix n Material n Finish n Entry size n Ring designator n Option 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 numbering system shown below. To select the right codes and designators, turn to the pages that follow. 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* 6 Adapters *For full range of options, consult Tyco Electronics. 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) *For full range of options, consult Tyco Electronics. 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. 6-17 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Raychem Part Number (Continued) Band Strap Adapters Part Numbering System BND 54 A B 00 - 12 06 A Product Designator BND -- Adapter and Band BNX -- Adapter only Adapter Code Material2 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 4W = 45 45 = 45 9W = 90 90 = 90 For BND 18, dash may be replaced by a letter Order Number Entry Size3 Band Termination Device Code1 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 Electronics discretion. 3. For standard entry sizes see relevant specification control drawing. For entry sizes larger than standard (Type II Adapters), see sheets 3 and 4. Band Strap Adapter Modification Option Field (Omit if not required) BND54AB00-1206A D F H J L N P S D -- Drain holes modification F -- Internal abrasion resistant coating H -- Helical conduit thread J -- Chain attachment assembly L -- Lock wire holes manufacturers 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-1225P or BND-XX25P) S -- Self-locking spin nut 6-18 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Material and Finish Selecting the Material and Finish To ensure optimum compatibility, select the adapter material and finish to match those of the connector. Most circular connectors are manufactured from aluminum with a cadmium finish. Raychem Material Codes Stainless steel Material Code Solid, Spin-Coupling, and Shielded Adapters 19 62 Nickel aluminum bronze 01 Material* Description Aluminum alloy Tinel-Lock Adapters Typical Applications A S Standard material for normal applications Corrosion-resistant and high-temperature (firewall) applications Exposed marine environments B *Other materials available upon request. 6 Adapters Raychem Finish Codes Finish* Description Cadmium, per QQ-P-416, Type II, Class 3 Cadmium, per QQ-P-416, Type II, Class 3 over electroless nickel (500-hour salt-spray-resistant finish) Electroless nickel, per MIL-C-26074, Class 4, Grade B Anodized, hard, per MIL-A-8625, Type III, Class 2 Color Finish Code Typical Applications Olive drab A Corrosion-resistant conductive finish Olive drab B Corrosion resistance for exposed environments -- C High conductivity for optimum screening performance Black G Nonconductive finish for aluminum adapters Passivated, per QQ-P-35 or MIL-S-5002 -- J Unplated, shotblast -- W Nonconductive, corrosion-resistant finish for stainless steel adapters Nonreflective finish for nickel aluminum bronze adapters *Other finishes available upon request. 6-19 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Entry Size Determining the Wire Bundle Size Example: A bundle of wires containing 27 x 44A0111-22 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 prototype or calculate the size. F = 6.00 (the multiplication factor for 27 wires from Table E) Calculation of the wire bundle size is based on three values: n Cable outside diameter (COD) n Cable jacket thickness n Jacketed cable diameter Instructions for calculating these values follow. COD Calculation To calculate the cable outside diameter, first determine 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, follow these steps: 1. Determine the number of wires in the wire bundle. 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 section (Section 9) of this catalog. 4. Multiply the wire diameter (from Step 3) by the multiplication factor (from Step 2) as shown below. Formula: D = Fd Where: D = Bundle diameter F = Multiplication factor d = Wire diameter d = 1.19 mm (.049 in)* D = 6 x 1.19 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 To determine the wire bundle diameter when using wires of different sizes, follow these steps: 1. Determine the number of wires in the wire bundle. 2. Find the diameter of the wires in the Wire and Cable section of this catalog. 3. Calculate the cable outside 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 3 x 44A0111-221* (1.192mm dia.) 5 x 44A0111-201* (1.42-mm dia.) 1 x 44A0111-181* (1.65-mm dia.) D = 1.2 3 x 1.192 2 + 5 x 1.42 2 + 1 x 1.65 2 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 *For wire information see the Wire and Cable Section 9 of this catalog. 6-20 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Entry Size (Continued) Table E. Multiplication Factors for Wire Bundles with Equal Size Wires This table provides multiplication factors for wire bundles of 1 to 61 wires. To determine the approximate 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 multiply the wire diameter by that factor. Multiplication Factor 1.00 1.60 2.00 2.41 2.70 3.00 3.00 3.60 4.00 4.00 4.00 4.00 4.41 4.41 4.70 4.70 5.00 5.00 5.00 5.31 5.31 5.61 5.61 5.61 6.00 6.00 6.00 6.41 6.41 6.41 6.70 Number of Wires 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 -- Multiplication Factor 6.70 6.70 7.00 7.00 7.00 7.00 7.31 7.31 7.31 7.61 7.61 7.61 7.61 8.00 8.00 8.00 8.00 8.41 8.41 8.41 8.41 8.70 8.70 8.70 8.70 9.00 9.00 9.00 9.00 9.00 -- 6 Adapters Number of Wires 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 6-21 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection 10 10 1 0 20 40 60 80 1 100 Recovered diameter (mm) 100 100 100 10 10 1 0 20 Unresolved Recovery (%) 40 To determine the wall thickness of a jacket over a wire bundle: 1. Use the chart in Figure 1 to determine the unresolved recovery of the tubing jacket 2. Use the chart in Figure 3 to determine the wall thickness reduction factor. 3. Calculate the jacket wall thickness by multiplying the fully shrunk wall thickness (as detailed in the Tubing section -- Section 3 -- of this catalog) by the wall thickness reduction factor. 80 1 100 Unresolved Recovery (%) Figure 1. Cable Jacket Thickness Calculation 60 Expanded diameter (mm) 100 Expanded diameter (mm) Recovered diameter (mm) Entry Size (Continued) Figure 2. Step 1. Determine the Unresolved Recovery of the Tubing Jacket. Example (see Figure 2): 1. Locate the recovered and expanded diameters of the chosen tubing size on the chart in Figure 1. Expanded tubing diameter = 20 mm 2. Lay a straight edge between the two values and pencil in a straight line connecting them. Recovered tubing diameter = 10 mm Wire bundle diameter =13 mm Unresolved recovery = 50% 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. 6-22 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 14 Adapter Selection Entry Size (Continued) 100 90 Unresolved recovery (%) 80 70 60 50 40 30 20 10 0 .3 .4 .5 .6 .7 .8 .9 1.0 Wall thickness reduction factor Figure 3. Step 2. Find the Wall Thickness Reduction Factor. Step 3. Calculate the Jacket Wall Thickness. 1. On the Unresolved Recovery scale of the chart in Figure 3 above, find the unresolved recovery value determined in Step 1. Multiply the fully shrunk wall thickness of the tubing by the reduction factor. 3. At the point where that line intersects the chart's curved line, read vertically down to the wall thickness reduction factor. Fully shrunk wall thickness of tubing 6 Wall thickness reduction factor (from Figure 3) Jacket wall thickness Example shown: Adapters 2. From the unresolved recovery value, draw a straight line across the chart to the curved line. Example: = 1.45 mm = 0.68 = 1.4 x 0.68 = 0.99 mm Unresolved recovery = 50% Reduction factor = 0.68 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 RAY 101 (36 AWG) braid to make a total wire bundle diameter of 13.8 mm. 6-23 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Entry Size (Continued) 24 22 20 18 Entry size 16 14 12 10 08 07 06 05 04 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 Cable outside diameter (mm) Figure 5. Cable outside diameter (in mm) Figure 4. Entry Size by Cable Outside Diameter (in millimeters) Determining the Entry Size Tinel-Lock Adapters Once you have the wire bundle size, you can use the chart in Figure 4 to select the entry size. This chart shows the minimum entry sizes for cables from 3 to 38 mm [.118 to 1.496 in] in diameter. In other words, the white spaces on the chart represent all of the cable outside diameters each entry size will fit. 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 entry size 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. Follow these steps: 1. Find the cable diameter on the chart. 2. Note the lowest entry size 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 standard entry size for any given adapter part number be specified as indicated on the relevant data sheet. Nonstandard entry sizes are available on special order. The selection chart in Figure 4 shows the minimum entry sizes for cable diameters in the range of 3 mm 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 sufficiently to fit the entry size selected and to ensure that the braid and boot can be rolled back. Use the selection chart in Figure 4 to ensure that the standard entry size will pass over the jacketed cable diameter. 6-24 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Entry Size (Continued) Ray 101 Tinned-Copper Braid Tyco Electronics manufactures 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: n n n n Good surface transfer impedance Large opening ratio Good handling characteristics 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 heatshrunk cable jacket. Compatibility with Tinel-Lock adapters Ray 101 Data Part No. Number of Ends/ Carrier Individual Strand Size (mm/AWG) 16 24 24 24 36 36 48 10 7 9 14 12 15 16 0.1 [38] 0.13 [36] 0.13 [36] 0.13 [36] 0.13 [36] 0.13 [36] 0.13 (36] Wire Bundle Diameter Range Wall Thickness Min. Max. (Nom.) 2.5 [.10] 5.0 [.20] N/A 3.5 [.14] 7.5 [.30] 0.4 [.02] 4.0 [.16] 9.5 [.37] 0.4 [.02] 6.0 [.24] 14.0 [.55] 0.4 [.02] 8.0 [.31] 22.0 [.87] 0.4 [.02] 10.0 [.39] 24.0 [.94] 0.4 [.02] 16.0 [.63] 38.0 [1.50] 0.4 [.02] Tinel Adapter Entry Size (Single-Layer Braid) N/A 04* 04, 05, 06*, 07 05, 06, 07, 10* 07, 08, 10 12* 08, 10, 12,14, 16* 12, 14, 16, 18, 20, 22 6 Adapters RAY 101-3.0 RAY 101-4.0 RAY 101-6.0 RAY 101-7.5 RAY 101-10.0 RAY 101-12.5 RAY 101-20.0 Number of Carriers *Combination is not preferred; use only if absolutely necessary. 6-25 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection Tinel-Lock Ring Tinel-Lock Ring and Braid Boot Groove The Tinel-Lock ring designator 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 temperature is reached. BI-type rings are identified with a red spot. Tinel Ring 1.8 [.071] Nom. Ring Area Spin Nut Thermochromic Paint Braid type, material, and construction are variable. If in doubt, contact Tyco Electronics for advice. Braid Type Single layer 36 AWG Single layer 34 AWG Single layer 32 AWG Single layer 30 AWG Double layer 36 AWG Double layer 34 AWG Ring Designator AI AI BI BI BI BI A or B = Size of Braid I = Insulating Layer Table F. Wire Gauge (AWG) to Diameter Cross-Reference Wire Gauge (AWG) 40 39 38 37 36 35 34 33 32 31 30 29 28 Use this table to establish wire gauge if not known. Diameter 0.079 [0.0031] 0.089 [0.0035] 0.102 [0.0040] 0.114 [0.0045] 0.127 [0.0050] 0.142 [0.0056] 0.160 [0.0063] 0.180 [0.0071] 0.203 [0.0080] 0.226 [0.0089] 0.254 [0.0100] 0.287 [0.0113] 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 n n n 6-26 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Selection CRES-Lock 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 entry sizes for both the CRES-Lock and BND adapter. Use the band strap designation A in Americas and Asia and B for Europe. 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 a standard configuration and does not require any notation. If precoiled bands 8.4 Ref. [0.33] 6.4 Max. [0.25] A Ref. 6.6 Ref. [0.26] 2.5 Ref. [0.10] .5 Ref. [0.02] 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). Available in: Part Number Entry SIzes BND-1225S 03 to 24 BND-1425S 03 to 34 A Ref. 1.5 [0.06] 305.0 12.00 362.0 14.25 Americas Europe Asia Pacific n n n 6-27 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 18 MIL-C-5015 (MS3100) Braided Adapters 29.7 [1.17] Max. 152.4 Min. [6.00] Tinned Copper Shield Z Dia. Y Dia. 218M7XX-XXXXX W C D E Z Dia. 152.4 Min. [6.00] Z Dia. Tinned Copper Shield 152.4 Min. [6.00] Y Dia. Tinned Copper Shield Y Dia. 218M8XX-XXXXX 218M9XX-XXXXX Manufacturer Code A B C D* R -- Connector Manufacturer MS3100/3101/3106 Amphenol-Class A Bendix-Class A/E/R Cannon-Class A/E/R Unknown-Class A/E/R Amphenol-Class R Manufacturer code not required *Additional pieces supplied when manufacturer is unknown. All thread sizes for order number apply. Available in: Americas Europe Asia Pacific n n n 6-28 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 18 MIL-C-5015 (MS3100) (Continued) Braided Adapters (continued) Table of Dimensions Shell Size Manufacturer Code Max. Entry Size, Type 1** Thread 08 08 08 08 10 11 11 11 12 12 12 14 16 18 20 20 20 22 24 28 32 32 32 36 36 36 36 36 40 40 40 44 48 48 48 8S 8S 8S 8S 10S 10SL 10SL 10SL 12 & 12S 12 & 12S 12 & 12S 14 & 14S 16 & 16S 18 20 20 20 22 24 28 32 32 32 36 36 36 36 36 40 40 40 44 48 48 48 B C A, R D -- C A, B, R D B, C A, R D -- -- -- A, B, C R D -- -- -- B, C A, R D B R C A D B A, C, R D - C A, R D 04 04 04 04 06 07 07 07 08 08 08 10 12 12 16 16 16 18 20 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 .375-32 UNEF .438-28 UNEF .438-27 UNS See * above. .500-28 UNEF .562-24 UNEF .625-24 UNEF See * above. .625-24 UNEF .688-24 UNEF See * above. .750-20 UNEF .875-20 UNEF 1.000-20 UNEF 1.125-18 UNEF 1.125-24 UNS See * above. 1.250-18 UNEF 1.375-18 UNEF 1.625-18 UNEF 1.875-16 UN 1.906-18 UN See * above. 2.062-16 UNS 2.062-20 UNS 2.125-16 UN 2.125-18 UNS See * above. 2.312-16 UNS 2.375-16 UN See * above. 2.625-16 UN 2.812-18 UNS 2.875-16 UN See * above. C Max. 20.3 [0.80] 20.3 [0.80] 20.3 [0.80] 20.3 [0.80] 21.1 [0.83] 21.1 [0.83] 21.1 [0.83] 21.1 [0.83] 21.1 [0.83] 21.8 [0.86] 21.8 [0.86] 21.8 [0.86] 22.6 [0.89] 23.4 [0.92] 24.1 [0.95] 24.1 [0.95] 24.1 [0.95] 24.9 [0.98] 24.9 [0.98] 27.4 [1.08] 28.2 [1.11] 28.2 [1.11] 28.2 [1.11] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 32.3 [1.27] 32.3 [1.27] 32.3 [1.27] 34.0 [1.34] 34.0 [1.34] 34.0 [1.34] 34.0 [1.34] Dimensions D Max. 23.4 [0.92] 23.4 [0.92] 23.4 [0.92] 23.4 [0.92] 24.1 [0.95] 24.1 [0.83] 24.1 [0.95] 24.1 [0.95] 24.1 [0.95] 24.9 [0.98] 24.9 [0.98] 24.9 [0.98] 25.9 [1.02] 26.7 [1.05] 27.4 [1.08] 27.4 [1.08] 27.4 [1.08] 28.2 [1.11] 28.2 [1.11] 29.7 [1.17] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 32.3 [1.27] 32.3 [1.27] 32.3 [1.27] 32.3 [1.27] 32.3 [1.27] 33.0 [1.30] 33.0 [1.30] 33.0 [1.30] 34.5 [1.36] 34.5 [1.36] 34.5 [1.36] 34.5 [1.36] E Max. 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 33.0 [1.30] 33.0 [1.30] 33.0 [1.30] 36.1 [1.42] 37.6 [1.48] 39.4 [1.55] 39.4 [1.55] 39.4 [1.55] 40.9 [1.61] 42.4 [1.67] 47.2 [1.86] 48.8 [1.92] 48.8 [1.92] 48.8 [1.92] 52.1 [2.05] 52.1 [2.05] 52.1 [2.05] 52.1 [2.05] 52.1 [2.05] 55.1 [2.17] 55.1 [2.17] 55.1 [2.17] 61.5 [2.42] 61.5 [2.42] 61.5 [2.42] 61.5 [2.42] 6 Adapters Order No. **For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied. Contact Tyco Electronics for information. Entry Size Dimensions Entry Size 04 05 06 07 08 10 12 14 16 18 20 22 24 Z Dia. +0.25-0.5 6.35 [0.250] 7.92 [0.312] 9.53 [0.375] 11.13 [0.438] 12.70 [0.500] 15.88 [0.625] 19.05 [0.750] 22.23 [0.875] 25.40 [1.000] 28.58 [1.125] 31.75 [1.250] 34.93 [1.375] 38.10 [1.500] Dimensions Y Dia. 0.38 11.58 [0.456] 13.08 [0.515] 14.76 [0.581] 16.33 [0.643] 17.91 [0.705] 21.11 [0.831] 24.21 [0.953] 27.46 [1.081] 30.61 [1.205] 35.08 [1.381] 38.25 [1.506] 41.43 [1.631] 44.60 [1.756] W Max. 31.2 [1.23] 32.8 [1.29] 34.3 [1.35] 36.1 [1.42] 37.6 [1.48] 40.6 [1.60] 43.9 [1.73] 47.0 [1.85] 50.8 [2.00] 54.1 [2.13] 57.2 [2.25] -- -- USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 6-29 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Adapter Products Code 18 MIL-C-5015 (MS3100) (Continued) Solid Adapters Manufacturer Code A B C D* R -- Connector Manufacturer MS3100/3101/3106 Amphenol-Class A Bendix-Class A/E/R Cannon-Class A/E/R Unknown-Class A/E/R Amphenol-Class R Manufacturer code not required 27.9 [1.10] Max. Z Dia. Y Dia. *Additional pieces supplied when manufacturer is unknown. All thread sizes for order number apply. 3.30 Min. [.130] 218M6XX-XXX Table of Dimensions Order No. Shell Size Manufacturer Code Thread 08 08 08 08 10 11 11 11 12 12 12 14 16 18 20 20 20 22 24 28 32 32 32 36 36 36 36 36 40 40 40 44 48 48 48 8S 8S 8S 8S 10S 10SL 10SL 10SL 12 & 12S 12 & 12S 12 & 12S 14 & 14S 16 & 16S 18 20 20 20 22 24 28 32 32 32 36 36 36 36 36 40 40 40 44 48 48 48 B C A, R D -- C A, B, R D B, C A, R D -- -- -- A, B, C R D -- -- -- B, C A, R D B R C A D B A, C, R D - C A, R D .375-32 UNEF .438-28 UNEF .438-27 UNS See * above. .500-28 UNEF .562-24 UNEF .625-24 UNEF See * above. .625-24 UNEF .688-24 UNEF See * above. .750-20 UNEF .875-20 UNEF 1.000 - 20 UNEF 1.125-18 UNEF 1.125-24 UNS See * above. 1.250-18 UNEF 1.375-18 UNEF 1.625-18 UNEF 1.875-16 UN 1.906-18 UN See * above. 2.062-16 UNS 2.062-20 UNS 2.125-16 UN 2.125-18 UNS See * above. 2.312-16 UNS 2.375-16 UN See * above. 2.625-16 UN 2.812-18 UNS 2.875-16 UN See * above. Available in: Dimensions Y 0.5 13.2 [0.52] 13.2 [0.52] 13.2 [0.52] 13.2 [0.52] 15.0 [0.59] 15.0 [0.59] 19.3 [0.76] 19.3 [0.76] 19.3 [0.76] 19.3 [0.76] 19.3 [0.76] 20.9 [0.82] 24.1 [0.95] 26.1 [1.03] 34.0 [1.34] 34.0 [1.34] 34.0 [1.34] 36.3 [1.43] 40.5 [1.59] 43.0 [1.69] 48.4 [1.91] 48.4 [1.91] 48.4 [1.91] 54.7 [2.15] 54.7 [2.15] 54.7 [2.15] 54.7 [2.15] 54.7 [2.15] 60.6 [2.39] 60.6 [2.39] 60.6 [2.39] 67.1 [2.64] 73.5 [2.89] 73.5 [2.89] 73.5 [2.89] Z Min. 6.22 [0.24] 7.80 [0.31] 7.80 [0.31] 7.80 [0.31] 9.40 [0.37] 11.00 [0.43] 12.57 [0.49] 11.00 [0.43] 12.57 [0.49] 14.15 [0.56] 12.57 [0.49] 15.75 [0.62] 18.92 [0.74] 20.50 [0.81] 25.27 [0.99] 25.27 [0.99] 25.27 [0.99] 28.45 [1.12] 31.62 [1.24] 34.80 [1.37] 41.15 [1.62] 41.15 [1.62] 41.15 [1.62] 47.50 [1.87] 47.50 [1.87] 47.50 [1.87] 47.50 [1.87] 47.50 [1.87] 53.85 [2.12] 53.85 [2.12] 53.85 [2.12] 60.20 [2.37] 66.55 [2.62] 66.55 [2.62] 66.55 [2.62] Americas Europe Asia Pacific n n n 6-30 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 18 MIL-C-5015 (MS3100) (Continued) Solid Adapters (continued) Molded Part Selection Guide (Solid) Y Diameter 13.2 [0.52] 13.2 [0.52] 15.0 [0.59] 19.2 [0.76] 20.9 [0.82] 24.1 [0.95] 26.1 [1.03] 34.0 [1.34] 36.2 [1.43] 40.5 [1.59] 43.0 [1.69] 48.4 [1.91] 54.7 [2.15] 60.6 [2.39] 67.1 [2.64] 73.5 [2.89] Straight Part No. 202W232 202K121 202K132 202K142 202K142 202K153 202K153 202K163 202K174 202K174 202K174 202K185 202K185 -- -- -- Standard K Parts 90 Part No. -- 222K121 222K132 222K142 222K142 222K152 222K152 222K163 222K174 222K174 222K174 222K185 222K185 -- -- -- Cable OD (min.) 4.3 [0.19] 5.6 [0.22] 5.9 [0.23] 7.1 [0.28] 7.1 [0.28] 8.4 [0.33] 8.4 [0.33] 9.9 [0.33] 15.7 [0.62] 15.7 [0.62] 15.7 [0.62] 16.8 [0.66] 16.8 [0.66] -- -- -- Straight Part No. -- 202D211 202D221 202D232 202D232 202D242 202D242 202D253 202D263 202D263 202D263 202D274 202D274 202D285 202D296 202D299 Low-Profile D Parts 90 Part No. -- 222D211 222D221 222D232 222D232 222D242 222D242 222D253 222D263 222D263 222D263 222D274 222D274 222D285 222D296 222D299 Cable OD (Min.) -- 6.4 [0.25] 7.4 [0.29] 8.4 [0.33] 8.4 [0.33] 9.7 [0.38] 9.7 [0.38] 10.4 [0.41] 12.2 [0.48] 12.2 [0.48] 12.2 [0.48] 14.3 [0.56] 14.3 [0.56] 17.5 [0.68] 19.6 [0.76] 22.9 [0.89] 6 Y Diameter 13.2 [0.52] 15.0 [0.59] 19.3 [0.76] 20.9 [0.82] 24.1 [0.95] 26.1 [1.03] 34.0 [1.34] 36.3 [1.43] 40.5 [1.59] 43.0 [1.69] 48.4 [1.91] 54.7 [2.15] 60.6 [2.39] 67.1 [2.64] 73.5 [2.89] Part No. 202C611 202C621 202C621 202C632 202C632 202C642 202C653 202C653 202C653 202C663 202C663 202C663 202C663 202C663 202C663 Adapters Uniboot Parts Cable OD (Min.) 4.8 [0.19] 8.1 [0.32] 8.1 [0.32] 12.7 [0.50] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] 22.4 [0.88] 22.4 [0.88] 22.9 [0.90] 22.9 [0.90] 22.9 [0.90] 22.9 [0.90] 22.9 [0.90] 22.9 [0.90] 6-31 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 18 MIL-C-5015 (MS3100) (Continued) Spin-Coupling Adapters Connector Manufacturer MS3100/3101/3106 Amphenol-Class A Bendix-Class A/E/R Cannon-Class A/E/R Unknown-Class A/E/R Amphenol-Class R Manufacturer code not required Manufacturer Code A B C D* R -- Thread 27.9 Max. [1.098] Z Y *Additional pieces supplied when manufacturer is unknown. All thread sizes for order number apply. 10.4 [.409] Min. 218M6XX-XXX Table of Dimensions Order No. Shell Size Manufacturer Code Thread 08 08 08 08 10 11 11 11 12 12 12 14 16 18 20 20 20 22 24 28 32 32 32 36 36 36 36 36 40 40 40 44 48 48 48 8S 8S 8S 8S 10S 10SL 10SL 10SL 12 & 12S 12 & 12S 12 & 12S 14 & 14S 16 & 16S 18 20 20 20 22 24 28 32 32 32 36 36 36 36 36 40 40 40 44 48 48 48 B C A, R D -- C A, B, R D B, C A, R D -- -- -- A, B, C R D -- -- -- B, C A, R D B R C A D B A, C, R D - C A, R D .375-32 UNEF .438-28 UNEF .438-27 UNS See * above. .500-28 UNEF .562-24 UNEF .625-24 UNEF See * above. .625-24 UNEF .688-24 UNEF See * above. .750-20 UNEF .875-20 UNEF 1.000 - 20 UNEF 1.125-18 UNEF 1.125-24 UNS See * above. 1.250-18 UNEF 1.375-18 UNEF 1.625-18 UNEF 1.875-16 UN 1.906-18 UN See * above. 2.062-16 UNS 2.062-20 UNS 2.125-16 UN 2.125-18 UNS See * above. 2.312-16 UNS 2.375-16 UN See * above 2.625-16 UN 2.812-18 UNS 2.875-16 UN See * above Available in: Dimensions Y 0.5 13.2 [0.52] 13.2 [0.52] 13.2 [0.52] 13.2 [0.52] 15.0 [0.59] 15.0 [0.59] 19.3 [0.76] 19.3 [0.76] 19.3 [0.76] 19.3 [0.76] 19.3 [0.76] 20.9 [0.82] 24.1 [0.95] 26.1 [1.03] 34.0 [1.34] 34.0 [1.34] 34.0 [1.34] 36.3 [1.43] 40.5 [1.59] 43.0 [1.69] 48.4 [1.91] 48.4 [1.91] 48.4 [1.91] 54.7 [2.15] 54.7 [2.15] 54.7 [2.15] 54.7 [2.15] 54.7 [2.15] 60.6 [2.39] 60.6 [2.39] 60.6 [2.39] 67.1 [2.64] 73.5 [2.89] 73.5 [2.89] 73.5 [2.89] Z Min. 6.22 [0.24] 7.80 [0.31] 7.80 [0.31] 7.80 [0.31] 9.40 [0.37] 11.00 [0.43] 12.57 [0.49] 11.00 [0.43] 12.57 [0.49] 14.15 [0.56] 12.57 [0.49] 15.75 [0.62] 18.92 [0.74] 20.50 [0.81] 25.27 [0.99] 25.27 [0.99] 25.27 [0.99] 28.45 [1.12] 31.62 [1.24] 34.80 [1.37] 41.15 [1.62] 41.15 [1.62] 41.15 [1.62] 47.50 [1.87] 47.50 [1.87] 47.50 [1.87] 47.50 [1.87] 47.50 [1.87] 53.85 [2.12] 53.85 [2.12] 53.85 [2.12] 60.20 [2.37] 66.55 [2.62] 66.55 [2.62] 66.55 [2.62] Americas Europe Asia Pacific n n n 6-32 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 18 MIL-C-5015 (MS3100) (Continued) Molded Part Selection Guide (Spin-Coupling) Y Diameter 13.2 [0.52] 13.2 [0.52] 15.0 [0.59] 19.2 [0.76] 20.9 [0.82] 24.1 [0.95] 26.1 [1.03] 34.0 [1.34] 36.2 [1.43] 40.5 [1.59] 43.0 [1.69] 48.4 [1.91] 54.7 [2.15] Uniboot Parts Straight Part No. 202K121 202K132 202K142 202K142 202K153 202K153 202K163 202K174 202K174 202K174 202K185 202K185 Part No. 202C611 202C621 202C621 202C632 202C632 202C642 202C653 202C653 202C653 202C663 202C663 202C663 Cable OD (Min.) 4.3 [0.19] 5.6 [0.22] 5.9 [0.23] 7.1 [0.28] 7.1 [0.28] 8.4 [0.33] 8.4 [0.33] 9.9 [0.33] 15.7 [0.62] 15.7 [0.62] 15.7 [0.62] 16.8 [0.66] 16.8 [0.66] Straight Part No. Low-Profile D Parts 90 Part No. Cable OD (Min.) 202D211 202D221 202D232 202D232 202D242 202D242 202D253 202D263 202D263 202D263 202D274 202D274 222D211 222D221 222D232 222D232 222D242 222D242 222D253 222D263 222D263 222D263 222D274 222D274 6.4 [0.25] 7.4 [0.29] 8.4 [0.33] 8.4 [0.33] 9.7 [0.38] 9.7 [0.38] 10.4 [0.41] 12.2 [0.48] 12.2 [0.48] 12.2 [0.48] 14.3 [0.56] 14.3 [0.56] 6 Cable OD (Min.) 4.8 [0.19] 8.1 [0.32] 8.1 [0.32] 12.7 [0.50] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] 22.4 [0.88] 22.4 [0.88] 22.9 [0.90] 22.9 [0.90] 22.9 [0.90] Adapters Y Diameter 13.2 [0.52] 15.0 [0.59] 19.3 [0.76] 20.9 [0.82] 24.1 [0.95] 26.1 [1.03] 34.0 [1.34] 36.3 [1.43] 40.5 [1.59] 43.0 [1.69] 48.4 [1.91] 54.7 [2.15] Standard K Parts 90 Part No. 202W232 222K121 222K132 222K142 222K142 222K152 222K152 222K163 222K174 222K174 222K174 222K185 222K185 6-33 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 18 MIL-C-5015 (MS3100) (Continued) Tinel-Lock Adapters 29.7 Max. [1.169] Thread Z S Y 13.0 [.512] Min. TXR18XX00-XXXXXX Thread Thread W Max. C Max. D Max. E Max. Z 13.0 Min. [.512] S 13.0 Min. [.512] Y Z S Y TXR18XX45-XXXXXX TXR18XX90-XXXXXX Manufacturer Code A B C D* R -- Connector Manufacturer MS3100/3101/3106 Amphenol-Class A Bendix-Class A/E/R Cannon-Class A/E/R Unknown-Class A/E/R Amphenol-Class R Manufacturer code not required *Additional pieces supplied when manufacturer is unknown. All thread sizes for order number apply. Available in: Americas Europe Asia Pacific n n n 6-34 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 18 MIL-C-5015 (MS3100) (Continued) Tinel-Lock Adapters (continued) Table of Dimensions Shell Size Manufacturer Code Max. Entry Size, Type 1** Thread 08 08 08 08 10 11 11 11 12 12 12 14 16 18 20 20 20 22 24 28 32 32 32 36 36 36 36 36 40 40 40 44 48 48 48 8S 8S 8S 8S 10S 10SL 10SL 10SL 12 & 12S 12 & 12S 12 & 12S 14 & 14S 16 & 16S 18 20 20 20 22 24 28 32 32 32 36 36 36 36 36 40 40 40 44 48 48 48 B C A, R D -- C A, B, R D B, C A, R D -- -- -- A, B, C R D -- -- -- B, C A, R D B R C A D B A, C, R D -- C A, R D 04 04 04 04 06 07 07 07 08 08 08 10 12 12 16 16 16 18 20 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 .375-32 UNEF .438-28 UNEF .438-27 UNS * .500-28 UNEF .562-24 UNEF .625-24 UNEF * .625-24 UNEF .688-24 UNEF * .750-20 UNEF .875-20 UNEF 1.000-20 UNEF 1.125-18 UNEF 1.125-24 UNS * 1.250-18 UNEF 1.375-18 UNEF 1.625-18 UNEF 1.875-16 UN 1.906-18 UN * 2.062-16 UNS 2.062-20 UNS 2.125-16 UN 2.125-18 UNS * 2.312-16 UNS 2.375-16 UN * 2.625-16 UN 2.812-18 UNS 2.875-16 UN * C Max. 20.3 [0.80] 20.3 [0.80] 20.3 [0.80] 20.3 [0.80] 21.1 [0.83] 21.1 [0.83] 21.1 [0.83] 21.1 [0.83] 21.1 [0.83] 21.8 [0.86] 21.8 [0.86] 21.8 [0.86] 22.6 [0.89] 23.4 [0.92] 24.1 [0.95] 24.1 [0.95] 24.1 [0.95] 24.9 [0.98] 24.9 [0.98] 27.4 [1.08] 28.2 [1.11] 28.2 [1.11] 28.2 [1.11] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 32.3 [1.27] 32.3 [1.27] 32.3 [1.27] 34.0 [1.34] 34.0 [1.34] 34.0 [1.34] 34.0 [1.34] Dimensions D Max. 23.4 [0.92] 23.4 [0.92] 23.4 [0.92] 23.4 [0.92] 24.1 [0.95] 24.1 [0.83] 24.1 [0.95] 24.1 [0.95] 24.1 [0.95] 24.9 [0.98] 24.9 [0.98] 24.9 [0.98] 25.9 [1.02] 26.7 [1.05] 27.4 [1.08] 27.4 [1.08] 27.4 [1.08] 28.2 [1.11] 28.2 [1.11] 29.7 [1.17] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 32.3 [1.27] 32.3 [1.27] 32.3 [1.27] 32.3 [1.27] 32.3 [1.27] 33.0 [1.30] 33.0 [1.30] 33.0 [1.30] 34.5 [1.36] 34.5 [1.36] 34.5 [1.36] 34.5 [1.36] E Max. 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 31.2 [1.23] 33.0 [1.30] 33.0 [1.30] 33.0 [1.30] 36.1 [1.42] 37.6 [1.48] 39.4 [1.55] 39.4 [1.55] 39.4 [1.55] 40.9 [1.61] 42.4 [1.67] 47.2 [1.86] 48.8 [1.92] 48.8 [1.92] 48.8 [1.92] 52.1 [2.05] 52.1 [2.05] 52.1 [2.05] 52.1 [2.05] 52.1 [2.05] 55.1 [2.17] 55.1 [2.17] 55.1 [2.17] 61.5 [2.42] 61.5 [2.42] 61.5 [2.42] 61.5 [2.42] 6 Adapters Order No. * 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. 6-35 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 18 MIL-C-5015 (MS3100) (Continued) Tinel-Lock Adapters (continued) Entry Size Dimensions Entry Size Z Dia. +0.25-0.5 6.35 [0.25] 7.92 [0.31] 9.52 [0.37] 11.09 [0.44] 12.70 [0.50] 15.87 [0.62] 19.05 [0.75] 22.23 [0.88] 25.40 [1.00] 28.57 [1.12] 31.75 [1.25] 34.93 [1.38] 38.10 [1.50] 04 05 06 07 08 10 12 14 16 18 20 22 24 Molded Part Selection Guide (Tinel) Tinel-Lock Entry Size 04 04 04 05, 06 07, 08 10, 12 14, 16 18, 20, 22 24 Uniboot Parts Straight Part No. 202K232 202W232 202K121 202K132 202K142 202K153 202K163 202K174 202K185 Tinel-Lock Entry Size 04 05, 06, 07 08, 10, 12 12, 14, 16 16, 18, 20, 22 Dimensions S Diameter (min.-max.) Y Dia. 0.38 9.39-9.56 [0.37-0.38] 13.97 [0.55] 10.97-11.13 [0.43-0.44] 15.54 [0.61] 12.57-12.73 [0.49-0.50] 17.14 [0.67] 14.12-14.31 [0.55-0.56] 18.71 [0.74] 15.72-15.91 [0.62-0.63] 20.32 [0.80] 18.84-19.11 [0.74-0.75] 23.49 [0.92] 22.02-22.28 [0.87-0.88] 26.67 [1.05] 25.17-25.46 [0.99-1.00] 29.84 [1.17] 28.34-28.63 [1.12-1.13] 33.02 [1.30] 31.52-31.81 [1.24-1.25] 36.19 [1.42] 34.69-34.98 [1.37-1.38] 39.37 [1.55] 37.79-38.15 [1.49-1.50] 42.55 [1.68] 40.97-41.33 [1.61-1.63] 45.72 [1.80] Standard K Parts 90 Cable OD Part No. (min.) -- 3.30 [0.13] -- 4.30 [0.19] 222K121 5.60 [0.22] 222K132 5.90 [0.23] 222K142 7.10 [0.28] 222K152 8.40 [0.33] 222K163 9.90 [0.39] 222K174 15.70 [0.62] 222K185 16.80 [0.66] Part No. 202C611 202C621 202C632 202C642 202C653 Straight Part No. -- -- 202D211 202D221 202D232 202D242 202D253 202D263 -- W Max. 31.50 [1.24] 34.30 [1.35] 35.80 [1.41] 37.30 [1.47] 39.10 [1.54] 41.40 [1.63] 45.50 [1.79] 48.80 [1.92] 51.80 [2.04] 54.90 [2.16] 58.20 [2.29] 66.80 [2.63] 70.10 [2.76] Low-Profile D Parts 90 Cable OD Part No. (Min.) -- -- -- -- 222D211 6.40 [0.25] 222D221 7.40 [0.29] 222D232 8.40 [0.33] 222D242 9.70 [0.38] 222D253 10.50 [0.41] 222D263 12.20 [0.48] -- -- Cable OD (min.) 4.8 [0.19] 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] 6-36 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 21 MIL-C-26482 Series 1 Braided Adapters 30.5 Max. [1.20] C 152.4 Max. [6.00] Tinned Copper Shield Z Dia. D Y Dia. 152.4 Z Dia. [6.00] Min. Tinned Copper Shield 206M0XX-XXXXX W Y Dia. 206M1XX-XXXXX E Z Dia. 152.4 [6.00] Min. 6 Adapters Tinned Copper Shield Y Dia. 206M2XX-XXXXX Table of Dimensions Order No. Shell Size Max. Entry Size, Type 1* Thread 08 10 12 14 16 18 20 22 24 8 10 12 14 16 18 20 22 24 04 06 08 10 12 12 14 16 18 .438-28 UNEF .562-24 UNEF .688-24 UNEF .812-20 UNEF .938-20 UNEF 1.062-18 UNEF 1.188-18 UNEF 1.312-18 UNEF 1.438-18 UNEF C Max. 21.6 [0.85] 22.4 [0.88] 23.1 [0.91] 23.4 [0.92] 24.1 [0.95] 24.4 [0.96] 25.1 [0.99] 25.7 [1.01] 26.2 [1.03] Dimensions D Max. 23.1 [0.91] 23.9 [0.94] 24.6 [0.97] 24.9 [0.98] 25.7 [1.01] 25.9 [1.02] 26.7 [1.05] 27.4 [1.08] 27.7 [1.09] E Max. 29.0 [1.14] 30.5 [1.20] 32.3 [1.27] 33.5 [1.32] 34.8 [1.37] 36.3 [1.43] 38.1 [1.50] 39.6 [1.56] 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 Size Dimensions Entry Size 04 05 06 07 08 10 12 14 16 18 Available in: Z +0.25-0.5 6.35 [0.25] 7.92 [0.31] 9.52 [0.37] 11.09 [0.44] 12.70 [0.50] 15.87 [0.62] 19.05 [0.75] 22.23 [0.88] 25.40 [1.00] 28.57 [1.12] Dimensions Y Dia. 13.97 [0.55] 15.54 [0.61] 17.14 [0.67] 18.71 [0.74] 20.32 [0.80] 23.49 [0.92] 26.67 [1.05] 29.84 [1.17] 33.02 [1.30] 36.19 [1.42] W Max. 31.0 [1.22] 32.8 [1.29] 34.3 [1.35] 35.8 [1.41] 37.3 [1.47] 40.6 [1.60] 43.7 [1.72] 47.0 [1.85] 50.0 [1.97] 53.3 [2.10] Americas Europe Asia Pacific n n n 6-37 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 21 MIL-C-26482 Series 1 (Continued) Solid Adapters Y Dia. Z Dia. 15.8 [0.62] Max. 203M6XX-XXX Table of Dimensions Molded Part Selection Guide (Solid) Order Number Shell Size Thread 08 10 12 14 16 18 20 22 24 8 10 12 14 16 18 20 22 24 .438-28 UNEF .562-24 UNEF .688-24 UNEF .812-20 UNEF .938-20 UNEF 1.062-18 UNEF 1.188-18 UNEF 1.312-18 UNEF 1.438-18 UNEF Order No. 08 10 12, 14 16, 18 20, 22, 24 Uniboot Parts Straight Part No. 202K132 202K142 202K153 202K163 202K174 Order No. 08 10 12, 14 16, 18, 20, 22, 24 Available in: Standard K Parts 90 Cable OD Part No. (Min.) 222K132 5.9 [0.23] 222K142 7.1 [0.28] 222K152 8.4 [0.33] 222K163 9.9 [0.39] 222K174 15.7 [0.62] Part No. 202C621 202C632 202C642 202C653 Dimensions Y +0.000-0.030 Z Min. (+0.00) (-0.76) Dia. 17.88 [0.704] 6.63 [0.26] 21.06 [0.829] 9.27 [0.36] 24.23 [0.954] 12.98 [0.51] 15.37 [0.61] 27.41 [1.079] 31.85 [1.254] 18.54 [0.73] 33.03 [1.316] 20.90 [0.82] 36.63 [1.442] 24.10 [0.95] 39.78 [1.566] 27.28 [1.07] 42.98 [1.692] 29.67 [1.17] Straight Part No. 202D221 202D232 202D242 202D253 202D263 Low-Profile D Parts 90 Part No. 222D221 222D232 222D242 222D253 222D263 Cable OD (Min.) 7.4 [0.29] 8.4 [0.33] 9.7 [0.38] 10.5 [0.41] 12.2 [0.48] Cable OD (Min.) 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] Americas Europe Asia Pacific n n n 6-38 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 21 MIL-C-26482 Series 1 (Continued) Spin-Coupling Adapters 30.15 [1.187] Max. Thread Z Y 10.4 [.409] Min. 203M9XX-XXX Table of Dimensions Shell Size Thread 08 10 12 14 16 18 20 22 24 8 10 12 14 16 18 20 22 24 .438-28 UNEF .562-24 UNEF .688-24 UNEF .812-20 UNEF .938-20 UNEF 1.062-18 UNEF 1.188-18 UNEF 1.312-18 UNEF 1.438-18 UNEF Order No. 08 08 10 12, 14 16, 18 20, 22 24 Uniboot Parts Straight Part No. 202W232 202K121 202K132 202K142 202K153 202K163 202K174 Standard K Parts 90 Part No. -- 222K121 222K132 222K142 222K152 222K163 222K174 Order No. 08 10, 12 14, 16 18, 20 22, 24 Available in: Part No. 202C611 202C621 202C632 202C642 202C653 Cable OD (Min.) 4.3 [0.19] 5.6 [0.22] 5.9 [0.23] 7.1 [0.28] 8.4 [0.33] 9.9 [0.39] 15.7 [0.62] Dimensions Z Min. Y +0.00-0.76 Dia. 13.54 [0.53] 6.63 [0.26] 15.37 [0.61] 9.27 [0.36] 19.66 [0.77] 12.98 [0.51] 21.29 [0.84] 15.37 [0.61] 24.46 [0.96] 18.54 [0.73] 26.47 [1.04] 20.90 [0.82] 30.91 [1.22] 24.10 [0.95] 34.42 [1.36] 27.28 [1.07] 36.65 [1.44] 29.67 [1.17] Straight Part No. -- 202D211 202D221 202D232 202D242 202D253 202D263 Low-profile D Parts 90 Part No. -- 222D211 222D221 222D232 222D242 222D253 222D263 6 Adapters Molded Part Selection Guide (Spin-Coupling) Order No. Cable OD (Min.) -- 6.4 [0.25] 7.4 [0.29] 8.4 [0.33] 9.7 [0.38] 10.5 [0.41] 12.2 [0.48] Cable OD (Min.) 4.8 [0.19] 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] Americas Europe Asia Pacific n n n 6-39 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 21 MIL-C-26482 Series 1 (Continued) Tinel-Lock Adapters 30.5 [1.201] Max. Thread Z S Y 13.0 Min. [.512] TXR21XX00-XXXX XX Thread Thread W Max. C Max. D Max. E Max. 13.0 Min. [.512] Z S 13.0 Min. [.512] Y Z S Y TXR21XX45-XXXXXX TXR21XX90-XXXXXX Available in: Americas Europe Asia Pacific n n n 6-40 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 21 MIL-C-26482 Series 1 (Continued) Tinel-Lock Adapters (continued) Table of Dimensions Order No. Shell Size Max. Entry Size, Type 1* Thread 08 10 12 14 16 18 20 22 24 8 10 12 14 16 18 20 22 24 04 06 08 10 12 12 14 16 18 .438-28 UNEF .562-24 UNEF .688-24 UNEF .812-20 UNEF .938-20 UNEF 1.062-18 UNEF 1.188-18 UNEF 1.312-18 UNEF 1.438-18 UNEF C Max. 21.6 [0.85] 22.4 [0.88] 23.1 [0.91] 23.4 [0.92] 24.1 [0.95] 24.4 [0.96] 25.1 [0.99] 25.7 [1.01] 26.2 [1.03] Dimensions D Max. 23.1 [0.91] 23.9 [0.94] 24.6 [0.97] 24.9 [0.98] 25.7 [1.01] 25.9 [1.02] 26.7 [1.05] 27.4 [1.08] 27.7 [1.09] E Max. 29.0 [1.14] 30.5 [1.20] 32.3 [1.27] 33.5 [1.32] 34.8 [1.37] 36.3 [1.43] 38.1 [1.50] 39.6 [1.56] 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 Size Dimensions Entry Size 04 05 06 07 08 10 12 14 16 18 Molded Part Selection Guide (Tinel) Tinel-Lock Entry Size 04 04 04 05, 06 07, 08 10, 12 14, 16 18, 20, 22 24 Uniboot Parts Straight Part No. 202K232 202W232 202K121 202K132 202K142 202K153 202K163 202K174 202K185 Tinel-Lock Entry Size 04 05, 06, 07 08, 10, 12 12, 14, 16 16, 18, 20, 22 24 Standard K Parts 90 Part No. -- -- 222K121 222K132 222K142 222K152 222K163 222K174 222K185 Part No. 202C611 202C621 202C632 202C642 202C653 202C663 Dimensions S Diameter(Min.-Max.) 9.39-9.56 [0.37-0.38] 10.97-11.13 [0.43-0.44] 12.57-12.73 [0.49-0.50] 14.12-14.31 [0.55-0.56] 15.72-15.91 [0.62-0.63] 18.84-19.11 [0.74-0.75] 22.02-22.28 [0.87-0.88] 25.17-25.46 [0.99-1.00] 28.34-28.63 [1.12-1.13] 31.52-31.81 [1.24-1.25] Cable OD (Min.) 3.3 [0.1] 4.3 [0.2] 5.6 [0.2] 5.9 [0.2] 7.1 [0.3] 8.4 [0.3] 9.9 [0.4] 15.7 [0.6] 16.8 [0.7] Straight Part No. -- -- 202D211 202D221 202D232 202D242 202D253 202D263 -- Y Dia. 13.97 [0.55] 15.54 [0.61] 17.14 [0.67] 18.71 [0.74] 20.32 [0.80] 23.49 [0.92] 26.67 [1.05] 29.84 [1.17] 33.02 [1.30] 36.19 [1.42] W Max. 31.0 [1.22] 32.8 [1.29] 34.3 [1.35] 35.8 [1.41] 37.3 [1.47] 40.6 [1.60] 43.7 [1.72] 47.0 [1.85] 50.0 [1.97] 53.3 [2.10] Low-profile D Parts 90 Part No. -- -- 222D211 222D221 222D232 222D242 222D253 222D263 -- 6 Adapters Z +0.25-0.5 6.35 [0.25] 7.92 [0.31] 9.52 [0.37] 11.09 [0.44] 12.7 [0.50] 15.87 [0.62] 19.05 [0.75] 22.23 [0.88] 25.4 [1.00] 28.57 [1.12] Cable OD (Min.) -- -- 6.4 [0.3] 7.4 [0.3] 8.4 [0.3] 9.7 [0.4] 10.5 [0.4] 12.2 [0.5] -- Cable OD (Min.) 4.8 [0.19] 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] 22.9 [0.90] 6-41 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 21 MIL-C-26482 Series 1 (Continued) CRES-Lock Adapters (USA) BND Adapters (Europe) Code 21 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 a connector. 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. 34.5 Max. [1.36] OB Max. Thd. OA Typ. Typ. OZ OS OY Typ. Typ. Typ. 16.5 [0.65] Max. Typ. Straight Adapter Code 00 C Max. E Max. D x. a M For additional codes available, contact Tyco Electronics. F Max. 45 Adapter Code 45 90 Adapter Code 90 16.0 [0.63] Max. OB Max. Thd. OA Typ. Typ. Type II Modification (See Note 5) Available in: Americas Europe Asia Pacific n n n 6-42 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 21 MIL-C-26482 Series 1 (Continued) CRES-Lock Adapters (USA) BND Adapters (Europe) (continued) Code 21 Band Strap Adapter (Continued) Table I Order Number Shell Size2 Entry Size Max. Type I1 O A Unified Thread UNEF Class 2B 08 08 04 0.4375-28 10 10 06 0.5625-24 12 12 08 0.6875-24 14 14 10 0.8125-20 16 16 12 0.9375-20 18 18 13 1.0625-18 20 20 15 1.1875-18 22 22 16 1.3125-18 24 24 18 1.4375-18 OB Max. C Max. D Max. F Max. 18.3 0.72 21.6 0.85 24.9 0.98 28.2 1.11 31.2 1.23 34.5 1.36 37.6 1.48 40.6 1.60 43.2 1.70 21.6 0.85 22.4 0.88 23.1 0.91 23.4 0.92 24.1 0.95 24.4 0.96 25.1 0.99 25.7 1.01 26.2 1.03 27.2 1.07 27.9 1.10 28.7 1.13 29.0 1.14 29.7 1.17 30.0 1.18 30.7 1.21 31.5 1.24 31.8 1.25 33.0 1.30 34.5 1.36 36.3 1.43 37.6 1.48 38.9 1.53 40.4 1.59 42.2 1.66 43.7 1.72 45.0 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. 03 04 05 06 07 08 09 10 11 12 13 14 OZ +0.25/-0.50 [+0.010/-0.020] 4.75 0.188 6.35 0.250 7.92 0.312 9.52 0.375 11.12 0.438 12.70 0.500 14.30 0.562 15.88 0.625 17.50 0.688 19.05 0.750 20.65 0.812 22.23 0.875 OS 0.51 [0.020] 7.92 0.312 9.52 0.375 11.12 0.438 12.70 0.500 14.30 0.562 15.88 0.625 17.50 0.688 19.05 0.750 20.65 0.812 22.23 0.875 23.83 0.938 25.40 1.000 OY 0.38 [0.015] 11.10 0.438 12.70 0.500 14.30 0.563 15.88 0.625 17.50 0.689 19.05 0.750 20.65 0.813 22.23 0.875 23.80 0.938 25.40 1.000 27.00 1.063 30.16 1.189 E Max. Entry Size 19.0 0.75 19.8 0.78 20.1 0.79 21.1 0.83 21.6 0.85 22.6 0.89 23.6 0.93 24.4 0.96 24.9 0.98 25.9 1.02 26.7 1.05 27.4 1.08 15 16 18 20 22 24 26 28 30 32 34 OZ +0.25/-0.50 [+0.010/-0.020] 23.83 .0938 25.40 1.000 28.58 1.125 31.75 1.250 34.90 1.375 38.10 1.500 41.28 1.625 44.45 1.750 47.65 1.875 50.80 2.000 54.00 2.125 OS 0.51 [0.020] 27.00 1.062 28.58 1.125 31.75 1.250 34.90 1.375 38.10 1.500 41.28 1.625 44.45 1.750 47.63 1.875 50.80 2.000 54.00 2.125 57.15 2.250 OY 0.38 [0.015] 31.75 1.250 33.34 1.313 36.51 1.438 39.69 1.563 42.86 1.688 46.83 1.844 49.61 1.953 52.78 2.078 56.36 2.219 59.53 2.344 62.71 2.469 E Max. Adapters Entry Size 6 Table II (Continued) Table II 28.2 1.11 29.0 1.14 30.5 1.20 N/A N/A N/A N/A N/A N/A N/A N/A 6-43 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 32 MIL-C-22992 Braided Adapters O-ring Silicone Typ. 152.4 Min. [6.00] 43.2 [1.70] Max. Tinned Copper Shield A Thd. Typ. Z Dia. Y Dia. 207M3XX-XXXXX W A Thd. Typ. C D E Z Dia. 152.4 [6.00] Min. Z Dia. Tinned Copper Shield 152.4 Min. [6.00] Y Dia. 212M4XX-XXXXX Y Dia. 212M5XX-XXXXX Available in: Americas Europe Asia Pacific n n n 6-44 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 32 MIL-C-22992 (Continued) Braided Adapters (continued) Table of Dimensions Order No. Shell Size Max. Entry Size, Type 1* A Left Hand Thd. Class 2B 12 14 16 18 20 22 24 28 32 36 40 12 14 16 18 20 22 24 28 32 36 40 08 10 12 14 16 18 22 24 28 28 28 .750-20 UNEF .875-20 UNEF 1.000-20 UNEF 1.125-18 UNEF 1.250-18 UNEF 1.375-18 UNEF 1.625-18 UNEF 1.875-16 UN 2.062-16 UNS 2.312-16 UNS 2.625-16 UN C Max. 29.0 [1.14] 29.7 [1.17] 30.0 [1.18] 30.7 [1.21] 31.2 [1.23] 32.0 [1.26] 33.5 [1.32] 34.8 [1.37] 36.3 [1.43] 37.6 [1.48] 38.9 [1.53] Dimensions D Max. 25.4 [1.00] 25.9 [1.02] 26.2 [1.03] 26.9 [1.06] 27.7 [1.09] 28.2 [1.11] 30.0 [1.18] 31.2 [1.23] 32.5 [1.28] 33.8 [1.33] 35.3 [1.39] E Max 33.5 [1.32] 35.3 [1.39] 37.1 [1.46] 38.6 [1.52] 40.1 [1.58] 41.7 [1.64] 46.5 [1.83] 49.8 [1.96] 52.8 [2.08] 56.1 [2.21] 58.9 [2.32] *For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied. Contact Tyco Electronics for information. Entry Size Dimensions Entry Size Dimensions Y Dia. Min. 9.98 [.393] 11.58 [.456] 13.08 [.515] 14.76 [.581] 16.33 [.643] 17.91 [.705] 17.91 [.705] 21.11 [.831] 22.68 [.893] 24.21 [.953] 24.21 [.953] 27.46 [1.081] 29.03 [1.143] 30.61 [1.205] 35.08 [1.381] 38.25 [1.506] 41.43 [1.631] 44.60 [1.756] 50.90 [2.004] W Max. 39.6 [1.56] 39.6 [1.56] 42.9 [1.69] 42.9 [1.69] 46.0 [1.81] -- 49.3 [1.94] 49.3 [1.94] 52.3 [2.06] 52.3 [2.06] 55.6 [2.19] 55.6 [2.19] 59.9 [2.36] 59.9 [2.36] 69.6 [2.74] 72.6 [2.86] 75.9 [2.99] 79.0 [3.11] 85.3 [3.36] 6 Adapters 03 04 05 06 07 08 09 10 11 12 13 14 15 16 18 20 22 24 28 Z 0.20 ( 0.51) 4.75 [.187] 6.35 [.250] 7.92 [.312] 9.53 [.375] 11.13 [.438] 12.70 [.500] 14.27 [.562] 15.88 [.625] 17.48 [.688] 19.05 [.750] 20.62 [.812] 22.23 [.875] 23.83 [.938] 25.40 [1.000] 28.58 [1.125] 31.75 [1.250] 34.93 [1.375] 38.10 [1.500] 44.45 [1.750] 6-45 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 32 MIL-C-22992 (Continued) Spin-Coupling Adapters 36.83 Max. [1.450] A Thread Z Dia. Y Dia. +.000 .145 - .015 +0.00 3.70 - 0.40 204M3XX-XXX Table of Dimensions Base Part Number Shell Size 12 14 16 18 20 22 24 28 32 36 40 44 12 14 16 18 20 22 24 28 32 36 40 44 Dimensions A L.H. Thread Class 2B .750-20 UNEF .875-20 UNEF 1.000-20 UNEF 1.125-18 UNEF 1.250-18 UNEF 1.375-18 UNEF 1.625-18 UNEF 1.875-16 UN 2.062-16 UNS 2.312-16 UNEF 2.625-16 UNS 2.875-16 UNS Y .020 (0.51) 20.24 [.797] 23.44 [.923] 26.42 [1.040] 31.17 [1.227] 34.49 [1.358] 37.21 [1.465] 42.82 [1.686] 50.06 [1.971] 55.35 [2.179] 61.01 [2.402] 67.46 [2.656] 70.66 [2.782] Z Min. 12.47 [.491] 14.35 [.565] 17.53 [.690] 18.19 [.716] 21.72 [.855] 25.02 [.985] 30.48 [1.200] 36.58 [1.440] 40.77 [1.605] 52.96 [2.085] 57.15 [2.250] 62.46 [2.549] *For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied. Contact Tyco Electronics for information. Molded Part Size Selection Guide (Spin-Coupling) Order No. 12 14, 16 18, 20 22, 24 26, 32, 36 Uniboot Parts Straight Part No. 202K142 202K153 202K163 202K174 202K185 Standard K Parts 90 Part No. 222K142 222K152 222K163 222K174 222K185 Order No. 12 14, 16 18, 20, 22, 24 Available in: Part No. 202C632 202C642 202C653 Cable OD (Min.) 7.1 [0.28] 8.4 [0.33] 9.9 [0.39] 15.7 [0.62] 16.8 [0.66] Straight Part No. 202D232 202D242 202D253 202D263 -- Low-profile D Parts 90 Part No. 222D232 222D242 222D253 222D263 -- Cable OD (Min.) 8.4 [0.33] 9.7 [0.38] 10.5 [0.41] 12.2 [0.48] -- Cable OD (Min.) 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] Americas Europe Asia Pacific n n n 6-46 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 32 MIL-C-22992 (Continued) Tinel-Lock Adapters A Thd. Typ. O-Ring Silicone Typ. Tinel-Lock Ring 38.1 Max. [1.50] B Dia. Typ.. Z Dia. S Dia. Y Dia. Typ.. Typ.. Typ.. TXR32XX00-XXXXXX W C D E 6 Adapters TXR32XX90-XXXXXX TXR32XX45-XXXXXX Dimensions Order No. Shell Size Max. Entry Size Type I A Left Hand Thd Class 2B C Max. D Max. E Max. Z + .010 - .020 12 12 08 .750-20 UNEF 29.0 [1.14] 25.4 [1.00] 33.5 [1.32] 19.05 [.750] 14 14 10 .875-20 UNEF 29.7 [1.17] 25.9 [1.02] 35.3 [1.39] 22.23 [.875] 16 16 12 1.000-20 UNEF 30.0 [1.18] 26.2 [1.03] 37.1 [1.46] 25.40 [1.000] 18 18 14 1.125-18 UNEF 30.7 [1.21] 26.9 [1.06] 38.6 [1.52] 28.57 [1.125] 20 20 16 1.250-18 UNEF 31.2 [1.23] 27.7 [1.09] 40.1 [1.58] 31.75 [1.250] 22 22 18 1.375-18 UNEF 32.0 [1.26] 28.2 [1.11] 41.7 [1.64] 34.93 [1.375] 24 24 22 1.625-18 UNEF 33.5 [1.32] 30.0 [1.18] 46.5 [1.83] 38.10 [1.500] 28 32 36 40 28 32 36 40 24 24 24 24 1.875-16 UN 2.062-16 UNS 2.312-16 UNS 2.625-16 UN 34.8 [1.37] 36.3 [1.43] 37.6 [1.48] 38.9 [1.53] 31.2 [1.23] 32.5 [1.28] 33.8 [1.33] 35.3 [1.39] 49.8 [1.96] 52.8 [2.08] 56.1 [2.21] 58.9 [2.32] -- -- -- -- Y .015 ( 0.38) S Dia. 22.28 [.877] 22.02 [.867] 25.46 [1.002] 25.17 [.991] 28.63 [1.127] 28.34 [1.116] 31.81 [1.252] 31.52 [1.241] 34.98 [1.377] 34.69 [1.366] 38.15 [1.502] 37.79 [1.488] 41.33 [1.627] 40.97 [1.613] -- -- -- -- W Max. 26.67 [1.050] 52.3 [2.06] 29.84 [1.175] 55.6 [2.19] 33.02 [1.300] 59.01 [2.36] 36.19 [1.425] 69.6 [2.74] 39..37 [1.550] 72.6 [2.86] 42.55 [1.675] 75.9 [2.99] 45.72 [1.800] 79.0 [3.11] -- -- -- -- -- -- -- -- **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 n n n 6-47 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 32 MIL-C-22992 (Continued) CRES-Lock Adapters (USA) BND Adapters (Europe) Code 32 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 a connector. 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. 41.2 Max. [1.62] OB Thd. Max. OA Typ. Typ. OZ OS OY Typ. Typ. Typ. 16.5 [0.65] Max. Typ. Straight Adapter Code 00 C Max. E Max. For additional codes available, contact Tyco Electronics. D x. a M F Max. 90 Adapter Code 90 45 Adapter Code 45 24.1 [0.95] Max. OB Max. Thd. OA Typ. Typ. Type II Modification (See Note 5) Available in: Americas Europe Asia Pacific n n n 6-48 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 32 MIL-C-22992 (Continued) CRES-Lock Adapters (USA) BND Adapters (Europe) (continued) Code 32 Band Strap Adapter (Continued) Table I Order Number Shell Size2 Entry Size Max. Type I1 OA Unified Thread Class 2B 12 12 08 0.7500-20 UNEF 14 14 10 0.8750-20 UNEF 16 16 12 1.0000-20 UNEF 18 18 14 1.1250-18 UNEF 20 20 16 1.2500-18 UNEF 22 22 18 1.3750-18 UNEF 24 24 22 1.6250-18 UNEF 28 28 26 1.8750-16 UN 32 32 30 2.0625-16 UNS 36 36 34 2.3125-16 UNS 40 40 34 2.6250-16 UN OB Max. C Max. D Max. F Max. 27.2 1.07 30.2 1.19 33.5 1.32 36.6 1.44 39.9 1.57 42.9 1.69 52.6 2.07 58.9 2.32 65.3 2.57 71.6 2.82 78.0 3.07 29.0 1.14 29.7 1.17 30.0 1.18 30.7 1.21 31.2 1.23 32.0 1.26 33.5 1.32 34.8 1.37 36.3 1.43 37.6 1.48 38.9 1.53 28.4 1.12 28.9 1.14 29.2 1.15 30.0 1.18 30.7 1.21 31.2 1.23 33.0 1.30 34.3 1.35 35.6 1.40 36.8 1.45 38.4 1.51 36.6 1.44 38.4 1.51 40.1 1.58 41.7 1.64 43.2 1.70 44.7 1.76 49.5 1.95 52.8 2.08 55.9 2.20 59.2 2.33 62.0 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. 6 Entry Size 03 04 05 06 07 08 09 10 11 12 13 14 Adapters Table II (Continued) Table II OZ +0.25/-0.50 [+0.010/-0.020] 4.75 0.188 6.35 0.250 7.92 0.312 9.52 0.375 11.12 0.438 12.70 0.500 14.30 0.562 15.88 0.625 17.50 0.688 19.05 0.750 20.65 0.812 22.23 0.875 OS 0.51 [0.020] 7.92 0.312 9.52 0.375 11.12 0.438 12.70 0.500 14.30 0.562 15.88 0.625 17.50 0.688 19.05 0.750 20.65 0.812 22.23 0.875 23.83 0.938 25.40 1.000 OY 0.38 [0.015] 11.10 0.438 12.70 0.500 14.30 0.563 15.88 0.625 17.50 0.689 19.05 0.750 20.65 0.813 22.23 0.875 23.80 0.938 25.40 1.000 27.00 1.063 30.16 1.189 E Max. Entry Size 28.3 1.12 29.3 1.15 30.0 1.18 30.8 1.21 31.5 1.24 32.3 1.27 33.3 1.31 34.0 1.34 35.0 1.38 35.8 1.41 36.0 1.42 37.5 1.48 15 16 18 20 22 24 26 28 30 32 34 OZ +0.25/-0.50 [+0.010/-0.020] 23.83 .0938 25.40 1.000 28.58 1.125 31.75 1.250 34.90 1.375 38.10 1.500 41.28 1.625 44.45 1.750 47.65 1.875 50.80 2.000 54.00 2.125 OS 0.51 [0.020] 27.00 1.062 28.58 1.125 31.75 1.250 34.90 1.375 38.10 1.500 41.28 1.625 44.45 1.750 47.63 1.875 50.80 2.000 54.00 2.125 57.15 2.250 OY 0.38 [0.015] 31.75 1.250 33.34 1.313 36.51 1.438 39.69 1.563 42.86 1.688 46.83 1.844 49.61 1.953 52.78 2.078 56.36 2.219 59.53 2.344 62.71 2.469 E Max. 37.8 1.49 38.3 1.51 39.8 1.57 41.3 1.63 43.0 1.69 44.5 1.75 46.3 1.82 48.3 1.90 50.0 1.97 51.5 2.03 53.3 2.10 6-49 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 40 MIL-C-38999 Series III and IV Braided Adapters Z Dia. Y Dia. 208M7XX-XXXXX W C D Z Dia. E Z Dia. 152.4 [6.00] Min. Y Dia. 208M8XX-XXXXX Y Dia. 208M9XX-XXXXX Table of Dimensions Order No. Shell Size Commercial Military Max. Entry* Size Type 1 Thread 08 10 12 14 16 18 20 22 24 9 11 13 15 17 19 21 23 25 A B C D E F G H J 04 07 09 10 12 14 16 18 20 M12 x 1.0 M15 x 1.0 M18 x 1.0 M2 x 1.0 M25 x 1.0 M28 x 1.0 M31 x 1.0 M34 x 1.0 M37 x 1.0 C Max. 20.8 [0.82] 21.3 [0.84] 22.1 [0.87] 22.6 [0.89] 23.4 [0.92] 24.1 [0.95] 24.6 [0.97] 25.4 [1.00] 25.9 [1.02] Dimensions D Max. 22.6 [0.89] 23.4 [0.92] 24.1 [0.95] 24.1 [0.95] 24.9 [0.98] 25.7 [1.01] 26.4 [1.04] 27.2 [1.07] 27.2 [1.07] E Max. 29.2 [1.15] 30.7 [1.21] 32.5 [1.28] 34.0 [1.34] 35.6 [1.40] 37.1 [1.46] 38.9 [1.53] 40.4 [1.59] 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 n n n 6-50 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 40 MIL-C-38999 Series III and IV (Continued) Braided Adapters (continued) Entry Size Dimensions Entry Size 04 05 06 07 08 10 12 14 16 18 20 Molded Part Selection Guide (Braided) Tinel-Lock Entry Size Uniboot Parts Straight Part No. 202K232 202W232 202K121 202K132 202K142 202K153 202K163 202K174 202K185 Standard K Parts 90 Part No. -- -- 222K121 222K132 222K142 222K152 222K163 222K174 222K185 Cable OD (Min.) 3.3 [0.1] 4.3 [0.2] 5.6 [0.2] 5.9 [0.2] 7.1 [0.3] 8.4 [0.3] 9.9 [0.4] 15.7 [0.6] 16.8 [0.7] Tinel- Lock Entry Size Part No. Cable OD (Min.) 04 05, 06, 07 08, 10, 12 12, 14, 16 16, 18, 20, 22 24 202C611 202C621 202C632 202C642 202C653 202C663 4.8 [0.19] 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] 22.9 [0.90] Straight Part No. -- -- 202D211 202D221 202D232 202D242 202D253 202D263 -- W Max. 31.2 [1.23] 32.8 [1.29] 34.3 [1.35] 36.1 [1.42] 37.6 [1.48] 40.6 [1.60] 43.9 [1.73] 47.0 [1.85] 50.8 [2.00] 54.1 [2.13] 57.21 [2.25] Low-Profile D Parts 90 Part No. -- -- 222D211 222D221 222D232 222D242 222D253 222D263 -- Cable OD (Min.) -- -- 6.4 [0.3] 7.4 [0.3] 8.4 [0.3] 9.7 [0.4] 10.5 [0.4] 12.2 [0.5] -- 6 Adapters 04 04 04 05, 06 07, 08 10, 12 14, 16 18, 20, 22 24 Dimensions Y Dia. 13.97 [0.55] 15.54 [0.61] 17.14 [0.67] 18.71 [0.74] 20.32 [0.80] 23.49 [0.92] 26.67 [1.05] 29.84 [1.17] 33.02 [1.30] 36.19 [1.42] 39.37 [1.55] Z +0.25-0.5 6.35 [0.25] 7.92 [0.31] 9.52 [0.37] 11.09 [0.44] 12.7 [0.50] 15.87 [0.62] 19.05 [0.75] 22.23 [0.88] 25.4 [1.00] 28.57 [1.12] 31.75 [1.25] 6-51 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 40 MIL-C-38999 Series III and IV (Continued) Solid Adapters A Thread Y Dia. Z Dia. 209M3XX-XXX Table of Dimensions Molded Part Selection Guide (Solid) Order No. Shell Size Commercial Military A Thread 08 10 12 14 16 18 20 22 24 9 11 13 15 17 19 21 23 25 A B C D E F G H J M12 x 1.0 M15 x 1.0 M18 x 1.0 M22 x 1.0 M25 x 1.0 M28 x 1.0 M31 x 1.0 M34 x 1.0 M37 x 1.0 Order No. 08 10 12, 14 16, 18 20, 22, 24 Uniboot Parts Straight Part No. 202K132 202K142 202K153 202K163 202K174 Standard K Parts 90 Part No. 222K132 222K142 222K152 222K163 222K174 Order No. 08 10 12, 14 16, 18, 20, 22 Available in: Part No. 202C621 202C632 202C642 202C653 Cable OD (Min.) 5.9 [0.23] 7.1 [0.28] 8.4 [0.33] 9.9 [0.39] 15.7 [0.62] Dimensions Y +.000- .030 (+0.00) (-0.76) 18.26 [.719] 21.44 [.844] 24.61 [.969] 30.91 [1.217] 34.40 [1.354] 37.50 [1.476] 38.89 [1.531] 42.06 [1.656] 45.24 [1.781] Straight Part No. 202D221 202D232 202D242 202D253 202D263 Low-Profile D Parts 90 Part No. 222D221 222D232 222D242 222D253 222D263 Z Dia. Min. 6.35 [.250] 9.52 [.375] 12.70 [.500] 15.88 [.625] 19.05 [.750] 20.62 [.812] 23.80 [.937] 26.97 [1.062] 30.18 [1.188] Cable OD (Min.) 7.4 [0.29] 8.4 [0.33] 9.7 [0.38] 10.5 [0.41] 12.2 [0.48] Cable OD (Min.) 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] Americas Europe Asia Pacific n n n 6-52 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 40 MIL-C-38999 Series III and IV (Continued) Spin-Coupling Adapters Thread 18.03 Max. [.710] Z Y 10.4 Min. [0.40] 209M4XX-XXX Table of Dimensions Shell Size Commercial Military Thread 08 10 12 14 16 18 20 22 24 9 11 13 15 17 19 21 23 25 A B C D E F G H J M12 x 1.0 M15 x 1.0 M18 x 1.0 M22 x 1.0 M25 x 1.0 M28 x 1.0 M31 x 1.0 M34 x 1.0 M37 x 1.0 Order No. 03, 08 03, 08 10, 11 12, 14 16, 18 20, 22 24, 28 32, 36 Uniboot Parts Straight Part No. 202W232 202K121 202K132 202K142 202K153 202K163 202K174 202K185 Standard K Parts 90 Part No. -- 222K121 222K132 222K142 222K152 222K163 222K174 222K185 Order No. 03, 08 10, 11, 12 14, 16 18, 20 22, 24 Available in: Part No. 202C611 202C621 202C632 202C642 202C653 Cable OD (Min.) 4.3 [0.19] 5.6 [0.22] 5.9 [0.23] 7.1 [0.28] 8.4 [0.33] 9.9 [0.39] 15.7 [0.62] 16.8 [0.66] Dimensions Z Dia. Max. Y Dia. Max. 13.54 [0.53] 6.35 [0.25] 15.37 [0.61] 9.52 [0.37] 19.66 [0.77] 12.7 [0.50] 21.29 [0.84] 15.75 [0.62] 24.46 [0.96] 18.92 [0.74] 26.47 [1.04] 20.62 [0.81] 30.91 [1.22] 23.8 [0.94] 34.42 [1.36] 26.97 [1.06] 36.65 [1.44] 29.85 [1.18] Straight Part No. -- 202D211 202D221 202D232 202D242 202D253 202D263 -- Low-Profile D Parts 90 Part No. -- 222D211 222D221 222D232 222D242 222D253 222D263 -- 6 Adapters Molded Part Selection Guide (Spin-Coupling) Order No. Cable OD (Min.) -- 6.4 [0.25] 7.4 [0.29] 8.4 [0.33] 9.7 [0.38] 10.5 [0.41] 12.2 [0.48] -- Cable OD (Min.) 4.8 [0.19] 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] Americas Europe Asia Pacific n n n 6-53 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 40 MIL-C-38999 Series III and IV (Continued) Tinel-Lock Adapters 26.9 [1.059] Max. Thread Z S Y 13.0 Min. [.512] TXR40XX00-XXXXXX Thread Thread W Max. C Max. D Max. E Max. Z 13.0 Min. [.512] S 13.0 Min. [.512] Y Z S TXR40XX45-XXXXXX Y TXR40XX90-XXXXXX Table of Dimensions Order No. Shell Size Commercial Military Max. Entry* Size Type 1 Thread 08 10 12 14 16 18 20 22 24 9 11 13 15 17 19 21 23 25 A B C D E F G H J 04 07 08 10 12 14 16 18 20 M12 x 1.0 M15 x 1.0 M18 x 1.0 M2 x 1.0 M25 x 1.0 M28 x 1.0 M31 x 1.0 M34 x 1.0 M37 x 1.0 C Max. 20.8 [0.82] 21.3 [0.84] 22.1 [0.87] 22.6 [0.89] 23.4 [0.92] 24.1 [0.95] 24.6 [0.97] 25.4 [1.00] 25.9 [1.02] Dimensions D Max. 22.6 [0.89] 23.4 [0.92] 24.1 [0.95] 24.1 [0.95] 24.9 [0.98] 25.7 [1.01] 26.4 [1.04] 27.2 [1.07] 27.2 [1.07] E Max. 27.9 [1.10] 30.5 [1.20] 32.0 [1.26] 34.0 [1.34] 35.6 [1.40] 36.8 [1.45] 38.4 [1.51] 39.9 [1.57] 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 n n n 6-54 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 40 MIL-C-38999 Series III and IV (Continued) Tinel-Lock Adapters (continued) Entry Size Dimensions Entry Size Z +0.25-0.5 6.35 [0.25] 7.92 [0.31] 9.52 [0.37] 11.09 [0.44] 12.7 [0.50] 15.87 [0.62] 19.05 [0.75] 22.23 [0.88] 25.4 [1.00] 28.57 [1.12] 31.75 [1.25] 04 05 06 07 08 10 12 14 16 18 20 Molded Part Selection Guide (Tinel) Tinel-Lock Entry Size Uniboot Parts Tinel-Lock Entry Size 04 05, 06, 07 08, 10, 12 12, 14, 16 16, 18, 20, 22 24 Standard K Parts 90 Part No. -- -- 222K121 222K132 222K142 222K152 222K163 222K174 222K185 Part No. 202C611 202C621 202C632 202C642 202C653 202C663 Cable OD (Min.) 3.3 [0.1] 4.3 [0.2] 5.6 [0.2] 5.9 [0.2] 7.1 [0.3] 8.4 [0.3] 9.9 [0.4] 15.7 [0.6] 16.8 [0.7] Y Dia. 13.97 [0.55] 15.54 [0.61] 17.14 [0.67] 18.71 [0.74] 20.32 [0.80] 23.49 [0.92] 26.67 [1.05] 29.84 [1.17] 33.02 [1.30] 36.19 [1.42] 39.37 [1.55] Straight Part No. -- -- 202D211 202D221 202D232 202D242 202D253 202D263 -- Low-Profile D Parts 90 Part No. -- -- 222D211 222D221 222D232 222D242 222D253 222D263 -- W Max. 31.2 [1.23] 32.8 [1.29] 34.3 [1.35] 36.1 [1.42] 37.6 [1.48] 40.6 [1.60] 43.9 [1.73] 47.0 [1.85] 50.8 [2.00] 54.1 [2.13] 57.21 [2.25] Cable OD (Min.) -- -- 6.4 [0.3] 7.4 [0.3] 8.4 [0.3] 9.7 [0.4] 10.5 [0.4] 12.2 [0.5] -- 6 Adapters 04 04 04 05, 06 07, 08 10, 12 14, 16 18, 20, 22 24 Straight Part No. 202K232 202W232 202K121 202K132 202K142 202K153 202K163 202K174 202K185 Dimensions S Diameter (Min.-Max.) 9.39-9.56 [0.37-0.38] 10.97-11.13 [0.43-0.44] 12.57-12.73 [0.49-0.50] 14.12-14.31 [0.55-0.56] 15.72-15.91 [0.62-0.63] 18.84-19.11 [0.74-0.75] 22.02-22.28 [0.87-0.88] 25.17-25.46 [0.99-1.00] 28.34-28.63 [1.12-1.13] 31.52-31.81 [1.24-1.25] 34.69-34.98 [1.37-1.38] Cable OD (Min.) 4.8 [0.19] 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] 22.9 [0.90] 6-55 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 40 MIL-C-38999 Series III and IV (Continued) CRES-Lock Adapters (USA) BND Adapters (Europe) Code 40 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 a connector. 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 watertight seal meeting the requirements of MIL-C-85049, paragraph 3.5.7. 7. Coupling nut shall have 3 lock wire holes 120 apart. 31.0 Max. [1.22] OB Thd. Max. OA Typ. Typ. OZ OS OY Typ. Typ. Typ. 16.5 [0.65] Max. Typ. Straight Adapter Code 00 C Max. E Max. D x. a M For additional codes available, contact Tyco Electronics. F Max. 90 Adapter Code 90 45 Adapter Code 45 16.5 Max. [0.65] OB Thd. Max. OA Typ. Typ. Type II Modification (See Note 5) Available in: Americas Europe Asia Pacific n n n 6-56 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 40 MIL-C-38999 Series III and IV (Continued) CRES-Lock Adapters (USA) BND Adapters (Europe) Table I Shell Size2 MIL Com. Order Number (continued) Code 40 Band Strap Adapter (Continued) Entry Size Max. Type I1 OA Metric Thread Class 2B 8 9 A 04 M12 x 1.0 10 11 B 07 M15 x 1.0 12 13 C 09 M18 x 1.0 14 15 D 10 M22 x 1.0 16 17 E 12 M25 x 1.0 18 19 F 14 M28 x 1.0 20 21 G 16 M31 x 1.0 22 23 H 18 M34 x 1.0 24 25 J 20 M37 x 1.0 OB Max. OB Max.3 C Max. D Max. F Max. 19.1 0.75 21.6 0.85 25.4 1.00 29.2 1.15 31.8 1.25 35.6 1.40 38.1 1.50 41.9 1.65 44.5 1.75 24.6 0.97 27.0 1.06 31.0 1.22 35.8 1.41 37.3 1.47 40.6 1.60 44.5 1.75 47.0 1.85 51.6 2.03 20.8 0.82 21.3 0.84 22.1 0.87 22.6 0.89 23.4 0.92 24.1 0.95 24.6 0.97 25.4 1.00 25.9 1.02 26.7 1.05 27.4 1.08 28.2 1.11 28.2 1.11 29.0 1.14 29.7 1.17 30.5 1.20 31.3 1.23 31.3 1.23 32.0 1.26 34.5 1.36 36.1 1.42 38.1 1.50 39.6 1.56 40.9 1.61 42.4 1.67 43.9 1.73 46.5 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". 6 Entry Size 03 04 05 06 07 08 09 10 11 12 13 14 Adapters Table II (Continued) Table II OZ +0.25/-0.50 [+0.010/-0.020] 4.75 0.188 6.35 0.250 7.92 0.312 9.52 0.375 11.12 0.438 12.70 0.500 14.30 0.562 15.88 0.625 17.50 0.688 19.05 0.750 20.65 0.812 22.23 0.875 OS 0.51 [0.020] 7.92 0.312 9.52 0.375 11.12 0.438 12.70 0.500 14.30 0.562 15.88 0.625 17.50 0.688 19.05 0.750 20.65 0.812 22.23 0.875 23.83 0.938 25.40 1.000 OY 0.38 [0.015] 11.10 0.438 12.70 0.500 14.30 0.563 15.88 0.625 17.50 0.689 19.05 0.750 20.65 0.813 22.23 0.875 23.80 0.938 25.40 1.000 27.00 1.063 30.16 1.189 E Max. Entry Size 15.8 0.62 16.3 0.64 16.8 0.66 17.8 0.70 18.3 0.72 19.8 0.78 21.3 0.84 22.4 0.88 22.9 0.90 23.4 0.92 24.4 0.96 25.4 1.00 15 16 18 20 22 24 26 28 30 32 34 OZ +0.25/-0.50 [+0.010/-0.020] 23.83 .0938 25.40 1.000 28.58 1.125 31.75 1.250 34.90 1.375 38.10 1.500 41.28 1.625 44.45 1.750 47.65 1.875 50.80 2.000 54.00 2.125 OS 0.51 [0.020] 27.00 1.062 28.58 1.125 31.75 1.250 34.90 1.375 38.10 1.500 41.28 1.625 44.45 1.750 47.63 1.875 50.80 2.000 54.00 2.125 57.15 2.250 OY 0.38 [0.015] 31.75 1.250 33.34 1.313 36.51 1.438 39.69 1.563 42.86 1.688 46.83 1.844 49.61 1.953 52.78 2.078 56.36 2.219 59.53 2.344 62.71 2.469 E Max. 25.4 1.00 26.4 1.04 27.7 1.09 29.2 1.15 N/A N/A N/A N/A N/A N/A N/A 6-57 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 41 MIL-C-38999 Series I and II Braided Adapters 152.4 Min. [6.00] 27.2 Max. [1.07] Z Dia. Y Dia. 204M0XX-XXXXX W C D Z Dia. 152.4 [6.00] Min. E Y Dia. Z Dia. 152.4 [6.00] Min. 204M1XX-XXXXX Y Dia. 204M2XX-XXXXX Table of Dimensions Order No. 08 10 12 14 16 18 20 22 24 Shell Size Series I Series II 9 8 11 10 13 12 15 14 17 16 19 18 21 20 23 22 25 24 Max. Entry* Size Type 1 A Unified Thread Class 2B 04 06 08 10 12 13 15 16 18 .438-28 UNEF .562-24 UNEF .688-24 UNEF .812-20 UNEF .938-20 UNEF 1.062-18 UNEF 1.188-18 UNEF 1.312-18 UNEF 1.438-18 UNEF C Max. 19.8 [0.78] 20.3 [0.80] 21.1 [0.83] 21.6 [0.85] 22.4 [0.88] 22.9 [0.90] 23.6 [0.93] 24.4 [0.96] 24.9 [0.98] Dimensions D Max. 23.1 [0.91] 23.6 [0.93] 24.4 [0.96] 24.9 [0.98] 25.4 [1.00] 26.2 [1.03] 26.9 [1.06] 27.4 [1.08] 28.2 [1.11] E Max. 29.2 [1.15] 30.7 [1.21] 32.5 [1.28] 34.0 [1.34] 35.6 [1.40] 37.1 [1.46] 38.9 [1.53] 40.4 [1.59] 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 n n n 6-58 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 41 MIL-C-38999 Series I and II (Continued) Braided Adapters (continued) Entry Size Dimensions Entry Size 03 04 05 06 07 08 09 10 11 12 13 14 15 16 18 20 22 24 28 Tinel-Lock Entry Size 04 04 04 05, 06 07, 08 10, 12 14, 16 18, 20, 22 24 Uniboot Parts Straight Part No. 202K232 202W232 202K121 202K132 202K142 202K153 202K163 202K174 202K185 Order No. 04 05, 06, 07 08, 10, 12 12, 14, 16 16, 18, 20, 22 24 Standard K Parts 90 Part No. -- -- 222K121 222K132 222K142 222K152 222K163 222K174 222K185 Part No. 202C611 202C621 202C632 202C642 202C653 202C663 Cable OD (Min.) 3.3 [0.1] 4.3 [0.2] 5.6 [0.2] 5.9 [0.2] 7.1 [0.3] 8.4 [0.3] 9.9 [0.4] 15.7 [0.6] 16.8 [0.7] Straight Part No. -- -- 202D211 202D221 202D232 202D242 202D253 202D263 -- W Max. 27.2 [1.07] 27.2 [1.07] 28.7 [1.13] 30.2 [1.19] 31.8 [1.25] 33.5 [1.32] 36.6 [1.44] 36.6 [1.44] 39.9 [1.57] 39.9 [1.57] 42.9 [1.69] 42.9 [1.69] 46.2 [1.82] 46.2 [1.82] 49.3 [1.94] -- -- -- -- Low-Profile D Parts 90 Part No. -- -- 222D211 222D221 222D232 222D242 222D253 222D263 -- 6 Adapters Molded Part Selection Guide (Braided) Dimensions Y Dia. Min. 9.98 [.393] 11.58 [.456] 13.08 [.515] 14.76 [.581] 16.33 [.643] 17.91 [.705] 17.91 [.705] 21.11 [.831] 22.68 [.893] 24.21 [.953] 24.21 [.953] 27.46 [1.081] 29.03 [1.143] 30.61 [1.205] 35.08 [1.381] 38.25 [1.506] 41.43 [1.631] 44.60 [1.756] 50.90 [2.004] Z 0.020 (0.51) 4.75 [.187] 6.35 [.250] 7.92 [.312] 9.53 [.375] 11.13 [.438] 12.70 [.500] 14.27 [.562] 15.88 [.625] 17.48 [.688] 19.05 [.750] 20.62 [.812] 22.23 [.875] 23.83 [.938] 25.40 [1.000] 28.58 [1.125] 31.75 [1.250] 34.93 [1.375] 38.10 [1.500] 44.45 [1.750] Cable OD (Min.) -- -- 6.4 [0.3] 7.4 [0.3] 8.4 [0.3] 9.7 [0.4] 10.5 [0.4] 12.2 [0.5] -- Cable OD (Min.) 4.8 [0.19] 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] 22.9 [0.90] 6-59 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 41 MIL-C-38999 Series I and II (Continued) Solid Adapters Y Z 202M1XX-XXX Table of Dimensions Molded Part Selection Guide (Solid) Order No. Shell Size Series I Series II Thread 08 10 12 14 16 18 20 22 24 9 11 13 15 17 19 21 23 25 8 10 12 14 16 18 20 22 24 .438-28 UNEF .562-24 UNEF .688-24 UNEF .812-20 UNEF .938-20 UNEF 1.062-18 UNEF 1.188-18 UNEF 1.312-18 UNEF 1.438-18 UNEF Order No. 08 10 12, 14 16, 18 20, 22, 24 Uniboot Parts Straight Part No. 202K132 202K142 202K153 202K163 202K174 Standard K Parts 90 Part No. 222K132 222K142 222K152 222K163 222K174 Order No. 08 10 12, 14 16, 18, 20, 22 Available in: Part No. 202C621 202C632 202C642 202C653 Cable OD (Min.) 5.9 [0.23] 7.1 [0.28] 8.4 [0.33] 9.9 [0.39] 15.7 [0.62] Dimensions Y +0.00-0.30 (+0.00) (-0.76) dia. Z min. 18.26 [.719] 6.71 [.264] 21.44 [.844] 9.96 [.392] 24.61 [.969] 12.85 [.506] 27.79 [1.094] 16.03 [.631] 32.54 [1.281] 19.20 [.756] 35.71 [1.406] 21.44 [.844] 38.89 [1.531] 24.64 [.970] 42.06 [1.656] 27.79 [1.094] 45.24 [1.781] 30.71 [1.209] Straight Part No. 202D221 202D232 202D242 202D253 202D263 Low-Profile D Parts 90 Part No. 222D221 222D232 222D242 222D253 222D263 Cable OD (Min.) 7.4 [0.29] 8.4 [0.33] 9.7 [0.38] 10.5 [0.41] 12.2 [0.48] Cable OD (Min.) 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] Americas Europe Asia Pacific n n n 6-60 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 41 MIL-C-38999 Series I and II (Continued) Spin-Coupling Adapters 23.78 Max. [.936] Thread Z Y 10.4 [.409] Min. 202M2XX-XXX Table of Dimensions Shell Size Series I Series II Thread 08 10 12 14 16 18 20 22 24 9 11 13 15 17 19 21 23 25 8 10 12 14 16 18 20 22 24 .438-28 UNEF .562-24 UNEF .688-24 UNEF .812-20 UNEF .938-20 UNEF 1.062-18 UNEF 1.188-18 UNEF 1.312-18 UNEF 1.438-18 UNEF Straight Part No. 202W232 202K121 202K132 202K142 202K153 202K163 202K174 Standard K Parts 90 Part No. -- 222K121 222K132 222K142 222K152 222K163 222K174 Order No. 08 08 10 12, 14 16, 18 20, 22 24, 28 Uniboot Parts Order No. 08 10, 12 14, 16 18, 20 22, 24 Available in: Part No. 202C611 202C621 202C632 202C642 202C653 Cable OD (Min.) 4.3 [0.19] 5.6 [0.22] 5.9 [0.23] 7.1 [0.28] 8.4 [0.33] 9.9 [0.39] 15.7 [0.62] Dimensions Z Min. Y +0.00-0.76 Dia. 13.54 [0.53] 6.35 [0.25] 15.37 [0.61] 9.53 [0.38] 19.66 [0.77] 12.70 [0.50] 21.29 [0.84] 15.88 [0.63] 24.46 [0.96] 19.05 [0.75] 26.47 [1.04] 20.62 [0.81] 30.91 [1.22] 23.80 [0.94] 34.42 [1.36] 26.97 [1.06] 36.65 [1.44] 30.18 [1.19] Straight Part No. -- 202D211 202D221 202D232 202D242 202D253 202D263 Low-Profile D Parts 90 Part No. -- 222D211 222D221 222D232 222D242 222D253 222D263 6 Adapters Molded Part Selection Guide (Spin-Coupling) Order No. Cable OD (Min.) -- 6.4 [0.25] 7.4 [0.29] 8.4 [0.33] 9.7 [0.38] 10.5 [0.41] 12.2 [0.48] Cable OD (Min.) 4.8 [0.19] 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] Americas Europe Asia Pacific n n n 6-61 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 41 MIL-C-38999 Series I and II (Continued) Tinel-Lock Adapters 26.9 Max. [1.059] Thread Z S Y 13.0 Min. [.512] TXR41XX00-XXXXXX Thread Thread W Max. C Max. D Max. E Max. 13.0 Min. [.512] Z S 13.0 [.512] Min. Y Z S Y TXR41XX45-XXXXXX TXR41XX90-XXXXXX Table of Dimensions Order No. Shell Size Series I Series II Max. Entry* Size Type 1 A Unified Thread Class 2B 08 10 12 14 16 18 20 22 24 9 11 13 15 17 19 21 23 25 8 10 12 14 16 18 20 22 24 -- -- 08 10 12 13 15 16 18 .438-28 UNEF .562-24 UNEF .688-24 UNEF .812-20 UNEF .938-20 UNEF 1.062-18 UNEF 1.188-18 UNEF 1.312-18 UNEF 1.438-18 UNEF C Max. 17.5 [0.69] 18.3 [0.72] 18.8 [0.74] 19.3 [0.76] 20.1 [0.79] 20.6 [0.81] 21.3 [0.84] 22.1 [0.87] 22.6 [0.89] Dimensions D Max. 23.1 [0.91] 23.6 [0.93] 24.4 [0.96] 24.9 [0.98] 25.4 [1.00] 26.2 [1.03] 26.9 [1.06] 27.4 [1.08] 28.2 [1.11] E Max. 29.2 [1.15] 30.7 [1.21] 32.5 [1.28] 34.0 [1.34] 35.6 [1.40] 37.1 [1.46] 38.9 [1.53] 40.4 [1.59] 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 n n n 6-62 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 41 MIL-C-38999 Series I and II (Continued) Tinel-Lock Adapters (continued) Entry Size Dimensions Entry Size Z +0.25-0.5 6.35 [0.25] 7.92 [0.31] 9.52 [0.37] 11.09 [0.44] 12.70 [0.50] 15.87 [0.62] 19.05 [0.75] 22.23 [0.88] 25.4 [1.00] 28.57 [1.12] 04 05 06 07 08 10 12 14 16 18 Molded Part Selection Guide (Tinel) Order No. Uniboot Parts Order No. 04 05, 06, 07 08, 10, 12 12, 14, 16 16, 18, 20, 22 24 Standard K Parts 90 Part No. -- -- 222K121 222K132 222K142 222K152 222K163 222K174 222K185 Part No. 202C611 202C621 202C632 202C642 202C653 202C663 Cable OD (Min.) 3.3 [0.1] 4.3 [0.2] 5.6 [0.2] 5.9 [0.2] 7.1 [0.3] 8.4 [0.3] 9.9 [0.4] 15.7 [0.6] 16.8 [0.7] Y 0.38 13.97 [0.55] 15.54 [0.61] 17.14 [0.67] 18.71 [0.74] 20.32 [0.80] 23.49 [0.92] 26.67 [1.05] 29.84 [1.17] 33.02 [1.30] 36.19 [1.42] Straight Part No. -- -- 202D211 202D221 202D232 202D242 202D253 202D263 -- Low-Profile D Parts 90 Part No. -- -- 222D211 222D221 222D232 222D242 222D253 222D263 -- W Max. 27.2 [1.07] 28.7 [1.13] 30.2 [1.19] 31.8 [1.25] 33.5 [1.32] 36.6 [1.44] 39.9 [1.57] 42.9 [1.69] 46.2 [1.82] 49.3 [1.94] Cable OD (Min.) -- -- 6.4 [0.3] 7.4 [0.3] 8.4 [0.3] 9.7 [0.4] 10.5 [0.4] 12.2 [0.5] -- 6 Adapters 04 04 04 05, 06 07, 08 10, 12 14, 16 18, 20, 22 24 Straight Part No. 202K232 202W232 202K121 202K132 202K142 202K153 202K163 202K174 202K185 Dimensions S Diameter (Min.-Max.) 9.39-9.56 [0.37-0.38] 10.97-11.13 [0.43-0.44] 12.57-12.73 [0.49-0.50] 14.12-14.31 [0.55-0.56] 15.72-15.91 [0.62-0.63] 18.84-19.11 [0.74-0.75] 22.02-22.28 [0.87-0.88] 25.17-25.46 [0.99-1.00] 28.34-28.63 [1.12-1.13] 31.52-31.81 [1.24-1.25] Cable OD (Min.) 4.8 [0.19] 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] 22.9 [0.90] 6-63 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 41 MIL-C-38999 Series I and II (Continued) CRES-Lock Adapters (USA) BND Adapters (Europe) Code 41 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 a connector. 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. 31.0 Max. [1.22] OB Thd. Max. OA Typ. Typ. OZ OS OY Typ. Typ. Typ. 16.5 [0.65] Max. Typ. Straight Adapter Code 00 C Max. E Max. For additional codes available, contact Tyco Electronics. D x. a M F Max. 90 Adapter Code 90 45 Adapter Code 45 17.0 Max. [0.67] OB Max. Thd. OA Typ. Typ. Type II Modification (See Note 5) Available in: Americas Europe Asia Pacific n n n 6-64 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 41 MIL-C-38999 Series I and II (Continued) CRES-Lock Adapters (USA) BND Adapters (Europe) Table I Order Number (continued) Code 41 Band Strap Adapter (Continued) Shell Size2 Series Series II I Entry Size Max. Type I1 OA Unified Thread UNEF Class 2B 08 9 08 04 0.4375-28 10 11 10 06 0.5625-24 12 13 12 08 0.6875-24 14 15 14 10 0.8125-20 16 17 16 12 0.9375-20 18 19 18 13 1.0625-18 20 21 20 15 1.1875-18 22 23 22 16 1.3125-18 24 25 24 18 1.4375-18 OB Max. OB Max.3 C Max. D Max. F Max. 19.1 0.75 20.8 0.85 25.4 1.00 27.2 1.10 31.8 1.25 35.6 1.40 38.1 1.50 41.9 1.65 44.5 1.75 24.6 0.97 27.0 1.06 31.0 1.22 35.8 1.41 37.3 1.47 40.6 1.60 44.5 1.75 46.8 1.84 51.6 2.03 17.5 0.69 18.3 0.72 18.8 0.74 19.3 0.76 20.1 0.79 20.6 0.81 21.3 0.84 22.1 0.87 22.6 0.89 27.2 1.07 27.7 1.09 28.4 1.12 29.0 1.14 29.5 1.16 30.2 1.19 31.0 1.22 31.5 1.24 32.3 1.27 33.3 1.31 34.8 1.37 36.6 1.44 38.1 1.50 39.6 1.56 41.1 1.62 42.9 1.69 44.5 1.75 46.0 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". 6 Entry Size 03 04 05 06 07 08 09 10 11 12 13 14 Adapters Table II (Continued) Table II OZ +0.25/-0.50 [+0.010/-0.020] 4.75 0.188 6.35 0.250 7.92 0.312 9.52 0.375 11.12 0.438 12.70 0.500 14.30 0.562 15.88 0.625 17.50 0.688 19.05 0.750 20.65 0.812 22.23 0.875 OS 0.51 [0.020] 7.92 0.312 9.52 0.375 11.12 0.438 12.70 0.500 14.30 0.562 15.88 0.625 17.50 0.688 19.05 0.750 20.65 0.812 22.23 0.875 23.83 0.938 25.40 1.000 OY 0.38 [0.015] 11.10 0.438 12.70 0.500 14.30 0.563 15.88 0.625 17.50 0.689 19.05 0.750 20.65 0.813 22.23 0.875 23.80 0.938 25.40 1.000 27.00 1.063 30.16 1.189 E Max. Entry Size 15.3 0.60 16.3 0.64 16.8 0.66 17.8 0.70 18.8 0.74 19.3 0.76 20.3 0.80 21.3 0.84 21.8 0.86 22.9 0.90 23.8 0.94 24.4 0.96 15 16 18 20 22 24 26 28 30 32 34 OZ +0.25/-0.50 [+0.010/-0.020] 23.83 .0938 25.40 1.000 28.58 1.125 31.75 1.250 34.90 1.375 38.10 1.500 41.28 1.625 44.45 1.750 47.65 1.875 50.80 2.000 54.00 2.125 OS 0.51 [0.020] 27.00 1.062 28.58 1.125 31.75 1.250 34.90 1.375 38.10 1.500 41.28 1.625 44.45 1.750 47.63 1.875 50.80 2.000 54.00 2.125 57.15 2.250 OY 0.38 [0.015] 31.75 1.250 33.34 1.313 36.51 1.438 39.69 1.563 42.86 1.688 46.83 1.844 49.61 1.953 52.78 2.078 56.36 2.219 59.53 2.344 62.71 2.469 E Max. 25.4 1.00 25.9 1.02 27.4 1.08 N/A N/A N/A N/A N/A N/A N/A N/A 6-65 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 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 Braided Adapters 152.4 [6.00] Min. Z Dia. Y Dia. 203M0XX-XXXXX W C D Z Dia. 152.4 Min. [6.00] E Z Dia. Y Dia. 203M1XX-XXXXX Y Dia. 203M2XX-XXXXX Table of Dimensions Order No. 03 08 10 12 14 16 18 20 22 24 28 32 36 40 44 48 61 Shell Size Max. Entry Size Type 1* MIL-C-81703 MIL-C-5015 3 -- 04 -- 8 & 8S 04 -- 10, 10S & 10 SL 06 12 & 12S 08 7 12 14 & 14S 08 19 16 & 16S 10 12 27 18 14 20 37 -- 22 16 -- 24 18 -- 28 22 -- 32 24 36 24 -- -- 40 24 -- 44 24 24 48 -- -- 18 61 Thread .562-24 UNEF .500-20 UNF .625-24 UNEF .750-20 UNEF .875-20 UNEF 1.000-20 UNEF 1.062-18 UNEF 1.188-18 UNEF 1.312-18 UNEF 1.438-18 UNEF 1.750-18 UNS 2.000-18 UNS 2.250-16 UN 2.500-16 UN 2.750-16 UN 3.000-16 UN 1.500-18 UNEF C Max. 19.10 [0.75] 19.10 [0.75] 19.60 [0.77] 20.30 [0.80] 20.80 [0.82] 21.30 [0.84] 21.80 [0.86] 22.40 [0.88] 23.10 [0.91] 23.60 [0.93] 24.90 [0.98] 26.20 [1.03] 27.40 [1.08] 29.00 [1.14] 30.20 [1.19] 31.50 [1.24] 23.90 [0.94] Dimensions D Max. 23.10 [0.91] 23.10 [0.91] 23.60 [0.93] 24.10 [0.95] 24.60 [0.97] 25.40 [1.00] 25.70 [1.01] 26.40 [1.04] 26.90 [1.06] 27.70 [1.09] 29.20 [1.15] 30.50 [1.20] 31.80 [1.25] 33.30 [1.31] 34.50 [1.36] 35.10 [1.38] 27.90 [1.10] E Max. 28.70 [1.13] 27.90 [1.10] 29.50 [1.16] 31.00 [1.22] 32.50 [1.28] 34.30 [1.35] 35.60 [1.40] 37.10 [1.46] 38.90 [1.53] 40.40 [1.59] 45.20 [1.78] 48.30 [1.90] 51.60 [2.03] 54.60 [2.15] 57.90 [2.28] 61.00 [2.40] 41.10 [1.62] *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 n n n 6-66 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 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) Braided Adapters (continued) Entry Size Dimensions Entry Size Z +0.25-0.5 6.35 [0.25] 7.92 [0.31] 9.52 [0.37] 11.09 [0.44] 12.7 [0.50] 15.87 [0.62] 19.05 [0.75] 22.23 [0.88] 25.4 [1.00] 28.57 [1.12] 31.75 [1.25] 34.93 [1.38] 38.1 [1.50] 04 05 06 07 08 10 12 14 16 18 20 22 24 Dimensions S Diameter (Min.-Max.) 9.39-9.56 [0.37-0.38] 10.97-11.13 [0.43-0.44] 12.57-12.73 [0.49-0.50] 14.12-14.31 [0.55-0.56] 15.72-15.91 [0.62-0.63] 18.84-19.11 [0.74-0.75] 22.02-22.28 [0.87-0.88] 25.17-25.46 [0.99-1.00] 28.34-28.63 [1.12-1.13] 31.52-31.81 [1.24-1.25] 34.69-34.98 [1.37-1.38] 37.79-38.15 [1.49-1.50] 40.97-41.33 [1.61-1.63] Y 0.38 13.97 [0.55] 15.54 [0.61] 17.14 [0.67] 18.71 [0.74] 20.32 [0.80] 23.49 [0.92] 26.67 [1.05] 29.84 [1.17] 33.02 [1.30] 36.19 [1.42] 39.37 [1.55] 42.55 [1.68] 45.72 [1.80] W Max. 28.4 [1.12] 30.2 [1.19] 31.8 [1.25] 33.3 [1.31] 35.1 [1.38] 38.1 [1.50] 41.1 [1.62] 44.5 [1.75] 47.8 [1.88] 50.8 [2.00] 53.8 [2.12] 57.2 [2.25] 60.5 [2.38] 6 Tinel-Lock Entry Size 04 04 04 05, 06 07, 08 10, 12 14, 16 18, 20, 22 24 Uniboot Parts Straight Part No. 202K232 202W232 202K121 202K132 202K142 202K153 202K163 202K174 202K185 Tinel-Lock Entry Size 04 05, 06, 07 08, 10, 12 12, 14, 16 16, 18, 20, 22 24 Standard K Parts 90 Part No. -- -- 222K121 222K132 222K142 222K152 222K163 222K174 222K185 Part No. 202C611 202C621 202C632 202C642 202C653 202C663 Cable OD (Min.) 3.3 [0.1] 4.3 [0.2] 5.6 [0.2] 5.9 [0.2] 7.1 [0.3] 8.4 [0.3] 9.9 [0.4] 15.7 [0.6] 16.8 [0.7] Straight Part No. -- -- 202D211 202D221 202D232 202D242 202D253 202D263 -- Low-Profile D Parts 90 Part No. -- -- 222D211 222D221 222D232 222D242 222D253 222D263 -- Adapters Molded Part Selection Guide (Braided) Cable OD (Min.) -- -- 6.4 [0.3] 7.4 [0.3] 8.4 [0.3] 9.7 [0.4] 10.5 [0.4] 12.2 [0.5] -- Cable OD (Min.) 4.8 [0.19] 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] 22.9 [0.90] 6-67 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 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) Solid Adapters Y Z 3.43 0.13 [.135 .005] 201M9XX-XXX Table of Dimensions Order No. 03 08 10 12 14 16 18 20 22 24 28 32 36 40 44 48 61 Molded Part Selection Guide (Solid) Uniboot Parts Shell Size MIL-C-5015 MIL-C-81703 3 -- -- 8 & 8S -- 10, 10S & 10SL 7 12 & 12S 12 14 & 14S 19 16 & 16S 27 18 37 20 -- 22 -- 24 -- 28 -- 32 -- 36 -- 40 -- 44 -- 48 61 -- Order No. Straight Part No. 03 202K132 10 202K142 12, 14 202K153 16, 18, 19, 27 202K163 20, 22, 24, 28, 37 202K174 28, 32 202K185 Standard K Parts 90 Part No. 222K132 222K142 222K152 222K163 222K174 222K185 Order No. 08 7, 10, 12 12, 14 24, 27, 37, 61 Available in: Part No. 202C621 202C632 202C642 202C653 Thread .562-24 UNEF .500-20 UNF .625-24 UNEF .750-20 UNEF .875-20 UNEF 1.000-20 UNEF 1.062-18 UNEF 1.188-18 UNEF 1.312-18 UNEF 1.438-18 UNEF 1.750-18 UNS 2.000-18 UNS 2.250-16 UN 2.500-16 UN 2.750-16 UN 3.000-16 UN 1.500-18 UNEF Cable OD (Min.) 5.9 [0.23] 7.1 [0.28] 8.4 [0.33] 9.9 [0.39] 15.7 [0.62] 16.8 [0.66] Dimensions Z Dia. Min. Y +0.00-0.51 Dia. 13.54 [0.53] 6.35 [0.25] 13.54 [0.53] 6.35 [0.25] 15.37 [0.61] 9.02 [0.36] 19.66 [0.77] 12.47 [0.49] 21.29 [0.84] 14.35 [0.56] 24.46 [0.96] 17.53 [0.69] 26.47 [1.04] 19.53 [0.77] 30.91 [1.22] 22.71 [0.89] 34.42 [1.36] 25.88 [1.02] 36.65 [1.44] 28.80 [1.13] 43.41 [1.71] 34.77 [1.37] 48.74 [1.92] 41.02 [1.61] 55.09 [2.17] 46.48 [1.83] 61.01 [2.40] 51.94 [2.04] 67.49 [2.66] 58.42 [2.30] 73.84 [2.91] 64.77 [2.55] 36.65 [1.44] 29.82 [1.17] Straight Part No. 202D221 202D232 202D242 202D253 202D263 -- Low-Profile D Parts 90 Part No. 222D221 222D232 222D242 222D253 222D263 -- Cable OD (Min.) 7.4 [0.29] 8.4 [0.33] 9.7 [0.38] 10.5 [0.41] 12.2 [0.48] -- Cable OD (Min.) 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] Americas Europe Asia Pacific n n n 6-68 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 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) Spin-Coupling Adapters Thread 26.90 Max. [1.059] Y Z 10.40 Min. [.409] 201M1XX-XXX Table of Dimensions Order No. Molded Part Selection Guide (Spin-coupling) Order No. 03, 08 03, 08 10, 11 12, 14 16, 18 20, 22 24, 28, 61 32, 36 Uniboot Parts Straight Part No. 202W232 202K121 202K132 202K142 202K153 202K163 202K174 202K185 Standard K Parts 90 Part No. -- 222K121 222K132 222K142 222K152 222K163 222K174 222K185 Part No. 202C621 202C632 202C642 202C653 Order No. 08 7, 10, 12 12, 14 24, 27, 37, 61 Available in: Thread .562-24 UNEF .500-20 UNF .625-24 UNEF .750-20 UNEF .875-20 UNEF 1.000-20 UNEF 1.062-18 UNEF 1.188-18 UNEF 1.312-18 UNEF 1.438-18 UNEF 1.750-18 UNS 2.000-18 UNS 2.250-16 UN 2.500-16 UN 2.750-16 UN 3.000-16 UN 1.500-18 UNEF Cable OD (Min.) 4.3 [0.19] 5.6 [0.22] 5.9 [0.23] 7.1 [0.28] 8.4 [0.33] 9.9 [0.39] 15.7 [0.62] 16.8 [0.66] Dimensions Y +0.00-0.51 Dia. Z Dia. Min. 13.54 [0.53] 6.35 [0.25] 13.54 [0.53] 6.35 [0.25] 15.37 [0.61] 9.02 [0.36] 19.66 [0.77] 12.47 [0.49] 21.29 [0.84] 14.35 [0.56] 24.46 [0.96] 17.53 [0.69] 26.47 [1.04] 19.53 [0.77] 30.91 [1.22] 22.71 [0.89] 34.42 [1.36] 25.88 [1.02] 36.65 [1.44] 28.80 [1.13] 43.41 [1.71] 34.77 [1.37] 48.74 [1.92] 41.02 [1.61] 55.09 [2.17] 46.48 [1.83] 61.01 [2.40] 51.94 [2.04] 67.49 [2.66] 58.42 [2.30] 73.84 [2.91] 64.77 [2.55] 36.65 [1.44] 29.82 [1.17] Straight Part No. -- 202D211 202D221 202D232 202D242 202D253 202D263 -- Low-Profile D Parts 90 Part No. -- 222D211 222D221 222D232 222D242 222D253 222D263 -- 6 Adapters 03 08 10 12 14 16 18 20 22 24 28 32 36 40 44 48 61 Shell Size MIL-C-81703 MIL-C-5015 3 -- -- 8 & 8S -- 10, 10S & 10SL 7 12 & 12S 12 14 & 14S 19 16 & 16S 27 18 37 20 -- 22 -- 24 -- 28 -- 32 -- 36 -- 40 -- 44 -- 48 61 -- Cable OD (Min.) -- 6.4 [0.25] 7.4 [0.29] 8.4 [0.33] 9.7 [0.38] 10.5 [0.41] 12.2 [0.48] -- Cable OD (Min.) 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] Americas Europe Asia Pacific n n n 6-69 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 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) Tinel-Lock Adapters Thread 27.9 Max. [1.098] Z S Y 13.0 Min. [.512] TXR54XX00-XXXXXX Thread C Max. Thread W Max. D Max. E Max. Z 13.0 [.512] Min. S 13.0 Min. [.512] Y Z S Y TXR54XX45-XXXXXX TXR54XX90-XXXXXX Available in: Americas Europe Asia Pacific n n n 6-70 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 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) Tinel-Lock Adapters (continued) Table of Dimensions Shell Size Max. Entry Size Type 1* MIL-C-5015 MIL-C-81703 3 -- 04 -- 8 & 8S 04 -- 10, 10S & 10 SL 06 7 12 & 12S 08 12 14 & 14S 08 19 16 & 16S 10 27 18 12 37 20 14 -- 22 16 -- 24 18 -- 28 22 -- 32 24 -- 36 24 -- 40 24 -- 44 24 -- 48 24 61 -- 18 Order No. 03 08 10 12 14 16 18 20 22 24 28 32 36 40 44 48 61 Thread .562-24 UNEF .500-20 UNF .625-24 UNEF .750-20 UNEF .875-20 UNEF 1.000-20 UNEF 1.062-18 UNEF 1.188-18 UNEF 1.312-18 UNEF 1.438-18 UNEF 1.750-18 UNS 2.000-18 UNS 2.250-16 UN 2.500-16 UN 2.750-16 UN 3.000-16 UN 1.500-18 UNEF C Max. 19.10 [0.75] 19.10 [0.75] 19.60 [0.77] 20.30 [0.80] 20.80 [0.82] 21.30 [0.84] 21.80 [0.86] 22.40 [0.88] 23.10 [0.91] 23.60 [0.93] 24.90 [0.98] 26.20 [1.03] 27.40 [1.08] 29.00 [1.14] 30.20 [1.19] 31.50 [1.24] 23.90 [0.94] Dimensions D Max. 23.10 [0.91] 23.10 [0.91] 23.60 [0.93] 24.10 [0.95] 24.60 [0.97] 25.40 [1.00] 25.70 [1.01] 26.40 [1.04] 26.90 [1.06] 27.70 [1.09] 29.20 [1.15] 30.50 [1.20] 31.80 [1.25] 33.30 [1.31] 34.50 [1.36] 35.10 [1.38] 27.90 [1.10] E Max. 28.70 [1.13] 27.90 [1.10] 29.50 [1.16] 31.00 [1.22] 32.50 [1.28] 34.30 [1.35] 35.60 [1.40] 37.10 [1.46] 38.90 [1.53] 40.40 [1.59] 45.20 [1.78] 48.30 [1.90] 51.60 [2.03] 54.60 [2.15] 57.90 [2.28] 61.00 [2.40] 41.10 [1.62] *For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied. Contact Tyco Electronics for information. Entry Size Dimensions Entry Size 04 05 06 07 08 10 12 14 16 18 20 22 24 Molded Part Selection Guide (Tinel) Tinel-Lock Entry Size 04 04 04 05, 06 07, 08 10, 12 14, 16 18, 20, 22 24 Uniboot Parts Straight Part No. 202K232 202W232 202K121 202K132 202K142 202K153 202K163 202K174 202K185 Tinel-Lock Entry Size 04 05, 06, 07 08, 10, 12 12, 14, 16 16, 18, 20, 22 24 Dimensions S Diameter (Min.-Max.) 9.39--9.56 [0.37--0.38] 10.97--11.13 [0.43--0.44] 12.57--12.73 [0.49--0.50] 14.12--14.31 [0.55--0.56] 15.72--15.91 [0.62--0.63] 18.84--19.11 [0.74--0.75] 22.02--22.28 [0.87--0.88] 25.17--25.46 [0.99--1.00] 28.34--28.63 [1.12--1.13] 31.52--31.81 [1.24--1.25] 34.69-34.98 [1.37-1.38] 37.79-38.15 [1.49-1.50] 40.97-41.33 [1.61-1.63] Standard K Parts 90 Part No. -- -- 222K121 222K132 222K142 222K152 222K163 222K174 222K185 Part No. 202C611 202C621 202C632 202C642 202C653 202C663 Cable OD (Min.) 3.3 [0.1] 4.3 [0.2] 5.6 [0.2] 5.9 [0.2] 7.1 [0.3] 8.4 [0.3] 9.9 [0.4] 15.7 [0.6] 16.8 [0.7] Y 0.38 13.97 [0.55] 15.54 [0.61] 17.14 [0.67] 18.71 [0.74] 20.32 [0.80] 23.49 [0.92] 26.67 [1.05] 29.84 [1.17] 33.02 [1.30] 36.19 [1.42] 39.37 [1.55] 42.55 [1.68] 45.72 [1.80] Straight Part No. -- -- 202D211 202D221 202D232 202D242 202D253 202D263 -- Low-Profile D Parts 90 Part No. -- -- 222D211 222D221 222D232 222D242 222D253 222D263 -- 6 W Max. 28.4 [1.12] 30.2 [1.19] 31.8 [1.25] 33.3 [1.31] 35.1 [1.38] 38.1 [1.50] 41.1 [1.62] 44.5 [1.75] 47.8 [1.88] 50.8 [2.00] 53.8 [2.12] 57.2 [2.25] 60.5 [2.38] Adapters Z +0.25-0.5 6.35 [0.25] 7.92 [0.31] 9.52 [0.37] 11.09 [0.44] 12.70 [0.50] 15.87 [0.62] 19.05 [0.75] 22.23 [0.88] 25.40 [1.00] 28.57 [1.12] 31.75 [1.25] 34.93 [1.38] 38.10 [1.50] Cable OD (Min.) -- -- 6.4 [0.3] 7.4 [0.3] 8.4 [0.3] 9.7 [0.4] 10.5 [0.4] 12.2 [0.5] -- Cable OD (Min.) 4.8 [0.19] 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] 22.9 [0.90] 6-71 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 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) 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 a connector. 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 in Table I. For larger entry sizes than the maximum, a Type II adapter may be supplied. See CH00-0250-016 for further details. 31.2 Max. [1.23] OB Thd. Max. OA Typ. Typ. OZ OS OY Typ. Typ. Typ. 16.5 [0.65] Max. Typ. For additional codes available, contact Tyco Electronics. Straight Adapter Code 00 C Max. E Max. D x. a M F Max. 45 Adapter Code 45 90 Adapter Code 90 22.4 Max. [0.88] OB Max. Thd. OA Typ. Typ. Type II Modification (See Note 5) Available in: Americas Europe Asia Pacific n n n 6-72 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 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) Table I CRES-Lock Adapters (USA) BND Adapters (Europe) (continued) Code 54 Band Strap Adapter (Continued) Order Number Shell Size Series2 Series3 Entry Size Max. Type I1 OA Unified Thread Class 2B -- 08 04 0.5000-20 UNF 10 -- 10 06 0.6250-24 UNEF 12 7 12 08 0.7500-20 UNEF 14 12 14 09 0.8750-20 UNEF 16 19 16 11 0.9375-20 UNEF 18 27 18 12 1.0000-20 UNEF 20 37 20 14 1.1875-18 UNEF 22 -- 22 16 1.3125-18 UNEF 24 -- 24 18 1.4375-18 UNEF 28 -- 28 22 1.7500-18 UNS 32 -- 32 26 2.0000-18 UNS 36 -- 36 28 2.2500-16 UN 40 -- 40 32 2.5000-16 UN 44 -- 44 34 2.75000-16 UN 48 -- 48 34 3.0000-16 UN 61 61 -- 18 1.5000-18 UNEF OB Max.4 C Max. D Max. F Max. 15.7 0.67 18.5 0.73 21.8 0.86 24.9 0.98 28.2 1.11 31.0 1.22 34.3 1.35 37.3 1.47 40.5 1.59 50.0 1.97 56.4 2.22 62.7 2.47 69.1 2.72 75.4 2.97 81.8 3.22 41.9 1.65 22.6 0.89 25.7 1.01 29.0 1.14 32.0 1.26 35.3 1.39 38.4 1.51 41.7 1.64 44.7 1.76 48.0 1.89 54.4 2.14 61.0 2.40 67.1 2.64 73.4 2.89 79.8 3.14 86.1 3.39 47.8 1.88 19.0 0.75 19.6 0.77 20.3 0.80 20.9 0.82 21.3 0.84 21.8 0.86 22.4 0.88 23.1 0.91 23.6 0.93 24.9 0.98 26.2 1.03 27.4 1.08 28.4 1.12 29.7 1.17 31.0 1.22 23.9 0.94 26.2 1.03 26.7 1.05 27.2 1.07 27.7 1.09 28.4 1.12 28.7 1.13 29.5 1.16 30.0 1.18 30.7 1.21 31.8 1.25 33.3 1.31 34.3 1.35 35.6 1.40 36.8 1.45 38.1 1.50 30.7 1.21 31.0 1.22 32.5 1.28 34.3 1.35 35.6 1.40 37.1 1.46 38.9 1.53 40.4 1.59 41.9 1.65 43.4 1.71 48.3 1.90 51.6 2.03 54.6 2.15 57.7 2.27 61.0 2.40 64.0 2.52 44.2 1.74 6 Adapters 08 OB Max. 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 L Connectors. 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 A and 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 (Continued) Table II Entry Size 03 04 05 06 07 08 09 10 11 12 13 14 OZ +0.25/-0.50 [+0.010/-0.020] 4.75 0.188 6.35 0.250 7.92 0.312 9.52 0.375 11.12 0.438 12.70 0.500 14.30 0.562 15.88 0.625 17.50 0.688 19.05 0.750 20.65 0.812 22.23 0.875 OS 0.51 [0.020] 7.92 0.312 9.52 0.375 11.12 0.438 12.70 0.500 14.30 0.562 15.88 0.625 17.50 0.688 19.05 0.750 20.65 0.812 22.23 0.875 23.83 0.938 25.40 1.000 OY 0.38 [0.015] 11.10 0.438 12.70 0.500 14.30 0.563 15.88 0.625 17.50 0.689 19.05 0.750 20.65 0.813 22.23 0.875 23.80 0.938 25.40 1.000 27.00 1.063 30.16 1.189 E Max. Entry Size 16.3 0.64 16.3 0.64 17.3 0.68 17.8 0.70 18.8 0.74 19.8 0.78 20.3 0.80 20.8 0.82 21.8 0.86 22.9 0.90 23.9 0.94 24.4 0.96 15 16 18 20 22 24 26 28 30 32 34 OZ +0.25/-0.50 [+0.010/-0.020] 23.83 0.938 25.40 1.000 28.58 1.125 31.75 1.250 34.90 1.375 38.10 1.500 41.28 1.625 44.45 1.750 47.65 1.875 50.80 2.000 54.00 2.125 OS 0.51 [0.020] 27.00 1.062 28.58 1.125 31.75 1.250 34.90 1.375 38.10 1.500 41.28 1.625 44.45 1.750 47.63 1.875 50.80 2.000 54.00 2.125 57.15 2.250 OY 0.38 [0.015] 31.75 1.250 33.34 1.313 36.51 1.438 39.69 1.563 42.86 1.688 46.83 1.844 49.61 1.953 52.78 2.078 56.36 2.219 59.53 2.344 62.71 2.469 E Max. 24.9 0.98 25.9 1.02 28.3 1.11 29.8 1.17 31.3 1.23 33.8 1.33 35.1 1.38 36.3 1.43 37.8 1.49 39.6 1.56 41.1 1.62 6-73 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 76 BS 9522 F0017 (Pattern 105) Spin-Coupling Adapters 29.4 Max. [1.157] Thread Z Y 10.4 Min. [.409] Table of Dimensions Molded Part Selection Guide (Spin-Coupling) Shell Size Thread 08 10 12 14 16 18 20 22 24 8 10 12 14 16 18 20 22 24 .438-28 UNEF .562-24 UNEF .688-24 UNEF .812-20 UNEF .938-20 UNEF 1.062-18 UNEF 1.188-18 UNEF 1.312-18 UNEF 1.438-18 UNEF Order No. 03, 08 03, 08 10, 11 12, 14 16, 18 20, 22 24, 28, 32, 36 Uniboot Parts Dimensions Order No. Straight Part No. 202W232 202K121 202K132 202K142 202K153 202K163 202K174 202K185 Standard K Parts 90 Part No. -- 222K121 222K132 222K142 222K152 222K163 222K174 222K185 Order No. 03, 08 10, 11, 12 14, 16 18, 20 22, 24 Available in: Part No. 202C611 202C621 202C632 202C642 202C653 Cable OD (Min.) 4.3 [0.19] 5.6 [0.22] 5.9 [0.23] 7.1 [0.28] 8.4 [0.33] 9.9 [0.39] 15.7 [0.62] 16.8 [0.66] Y Max. 13.54 [0.53] 15.37 [0.61] 19.66 [0.77] 21.29 [0.84] 24.47 [0.96] 26.47 [1.04] 30.92 [1.22] 34.42 [1.36] 36.40 [1.44] Straight Part No. -- 202D211 202D221 202D232 202D242 202D253 202D263 202D274 Z Min. 6.9 [0.27] 9.9 [0.39] 13.4 [0.53] 15.9 [0.63] 18.9 [0.74] 21.4 [0.84] 23.9 [0.94] 27.4 [1.08] 29.9 [1.18] Low-Profile D Parts 90 Part No. -- 222D211 222D221 222D232 222D242 222D253 222D263 222D274 Cable OD (Min.) -- 6.4 [0.25] 7.4 [0.29] 8.4 [0.33] 9.7 [0.38] 10.5 [0.41] 12.2 [0.48] 14.3 [0.56] Cable OD (Min.) 4.8 [0.19] 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] Americas Europe Asia Pacific n n n 6-74 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 76 BS 9522 F0017 (Pattern 105) (Continued) Tinel-Lock Adapters 36.8 [1.449] Max. Thread Z S Y 13.0 Min. [.512] TXR76XX00-XXXXXX Thread W Max Thread C Max. D Max. E Max Z S 13.0 Min. [.512] 6 13.0 Min [.512] Y Adapters Z S TXR76XX45-XXXXXX Y TXR76XX90-XXXXXX Table of Dimensions Order No. Shell Size Max. Entry Size Type 1* Thread 08 10 12 14 16 18 20 22 24 8 10 12 14 16 18 20 22 24 04 07 08 10 12 12 16 18 20 .438-28 UNEF .562-24 UNEF .688-24 UNEF .812-20 UNEF .938-20 UNEF 1.062-18 UNEF 1.188-18 UNEF 1.312-18 UNEF 1.438-18 UNEF C Max. 18.0 [.74] 18.8 [.76] 19.3 [.79] 20.1 [.82] 20.8 [.84] 21.3 [.87] 22.1 [.89] 22.6 [.92] 23.4 [.97] Dimensions D Max. 21.3 [.87] 22.1 [.90] 22.9 [.92] 23.4 [.95] 24.1 [.97] 24.6 [1.00] 25.4 [1.02] 25.9 [1.05] 26.7 [1.07] E Max. 26.7 [1.05] 28.2 [1.11] 30.2 [1.19] 31.8 [1.25] 33.5 [1.32] 35.1 [1.38] 36.6 [1.44] 38.1 [1.50] 39.4 [1.55] *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 n n n 6-75 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Adapter Products Code 76 BS 9522 F0017 (Pattern 105) (Continued) Tinel-Lock Adapters (continued) Entry Size Dimensions Entry Size Z +0.25-0.5 6.35 [0.25] 7.92 [0.31] 9.52 [0.37] 11.09 [0.44] 12.7 [0.50] 15.87 [0.62] 19.05 [0.75] 22.23 [0.88] 25.4 [1.00] 28.57 [1.12] 31.75 [1.25] 04 05 06 07 08 10 12 14 16 18 20 Molded Part Selection Guide (Tinel) Tinel-Lock Entry Size 04 04 04 05, 06 07, 08 10, 12 14, 16 18, 20, 22 24 Uniboot Parts Straight Part No. 202K232 202W232 202K121 202K132 202K142 202K153 202K163 202K174 202K185 Tinel-Lock Entry Size 04 05, 06, 07 08, 10, 12 12, 14, 16 16, 18, 20, 22 24 Dimensions S Diameter (Min.-Max.) 9.39--9.56 [0.37--0.38] 10.97--11.13 [0.43--0.44] 12.57--12.73 [0.49--0.50] 14.12--14.31 [0.55--0.56] 15.72--15.91 [0.62--0.63] 18.84--19.11 [0.74--0.75] 22.02--22.28 [0.87--0.88] 25.17--25.46 [0.99--1.00] 28.34--28.63 [1.12--1.13] 31.52--31.81 [1.24--1.25] 34.69--34.98 [1.37--1.38] Standard K Parts 90 Part No. -- -- 222K121 222K132 222K142 222K152 222K163 222K174 222K185 Part No. 202C611 202C621 202C632 202C642 202C653 202C663 Cable OD (Min.) 3.3 [0.1] 4.3 [0.2] 5.6 [0.2] 5.9 [0.2] 7.1 [0.3] 8.4 [0.3] 9.9 [0.4] 15.7 [0.6] 16.8 [0.7] Y 0.38 13.97 [1.22] 15.54 [1.29] 17.14 [1.35] 18.71 [1.41] 20.32 [1.47] 23.49 [1.60] 26.67 [1.72] 29.84 [1.85] 33.02 [1.97] 36.19 [2.10] 39.37 [1.55] Straight Part No. -- -- 202D211 202D221 202D232 202D242 202D253 202D263 -- Low-Profile D Parts 90 Part No. -- -- 222D211 222D221 222D232 222D242 222D253 222D263 -- W Max. 31.0 [0.55] 32.8 [0.61] 34.3 [0.67] 35.8 [0.74] 37.3 [0.80] 40.6 [0.92] 43.7 [1.05] 47.0 [1.17] 50.0 [1.30] 53.3 [1.42] 53.8 [2.19] Cable OD (Min.) -- -- 6.4 [0.3] 7.4 [0.3] 8.4 [0.3] 9.7 [0.4] 10.5 [0.4] 12.2 [0.5] -- Cable OD (Min.) 4.8 [0.19] 8.1 [0.32] 12.7 [0.50] 17.5 [0.69] 22.4 [0.88] 22.9 [0.90] 6-76 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Assemblies Table of Contents Raychem assemblies and kits fit a wide variety of applications. KTKK assemblies are available 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. 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'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 construction, allowing modular wiring techniques and use of existing wiring when jumbo-sizing commercial ships. 7 Assemblies Ship-to-shore kits are used 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. 7-1 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Assemblies KTKK Product Family Overview Applications 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 effected by coupling the adapter to the connector and shrinking the rear of the molded part onto the cable with a hot air gun. The molded part has a hot-melt adhesive preinstalled 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 a b Straight Assemblies 45 Assemblies a b 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). a b 90 Assemblies Materials Available Material Specification -25 fluid-resistant modified elastomer -100 low-fire-hazard material Precoated Adhesives Material -25 -25S -100 -25S fluid-resistant modified elastomer; shielded -100S low-fire-hazard; shielded Available Coatings (Unshielded) S-1048 (/86) high-temperature hot-melt adhesive -- S-1030 (/180) low-fire-hazard hot-melt adhesive -100S Available in: RK-6719 RK-6724 Available Coatings (Shielded) -- S-1030 (/180) low-fire-hazard hot-melt adhesive -- S-1275 conductive adhesive for use with Rayaten molded parts. -- Americas Europe Asia Pacific n n n 7-2 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Assemblies KTKK Assemblies Screened Pattern 105 Connectors or Connector Code 76 25S Fluid Resistant Elastomer 08 10 12 14 16 18 20 22 24 Straight Assemblies 45 Assemblies 90 Assemblies Cable O.D. Raychem Cable O.D. Raychem Range Part No. Range Part No. KTKK 0520 5.0-8.0 [.197-.315] KTKK 0560 5.0-7.0 [.197-.276] KTKK 0521 6.0-13.0 [.236-.512] KTKK 0561 6.0-9.0 [.236-.354] KTKK 0522 7.2-15.0 [.283-.591] KTKK 0562 7.2-11.0 [.283-.433] KTKK 0523 7.2-15.0 [.283-.591] KTKK 0563 7.2-11.0 [.283-.433] KTKK 0524 8.5-19.0 [.335-.748] KTKK 0564 8.5-17.0 [.335-.669] KTKK 0525 8.5-20.0 [.335-.748] KTKK 0565 8.5-17.0 [.335-.669] KTKK 0526 10.0-24.0 [.394-.945] KTKK 0566 10.0-21.0 [.394-.827] KTKK 0527 10.0-24.0 [.394-.945] KTKK 0567 10.0-21.0 [.394-.827] KTKK 0528 15.8-33.0 [.622-1.299] KTKK 0568 15.8-29.0 [.622-1.142] Raychem Part No. -- KTKK 1051 KTKK 1052 KTKK 1053 KTKK 1054 KTKK 1055 KTKK 1056 KTKK 1057 KTKK 1058 Cable O.D. Range -- 6.0-13.0 [.236-.512] 7.2-15.0 [.283-.591] 7.2-15.0 [.283-.591] 8.5-19.0 [.335-.748] 8.5-19.0 [.335-.748] 10.0-24.0 [.394-.945] 10.0-24.0 [.394-.945] 15.8-33.0 [.622-1.299] 08 10 12 14 16 18 20 22 24 KTKK 0465 5.0-7.0 [.197-.276] 6.0-9.0 [.236-.354] KTKK 0466 KTKK 0467 7.2-11.0 [.283-.433] KTKK 0468 7.2-11.0 [.283-.433] KTKK 0469 8.5-17.0 [.335-.669] KTKK 0470 8.5-17.0 [.335-.669] KTKK 0471 10.0-21.0 [.394-.827] KTKK 0472 10.0-21.0 [.394-.827] KTKK 0473 15.8-29.0 [.622-1.142] -- KTKK 1251 KTKK 1252 KTKK 1253 KTKK 1254 KTKK 1255 KTKK 1256 KTKK 1257 KTKK 1258 -- 6.0-9.0 [.236-.354] 7.2-11.0 [.283-.433] 7.2-11.0 [.283-.433] 8.5-17.0 [.335-.669] 8.5-17.0 [.335-.669] 10.0-21.0 [.394-.827] 10.0-21.0 [.394-.827] 15.8-29.0 [.622-1.142] Connector Shell Size 100S Low Fire Hazard Material KTKK 0603 5.0-7.0 [.197-.276] KTKK 0604 6.0-9.0 [.236-.354] KTKK 0605 7.2-11.0 [.283-.433] KTKK 0606 7.2-11.0 [.283-.433] KTKK 0607 8.5-17.0 [.335-.669] KTKK 0608 8.5-17.0 [.335-.669] KTKK 0609 10.0-21.0 [.394-.827] KTKK 0610 10.0-21.0 [.394-.827] KTKK 0611 15.8-29.0 [.622-1.142] Pattern 602 Connectors or Connector Code 54 7 08 10 12 14 16 18 20 22 24 Straight Assemblies 45 Assemblies 90 Assemblies Raychem Cable O.D. Raychem Cable O.D. Part No. Range Part No. Range KTKK 0840 5.0-8.0 [.197-.315] KTKK 0970 5.0-7.0 [.197-.276] KTKK 0841 6.0-13.0 [.236-.512] KTKK 0971 6.0-9.0 [.236-.354] KTKK 0842 7.2-15.0 [.283-.591] KTKK 0972 7.2-11.0 [.283-.433] KTKK 0843 7.2-15.0 [.283-.591] KTKK 0973 7.2-11.0 [.283-.433] KTKK 0844 8.5-19.0 [.335-.748] KTKK 0974 8.5-17.0 [.335-.669] KTKK 0845 8.5-19.0 [.335-.748] KTKK 0975 8.5-17.0 [.335-.669] KTKK 0846 10.0-24.0 [.394-.945] KTKK 0976 10.0-21.0 [.394-.827] KTKK 0847 10.0-24.0 [.394-.945] KTKK 0977 10.0-21.0 [.394-.827] KTKK 0848 15.8-33.0 [.622-1.299] KTKK 0978 15.8-29.0 [.622-1.142] Raychem Part No. -- KTKK 0851 KTKK 0852 KTKK 0853 KTKK 0854 KTKK 0855 KTKK 0856 KTKK 0857 KTKK 0858 Cable O.D. Range -- 6.0-13.0 [.236-.512] 7.2-15.0 [.283-.591] 7.2-15.0 [.283-.591] 8.5-19.0 [.335-.748] 8.5-19.0 [.335-.748] 10.0-24.0 [.394-.945] 10.0-24.0 [.394-.945] 15.8-33.0 [.622-1.299] 08 10 12 14 16 18 20 22 24 5.0-7.0 [.197-.276] KTKK 0612 KTKK 0613 6.0-9.0 [.236-.354] KTKK 0614 7.2-11.0 [.283-.433] KTKK 0615 7.2-11.0 [.283-.433] KTKK 0616 8.5-17.0 [.335-.669] KTKK 0617 8.5-17.0 [.335-.669] KTKK 0618 10.0-21.0 [.394-.827] KTKK 0619 10.0-21.0 [.394-.827] KTKK 0620 15.8-29.0 [.622-1.142] 5.0-7.0 [.197-.276] KTKK 0780 KTKK 0781 6.0-9.0 [.236-.354] KTKK 0782 7.2-11.0 [.283-.433] KTKK 0783 7.2-11.0 [.283-.433] KTKK 0784 8.5-17.0 [.335-.669] KTKK 0785 8.5-17.0 [.335-.669] KTKK 0786 10.0-21.0 [.394-.827] KTKK 0787 10.0-21.0 [.394-.827] KTKK 0788 15.8-29.0 [.622-1.142] -- KTKK 1241 KTKK 1242 KTKK 1243 KTKK 1244 KTKK 1245 KTKK 1246 KTKK 1247 KTKK 1248 -- 6.0-9.0 [.236-.354] 7.2-11.0 [.283-.433] 7.2-11.0 [.283-.433] 8.5-17.0 [.335-.669] 8.5-17.0 [.335-.669] 10.0-21.0 [.394-.827] 10.0-21.0 [.394-.827] 15.8-29.0 [.622-1.142] Connector Shell Size 100S Low Fire Hazard Material Assemblies 25S Fluid Resistant Elastomer 7-3 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Assemblies KTKK Assemblies Screened (Continued) Pattern 608 Connectors or Connector Code 79 25S Fluid Resistant Elastomer 08 10 12 14 16 18 20 22 24 Straight Assemblies 45 Assemblies 90 Assemblies Raychem Cable O.D. Raychem Cable O.D. Range Part No. Range Part No. KTKK 0530 5.0-8.0 [.197-.315] KTKK 0540 5.0-7.0 [.197-.276] KTKK 0531 6.0-13.0 [.236-.512] KTKK 0541 6.0-9.0 [.236-.354] KTKK 0532 7.2-15.0 [.283-.591] KTKK 0542 7.2-11.0 [.283-.433] KTKK 0533 7.2-15.0 [.283-.591] KTKK 0543 7.2-11.0 [.283-.433] KTKK 0534 8.5-19.0 [.335-.748] KTKK 0544 8.5-17.0 [.335-.669] KTKK 0535 8.5-19.0 [.335-.748] KTKK 0545 8.5-17.0 [.335-.669] KTKK 0536 10.0-24.0 [.394-.945] KTKK 0546 10.0-21.0 [.394-.827] KTKK 0537 10.0-24.0 [.394-.945] KTKK 0547 10.0-21.0 [.394-.827] KTKK 0538 15.8-33.0 [.622-1.299] KTKK 0548 15.8-29.0 [.622-1.142] Raychem Part No. -- KTKK 1261 KTKK 1262 KTKK 1263 KTKK 1264 KTKK 1265 KTKK 1266 KTKK 1267 KTKK 1268 Cable O.D. Range -- 6.0-13.0 [.236-.512] 7.2-15.0 [.283-.591] 7.2-15.0 [.283-.591] 8.5-19.0 [.335-.748] 8.5-19.0 [.335-.748] 10.0-24.0 [.394-.945] 10.0-24.0 [.394-.945] 15.8-33.0 [.622-1.299] 08 10 12 14 16 18 20 22 24 KTKK 0444 5.0-7.0 [.197-.276] KTKK 0445 6.0-9.0 [.236-.354] KTKK 0446 7.2-11.0 [.283-.433] KTKK 0447 7.2-11.0 [.283-.433] KTKK 0448 8.5-17.0 [.335-.669] KTKK 0449 8.5-17.0 [.335-.669] KTKK 0450 10.0-21.0 [.394-.827] KTKK 0451 10.0-21.0 [.394-.827] KTKK 0452 15.8-29.0 [.622-1.142] -- KTKK 1021 KTKK 1022 KTKK 1023 KTKK 1024 KTKK 1025 KTKK 1026 KTKK 1027 KTKK 1028 -- 6.0-9.0 [.236-.512] 7.2-11.0 [.283-.591] 7.2-11.0 [.283-.591] 8.5-17.0 [.335-.748] 8.5-17.0 [.335-.748] 10.0-21.0 [.394-.827] 10.0-21.0 [.394-.827] 15.8-29.0 [.622-1.142] Connector Shell Size 100S Low Fire Hazard Material KTKK 0580 5.0-7.0 [.197-.276] KTKK 0581 6.0-9.0 [.236-.354] KTKK 0582 7.2-11.0 [.283-.433] KTKK 0583 7.2-11.0 [.283-.433] KTKK 0584 8.5-17.0 [.335-.669] KTKK 0585 8.5-17.0 [.335-.669] KTKK 0586 10.0-21.0 [.394-.827] KTKK 0587 10.0-21.0 [.394-.827] KTKK 0588 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 08 10 12 14 16 18 20 22 24 Straight Assemblies 45 Assemblies 90 Assemblies Raychem Cable O.D. Raychem Cable O.D. Part No. Range (mm) Part No. Range (mm) KTKK 1110 5.0-8.0 [.197-.315] KTKK 1120 5.0-7.0 [.197-.276] KTKK 1111 6.0-13.0 [.236-.512] KTKK 1121 6.0-9.0 [.236-.354] KTKK 1112 7.2-15.0 [.283-.591] KTKK 1122 7.2-11.0 [.283-.433] KTKK 1113 7.2-15.0 [.283-.591] KTKK 1123 7.2-11.0 [.283-.433] KTKK 1114 8.5-19.0 [.335-.748] KTKK 1124 8.5-17.0 [.335-.669] KTKK 1115 8.5-19.0 [.335-.748] KTKK 1125 8.5-17.0 [.335-.669] KTKK 1116 10.0-24.0 [.394-.945] KTKK 1126 10.0-21.0 [.394-.827] KTKK 1117 10.0-24.0 [.394-.945] KTKK 1127 10.0-21.0 [.394-.827] KTKK 1118 15.8-33.0 [.622-1.299] KTKK 1128 15.8-29.0 [.622-1.142] Raychem Cable O.D. Part No. Range (mm) -- -- KTKK 1131 6.0-13.0 [.236-.512] KTKK 1132 7.2-15.0 [.283-.591] KTKK 1133 7.2-15.0 [.283-.591] KTKK 1134 8.5-19.0 [.335-.748] KTKK 1135 8.5-19.0 [.335-.748] KTKK 1136 10.0-24.0 [.394-.945] KTKK 1137 10.0-24.0 [.394-.945] KTKK 1138 15.8-33.0 [.622-1.299] 08 10 12 14 16 18 20 22 24 5.0-7.0 [.197-.276] KTKK 0670 KTKK 0671 6.0-9.0 [.236-.354] KTKK 0672 7.2-11.0 [.283-.433] KTKK 0673 7.2-11.0 [.283-.433] KTKK 0674 8.5-17.0 [.335-.669] KTKK 0675 8.5-17.0 [.335-.669] KTKK 0676 10.0-21.0 [.394-.827] KTKK 0677 10.0-21.0 [.394-.827] KTKK 0678 15.8-29.0 [.622-1.142] KTKK 0660 5.0-7.0 [.197-.276] KTKK 0661 6.0-9.0 [.236-.354] KTKK 0662 7.2-11.0 [.283-.433] KTKK 0663 7.2-11.0 [.283-.433] KTKK 0664 8.5-17.0 [.335-.669] KTKK 0665 8.5-17.0 [.335-.669] KTKK 0666 10.0-21.0 [.394-.827] KTKK 0667 10.0-21.0 [.394-.827] KTKK 0668 15.8-29.0 [.622-1.142] -- -- KTKK 1181 6.0-9.0 [.236-.354] KTKK 1182 7.2-11.0 [.283-.433] KTKK 1183 7.2-11.0 [.283-.433] KTKK 1184 8.5-17.0 [.335-.669] KTKK 1185 8.5-17.0 [.335-.669] KTKK 1186 10.0-21.0 [.394-.827] KTKK 1187 10.0-21.0 [.394-.827] KTKK 1188 15.8-29.0 [.622-1.142] USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Connector Shell Size 7-4 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Assemblies KTKK Assemblies Screened (Continued) 38999 Series I and II Connectors or Connector Code 41 25S Fluid Resistant Elastomer 08 10 12 14 16 18 20 22 24 90 Assemblies Straight Assemblies 45 Assemblies Cable O.D. Raychem Cable O.D. Raychem Range Part No. Range Part No. KTKK 0500 5.0-8.0 [.197-.315] KTKK 0510 5.0-7.0 [.197-.276] KTKK 0501 6.0-13.0 [.236-.512] KTKK 0511 6.0-9.0 [.236-.354] KTKK 0502 7.2-15.0 [.283-.591] KTKK 0512 7.2-11.0 [.283-.433] KTKK 0503 7.2-15.0 [.283-.591] KTKK 0513 7.2-11.0 [.283-.433] KTKK 0504 8.5-19.0 [.335-.748] KTKK 0514 8.5-17.0 [.335-.669] KTKK 0505 8.5-19.0 [.335-.748] KTKK 0515 8.5-17.0 [.335-.669] KTKK 0506 10.0-24.0 [.394-.945] KTKK 0516 10.0-21.0 [.394-.827] KTKK 0507 10.0-24.0 [.394-.945] KTKK 0517 10.0-21.0 [.394-.827] KTKK 0508 15.8-33.0 [.622-1.299] KTKK 0518 15.8-29.0 [.622-1.142] Raychem Part No. -- KTKK 0831 KTKK 0832 KTKK 0833 KTKK 0834 KTKK 0835 KTKK 0836 KTKK 0837 KTKK 0838 Cable O.D. Range -- 6.0-13.0 [.236-.512] 7.2-15.0 [.283-.591] 7.2-15.0 [.283-.591] 8.5-19.0 [.335-.748] 8.5-19.0 [.335-.748] 10.0-24.0 [.394-.945] 10.0-24.0 [.394-.945] 15.8-33.0 [.622-1.299] 08 10 12 14 16 18 20 22 24 KTKK 0640 5.0-7.0 [.197-.276] KTKK 0641 6.0-9.0 [.236-.354] KTKK 0642 7.2-11.0 [.283-.433] KTKK 0643 7.2-11.0 [.283-.433] KTKK 0644 8.5-17.0 [.335-.669] KTKK 0645 8.5-17.0 [.335-.669] KTKK 0646 10.0-21.0 [.394-.827] KTKK 0647 10.0-21.0 [.394-.827] KTKK 0648 15.8-29.0 [.622-1.142] -- KTKK 0721 KTKK 0722 KTKK 0723 KTKK 0724 KTKK 0725 KTKK 0726 KTKK 0727 KTKK 0728 -- 6.0-9.0 [.236-.354] 7.2-11.0 [.283-.433] 7.2-11.0 [.283-.433] 8.5-17.0 [.335-.669] 8.5-17.0 [.335-.669] 10.0-21.0 [.394-.827] 10.0-21.0 [.394-.827] 15.8-29.0 [.622-1.142] Connector Shell Size 100S Low Fire Hazard Material KTKK 0630 5.0-7.0 [.197-.276] KTKK 0631 6.0-9.0 [.236-.354] KTKK 0632 7.2-11.0 [.283-.433] KTKK 0633 7.2-11.0 [.283-.433] KTKK 0634 8.5-17.0 [.335-.669] KTKK 0635 8.5-17.0 [.335-.669] KTKK 0636 10.0-21.0 [.394-.827] KTKK 0637 10.0-21.0 [.394-.827] KTKK 0638 15.8-29.0 [.622-1.142] 7 Assemblies 7-5 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable Feedthroughs TCFS/R Product Facts n Screened or unscreened cables n One-piece part n Each size covers a wide cable range n Light weight n Single- or double-sided assembly Single-Sided Standard Assembly Double-Sided Assembly Applications Provides environmental sealing and screen continuity to a bulkhead as a cable passes through. The assembly consists of a specifically designed locknut and O-ring seal, onto the rear of which is preinstalled a Raychem heatshrinkable molded part. Feedthrough installation is simply effected by tightening the locknut on the rear of the bulkhead, which compresses the O-ring and ensures that a small knifeedge provides electrical contact between the assembly and the bulkhead. Available in: When heat is applied to the molded part in the form of hot air, a seal to the cable is formed with hot-melt adhesive. When specified for screened cables, the assembly contains a conductive adhesive, which provides electrical continuity between the screen and the bulkhead via Rayaten molded parts. These molded parts are shielded (screened), heatshrinkable parts providing shielding levels better than 80 dB at 100 MHz. Americas Europe Asia Pacific n n n 7-6 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable Feedthroughs TCFS/R (Continued) Part Numbering System TCFX* - 12 62C - 0 - 20 - 100 A H 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) 7 Assemblies *See Molded Parts Materials Section 4 for -25 and -100 information. 7-7 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable Feedthroughs TCFS/R (Continued) Double knife-edge to ensure good electrical contact. Single-sided dovetail to ensure O-ring remains in place. 5.0 [.20] PS PR A/F size 5.0 [.20] M thread A/F size P A dia. J dia. Washer Hexagonal Nut Double-nut Assembly Adhesive PS = screened Feedthrough Body Hot-melt Adhesive Preinstalled Molded Part PR = unscreened Product Dimensions Feedthrough Size TCFS/R-12 TCFS/R-16 TCFS/R-20 TCFS/R-24 TCFS/R-30 TCFS/R-36 TCFR-48 J Diameter* Unshielded a Min. 11 [.43] 15 [.59] 19 [.75] 23 [.90] 29 [1.14] 35 [1.38] 45 [1.77] b Max. 5.6 [.22] 5.9 [.23] 7.1 [.28] 8.4 [.33] 9.9 [.39] 15.7 [.62] 16.8 [.66] Shielded a Min. -25S 7.5 [.30] 12.5 [.49] 14.5 [.57] 18.5 [.73] 23.5 [.93] 32.5 [1.28] 38.5 [1.52] -100S 6.5 [.26] 8.5 [.33] 10.5 [.41] 16.5 [.65] 20.5 [.81] 28.5 [1.12] 35.5 [1.40] M Thread b Max. 5.0 [.20] 6.0 [.24] 7.2 [.28] 8.5 [.33] 10.0 [.39] 15.8 [.62] N/A M12 x 1.5 M16 x 1.5 M20 x 1.5 M24 x 1.5 M30 x 1.5 M36 x 1.5 M48 x 1.5 A Dia. Max. 7.5 [.30] 10.2 [.40] 14.0 [.55] 19.2 [.76] 24.2 [.95] 30.2 [1.49] 40.2 [1.58] A/F Body A/F Nut 24 [.95] 29 [1.14] 34 [1.34] 38 [1.50] 48 [1.89] 52 [2.05] 67 [2.64] 17 [.67] 22 [.87] 27 [1.06] 30 [1.18] 36 [1.48] 41 [1.61] 55 [2.17] P 10% Unscreened P 52 57 61 74 73 104 144 PS 50 65 77 90 115 140 110 Hole Size PR 43 48 52 65 64 95 135 13.0 [.51] 17.0 [.67] 21.0 [.83] 25.0 [.98] 31.0 [1.22] 37.0 [1.46] 50.0 [1.97] *a = Supplied dimension b = Dimension after free recovery 7-8 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Preinstalled Adhesives S-1030, S-1048, S-1275 (Rayaten) Product Characteristics S-1030 Polyolefin Hot-Melt Adhesive Precoat designation Type Operating temperature range Bonding temperature Minimum shelf life at or below 25C Specification Comments S-1048 HIgh-Performance Hot-Melt Adhesive Precoat designation Type Operating temperature range Bonding temperature Minimum shelf life at or below 25C Specification Comments /180 Polyolefin hot-melt adhesive -80C to 80C [-112F to 176F] 120C [248F] 4 years RK-6017, RT-1050/6 Excellent water blocking and low temperature /86 High-performance hot-melt adhesive -55C to 120C [-67F to 248F] 160C [320F] 4 years RK-6626, RT-1050/3 Good solvent resistance but requires higher temperature to achieve bonding S-1275 Rayaten Conductive Adhesive* (for KTKK assemblies only) Type Electrically conductive polyamide hot-melt adhesives Operating temperature range -40C to 70C [-40F to 158F] 160C [320F] Bonding temperature Minimum shelf life at or below 25C 2 years RK-6637 Specification Comments Conductive adhesive for use with Rayaten parts *Not sold separately. 7 Assemblies Available in: Americas Europe Asia Pacific n n n 7-9 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Kits SESK -- Shipboard Electrical Splice Kits Product Facts n Waterproofing and corrosion proofing n Standard sizes that cover most single-, two-, three-, four-, and multi-conductor cables n Excellent electricalinsulation properties and abrasion protection n Easy installation n Operating temperature range of -55C to +90C [-67F to +194F] n Approved for new ship construction Specifications/Approvals Applications Installation SESK kits provide fast, waterproof repair of single-, two-, three-, four-, and multiconductor cables. Kits are suitable for both permanent and temporary repairs. The self-sealing heat-shrinkable tubing used in each kit provides a watertight seal for the inner insulation and outer jacket. The flameretardant tubing material provides electrical and thermal properties similar to those of most Navy standard cables. Minimum shrink temperature: 121C [250F] Series Military MIL-DTL-23053* SESK USCG CGHQ-3774 U.S. Navy drawing 5001027-19 SST-FR Tubing used to replace cable jacket -- Industry IEEE-383 Massive Flame Vertical Tray Test SST-FR RW-2011 SST-FR -- Agency Lloyd's Register DNV ABS -- SST-FR Raychem -- -- -- Sigmaform FR RW-2011 *Formerly MIL+23053/15A Available in: Americas Europe Asia Pacific n n n 7-10 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Kits SESK -- Shipboard Electrical Splice Kits (Continued) Cable Range (Navy Standard) Approx. AWG Equivalent Single-Conductor Cable SESK S-4 SESK S-16 SESK S-52 SESK S-133 SESK S-300 SESK S-650 S-4-S-10 S-16-S-41 S-52-S-106 S-133-S-250 S-300-S-600 S-650-S-1000 #14-#10 #8-#4 #3-#1/0 #2/0-250 mcm 300 mcm-600 mcm 650 mcm-1000 mcm Two-Conductor Cable SESK D-3 SESK D-4 SESK D-14 SESK D-23 SESK D-50 SESK D-200 SESK D-300 SESK D-400 D-3 D-4-D-10 D-14 D-23-D-41 D-50-D-168 D-200-D-250 D-300-D-350 D-400-D-450 #22-#16 #14-#10 #9 #7-#4 #3-#3/0 #4/0-250 mcm 300 mcm-350 mcm 400 mcm-450 mcm Three-Conductor Cable SESK T-3 SESK T-4 SESK T-14 SESK T-23 SESK T-50 SESK T-200 SESK T-300 SESK T-400 SESK T-500 T-3 T-4-T-10 T-14-T-20 T-23-T-41 T-50-T-168 T-200-T-250 T-300-T-350 T-400-T-450 T-500-T-600 #22-#16 #14-#10 #9-#7 #6-#4 #3/0 #4/0-250 mcm 300 mcm-350 mcm 400 mcm-450 mcm 500 mcm-600 mcm Four-Conductor Cable SESK F-3 SESK F-4 SESK F-23 SESK F-50 SESK F-75 SESK F-150 F-3 F-4-F-9 F-23 F-50 F-75-F-100 F-150-F-200 #22-#16 #14-#10 #6 #3 #1-#1/0 #3/0-#4/0 7 Assemblies Part No. 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 #18-#22 18 SESK M-18 #18-#22 20 SESK M-20 SESK M-22 22 #18-#22 SESK M-24 24 #18-#22 SESK M-26 26 #18-#22 SESK M-28 28 #18-#22 #18-#22 30 SESK M-30 32 #18-#22 SESK M-32 Note: SESK kits are also available for UJIS cables. Contact Tyco Electronics for details. 7-11 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Kits SESK -- Shipboard Electrical Splice Kits (Continued) Part Numbering System SESK-300 C TSGU-300 Example Cable Number Connector Option = C Armor Option = E (if electrical continuity is desired) Both Connector and Armor = CE Kit Part Number 7-12 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Kits Ship or Shore Breakout Kits Product Facts n Heat-shrinkable boot replaces potting or molding n Flame-retardant tubing has a 3:1 shrink ratio n Kit offers resistance to moisture, fungus, and weathering n Operating temperature range of -55C to +90C [-67F to +194F] Applications Waterproof splices for power cables are available in red, white, and black for positive identification of each conductor. Specifications/Approvals Series 2E171-4 Ordering Information Part No. 2E171-4 Military NAVSEA 803-5001027-17 MIL-C-24368 MIL-DTL-23053/15* and MIL-I-81765/1 Installation Minimum shrink temperature: 121C [250F] 7 Assemblies 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 sealing, and phase identification for power cables. Tubing accommodates a large difference between cable diameters. Sigmaform boots can replace tapes, epoxies, and dips. Industry DNV Lloyd's ABS Model 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 Available in: Americas Europe Asia Pacific n n n 7-13 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Assemblies Engineering Notes 7-14 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnect Products Table of Contents 8 Electrical Interconnect Products Note: Users should independently evaluate the suitability of the product for their application. Before ordering, check with Tyco Electronics for most current data. 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 8-1 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnect Products Introduction Tyco Electronics' dependable, economical wire and cable termination products provide solutions for hundreds of wire and cable interconnect requirements. All Raychem wire termination products are housed inside transparent heatshrinkable 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 highreliability joints on the widest variety of conductor types and platings. Typical SolderSleeve Device (illustration of shield terminator concept) Transparent, heat-shrinkable thermoplastic sleeve SolderSleeve technology ensures high-quality electrical and mechanical performance time after time. Premeasured solder and flux create repeatable, reliable 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, strainrelieved, protected solder connection. Heat-shrinkable tubing provides the benefits of insulation, strain relief, and protection for our controlled crimp products. Many Raychem interconnect 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-DTL23053/8 (formerly MIL-DTL23053/8). Raychem interconnect devices combine highstrength 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 sophisticated electronic systems, either sealed or unsealed, and for high- or lowtemperature environments. Thermoplastic sealing ring Optional preinstalled wire lead Fluxed solder preform Typical Installation 1. Insert prepared cable Solder preform melts and flows, Installation quality is fully visible through transparent sleeve 2. Apply heat Sleeve shrinks, conforms to cable contours, and provides strain relief Sealing rings melt to provide environmental protection 8-2 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnect Products Product Selection Application Type Wire-to-wire splicing Terminals and disconnects Wire termination to pin/post/tab Max. Operating Temp. 125C [257F] 150C [302F] Connection Type Solder Solder 125C [257F] Coil and solder 125C [257F] 125C [257F] 150C [302F] Crimp Crimp Crimp 125C [257F] Crimp 150C [302F] 125C [257F] Coil and solder Solder Product Description Series SolderSleeve wire splices SolderSleeve wire splices SolderGrip closed end connector splices (stub) DuraSeal crimp splices PolyCrimp wire splices MiniSeal crimp splices DuraSeal crimp terminals and disconnects SolderGrip terminals SolderSleeve wire terminators CWT-900X D-110, D-1744 Page Number 8-6 8-6 SGRP, SGRS 8-12 D-406 C-203 D-436 (M81824) 8-18 8-20 8-22 B-106 8-27 SGRT CWT-15XX D-129, D-141, D-71X CWT-X S01, S02, M83519, SO63 SO96 CWT-4XXX B-02X, B-04X D-607, B-046 RBD, RTD D-150 D-602 D-621, DK-621 D-621, DK-621 D-621, DK-621 8-33 8-39 150C [302F] Solder SolderSleeve wire terminators 125C [257F] Solder SolderSleeve shield terminators Solder SolderSleeve shield terminators 150C [302F] Solder Solder Solder Solder Solder Solder/Crimp Solder Solder Solder Solder Solder or connectorized Connectorized SolderSleeve shield terminators SolderSleeve coaxial cable terminators SolderSleeve coaxial cable terminators SolderSleeve PCB/coaxial cable terminators RF one-step BNC/TNC connectors SolderShield cable splices SolderTacts shielded contacts Triax discrete connectors Triax discrete connectors Triax discrete connectors In-line data bus microcoupler Data bus box couplers Triaxial size 8 contacts 150C [302F] Solder Data bus cables 150C [302F] Data bus terminators 150C [302F] Data bus accessories 150C [302F] Crimp or solder Solder or connectorized Solder or mechanical Coaxial cable termination Cable-to-cable splicing Shielded contacts Triax connectors MIL-STD-1553 Data bus connectors MIL-STD-1553 In-line couplers MIL-STD-1533 150C [302F] 8-44 8-44 8-44 8-51 8-51 8-53 8-55 8-62 8-67 8-87 8-87 8-87 D-500-04 8-79 D-500-025 8-85 Size 8, triaxial MIL-C-38999 contacts D-602, DK-602 8-94 MIL-STD-1553 B shielded cable MIL-STD-1553 78 Ohms and 3000 Ohms terminators 1061X 8-77 D-621, D-500 8-89 Dust caps, braid terminators, splices D-600,D-150 8-89 8 Electrical Interconnect Products 150C [302F] 175C [347F] 125C [257F] 150C [302F] 150C [302F] 135C [275F] 150C [302F] 150C [302F] 150C [302F] 150C [302F] 150C [302F] Shield termination 8-39 8-3 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnect Products Product Selection (Continued) Application Type Connection Type Max. Operating Temp. Product Description Series Page Number 125C SolderSleeve wire splices CWT-900X 8-6 150C SolderSleeve wire splices D-110, D-1744 8-6 125C DuraSeal crimp splices D-406 8-18 125C PolyCrimp crimp splices C-203 8-20 150C MiniSeal crimp splices D-436 (M81824) 8-22 125C SolderGrip closed end connector splices (stub) SGRP, SGRS 8-12 125C DuraSeal crimp terminals and disconnects B-106 8-27 150C SolderGrip terminals SGRT 8-33 125C SolderSleeve wire terminators CWT-15XX 8-39 150C SolderSleeve wire terminators D-129, D-141, D-71X 8-39 125C SolderSleeve shield terminators CWT-X 8-44 150C SolderSleeve shield terminators S01, S02, M83519, SO63 8-44 175C SolderSleeve shield terminators SO96 8-44 125C SolderSleeve coaxial cable terminators CWT-4XXX 8-51 135C RF one-step BNC/TNC connector RBD, RTD 8-55 B-02X/04X 8-51 SolderSleeve PCB/coaxial cable terminators D-607, B-046 8-53 150C SolderShield cable splices D-150, B-202 8-62 150C SolderTacts shielded contacts D-602 8-67 150C Data bus couplers, connectors, terminators, accessories D-500, D-600, D(K)-621 8-76 Solder Wire-to-Wire Splicing Crimp Coil and Solder Crimp Terminals and Disconnects Wire Termination to pin/post/tab Shield Termination Coax Cable Termination Coil and Solder Solder Solder Solder SolderSleeve coaxial cable terminators 150C Cable-to-Cable Splicing Shielded Contacts MIL-STD-1553B Data Bus Components Solder/Crimp Solder Solder 8-4 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 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 interconnect products, the wire-towire splicing devices are rugged and reliable, yet easy to install. Designed for applications with temperatures up to 150C [302F], products in this section include: n SolderSleeve 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 wire sizes. n n DuraSeal 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. Small, lightweight, and low-profile MiniSeal highperformance crimp splices, which substantially reduce wire bundle size and weight, are QPL-listed to the MIL-S-81824 specification, and are required by the MIL-W5088 specification. n n SolderGrip splices, which are closed-end connectors 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. PolyCrimp 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 provides strain relief and protection against the environment. 8 Electrical Interconnect Products 8-5 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderSleeve Wire Splices Product Facts n Transparent polyvinylidene fluoride or polyolefin sleeve provides encapsulation, inspectability, strain relief, and insulation n Prefluxed solder preform provides a controlled soldering process n One-piece design makes installation easy and lowers the installed cost n With one or two wires per end, the NAS 1744 splices meet 75,000 ft [22,000 m] altitude immersion requirement n Thermochromic temperature indicator in the NAS splices facilitates termination and inspection n UL and CUL recognized R Applications In-line wire splices. Product Options Product Series CWT D-110 D-1744 (NAS 1744) Note: Minimum Wire Temperature Rating 85C [185F] 125C [257F] 125C [257F] From the Product Options table above, select the product series appropriate for your application based on the temperature rating and sealing performance required. If the application has only one size of wire per side 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: n n n n Intended Application Environment Splashproof Splashproof Immersion sealed Cadmium-free option (B-152 series) is available for operating temperature of 125C [257F]. Consult Tyco Electronics for details. Product Selection Process Available in: Americas Europe Asia Pacific Maximum Operating Temperature 125C [257F] 150C [302F] 150C [302F] For CWT series (low temperature): Use Table A on page 8-7. n n For D-110 series (splashproof): Use Table B on page 8-8. For D-1744 series (immersion sealed): Use Table C on page 8-9. If the application has more than one size of wire per side or more than two wires on either side (or if you prefer to work with CMA or mm2 sizes): 1. Turn to "CMA/mm2 Calculation" on page 8-10 and use the workspace 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 diameter 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 having 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. 8-6 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderSleeve Wire Splices (Continued) Table A: CWT Series Selection Side A: Size and Number of Conductors 26 AWG 24 AWG 22 AWG 20 AWG 18 AWG 16 AWG 14 AWG 12 AWG 10 AWG Side B: Size and Number of Conductors 26 AWG 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 24 AWG 1 2 1 2 1 2 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005 CWT-9001 CWT-9002 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005 Side A: 24 AWG 22 AWG 20 AWG 18 AWG 16 AWG Side B: Size and Number of Conductors 12 AWG 10 AWG 18 AWG 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 16 AWG 14 AWG 12 AWG 10 AWG 1 2 1 2 1 2 1 2 1 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 8 Electrical Interconnect Products 14 AWG 20 AWG 2 Size and Number of Conductors 26 AWG 22 AWG 1 8-7 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderSleeve Wire Splices (Continued) Table B: D-110 Series Selection Side A: Size and Number of Conductors 26 AWG 24 AWG 22 AWG 20 AWG 18 AWG 16 AWG 14 AWG 12 AWG 10 AWG Side B: Size and Number of Conductors 26 AWG 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 24 AWG 22 AWG 20 AWG 18 AWG 16 AWG 14 AWG 12 AWG 10 AWG 22 AWG 20 AWG 2 1 2 1 2 1 2 D-110-35 D-110-35 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41 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 D-110-35 D-110-35 D-110-35 D-110-41 D-110-35 D-110-41 D-110-41 D-110-41 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 D-110-35 D-110-35 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41 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 D-110-35 D-110-41 D-110-35 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 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 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 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 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 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-110-0101 D-110-0090 D-110-0083 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181 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-110-0083 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181 D-110-0181 D-110-0181 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-110-0083 Side A: Size and Number of Conductors 26 AWG 24 AWG 1 Side B: Size and Number of Conductors 18 AWG 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 16 AWG 14 AWG 12 AWG 10 AWG 1 2 1 2 1 2 1 2 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 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-110-0083 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0101 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 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181 D-110-0181 D-110-0181 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-110-0083 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0101 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 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0101 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 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 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 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 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 D-110-0090 D-110-0090 D-110-0090 D-110-0090 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-110-0090 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0090 D-110-0090 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-110-0090 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 Fine Wire Splices 26 AWG (0.15 mm2) and Smaller Part No. D-110-0071 D-110-0213 D-110-0214 D-110-0217 D-110-40 As Supplied* 0.9 [0.035] 0.9 [0.035] 0.6 [0.025] 1.0 [0.040] 0.6 [0.025] Inside Diameter Fully Recovered** 0.6 [0.025] 0.6 [0.025] 0.3 [0.013] 0.6 [0.025) 0.5 [0.021] Length*** 4.7 [0.185] 4.2 [0.165] 6.3 [0.250] 9.1 [0.360] 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. 8-8 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderSleeve Wire Splices (Continued) Table C: D-1744 Series Selection Side A: Size and Number of Conductors 26 AWG 24 AWG 22 AWG 20 AWG 18 AWG 16 AWG 14 AWG 12 AWG Side B: Size and Number of Conductors 26 AWG 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 24 AWG 22 AWG 20 AWG 18 AWG 16 AWG 2 1 2 1 2 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 -- D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 -- D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-04 -- D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04 -- 12 AWG Side B: Size and Number of Conductors 16 AWG 14 AWG 12 AWG 1 2 1 2 1 2 1 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 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 D-1744-04 D-1744-04 D-1744-04 D-1744-04 -- -- D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 -- D-1744-04 D-1744-04 D-1744-04 D-1744-04 -- D-1744-04 -- -- -- -- -- -- -- -- -- -- 8 Electrical Interconnect Products 14 AWG 20 AWG 1 18 AWG 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 22 AWG 2 Side A: Size and Number of Conductors 26 AWG 24 AWG 1 8-9 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderSleeve Wire Splices (Continued) CMA/mm2 Calculation To calculate the total circular mil or mm2 area of the conductors to be terminated in a single splice, follow these steps: 1. Choose either CMA or mm2 as 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 mm2 for each conductor that will go into the same splice. (To assist you, Table D on this page provides the CMA of typical conductors.) Wire Number 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. CMA mm2 1 2 3 4 5 Part Number: Total CMA/mm2 Examples One-to-One Wire Splice Multiwire Splice 1.50 [.060] 1.50 [.060] 3.00 [.120] 2.50 [.100] 16 AWG (CMA 2426) [1.21 mm2] Table D. 2.25 [.090] 1.50 [.060] 22 AWG (CMA 754) [0.38 mm2] 2 at 22 AWG (CMA 1508) [0.38 mm2] 18 AWG (CMA 1900) [0.24 mm2] Total CMA = 3180 Total mm2 = 1.59 Total CMA = 3408 Total mm2 = 1.71 Correct part number selection from Table E (based on CMA/mm2 and nominal jacket wire OD) = CWT-9002 or D-110-41 or D-1744-02. Correct part number selection from Table E (based on CMA/mm2 and nominal jacket wire OD) = CWT-9003 or D-110-0181 or D-1744-03. CMA of Typical AWG Conductors AWG CMA mm2 28 177 0.09 26 304 0.15 24 475 0.24 22 754 0.38 20 1216 0.61 18 1900 0.95 16 2426 1.21 14 3831 1.92 12 5874 2.94 8-10 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderSleeve Wire Splices (Continued) Installation Requirements Table E: Multiwire Splice Selection 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: n HL1802E n IR-1759 MiniRay n AA-400 Super Heater n CV-1981 Product Series Refer to Raychem installation 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. Wire Jacket OD Min. Max. 0.4 [0.015] 1.7 [0.066] 1.3 [0.05] 2.7 [0.106] 1.8 [0.07] 4.5 [0.18] 6.0 [0.236] 2.8 [0.11] 3.2 [0.125] 7.0 [0.275] 0.50 [0.020] 1.90 [0.075] 0.80 [0.031] 2.80 [0.110] 1.30 [0.050] 4.57 [0.180] 2.00 [0.080] 7.11 [0.280] 0.51 [0.020] 1.78 [0.070] 1.27 [0.050] 2.54 [1.00] 1.9 [0.075] 4.5 [0.177] 2.41 [0.095] 4.32 [0.17] 3.56 [0.140] 7.11 [0.28] 4.0 [0.160] 8.76 [0.345] CWT-9001 CWT-9002 CWT-9003 CWT-9004 CWT-9005 D-1744-01 D-1744-02 D-1744-03 D-1744-04 D-110-35 D-110-41 D-110-0181 D-110-0101 D-110-0090 D-110-0083 CMA Combined Total Min. Max. 450 1500 1250 3500 2500 7200 6100 19000 12000 25000 350 2000 2000 4000 4000 10000 10000 13000 500 1500 1200 3500 3600 6000 4800 9000 8500 16200 16200 25000 mm2 Combined Total Min. Max. 0.3 1.8 0.8 2.0 2.0 4.0 4.0 6.0 6.0 10.0 - - - - - - - - - - - - - - - - - - - - 8 Product Characteristics Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride Radiation-crosslinked, heat-shrinkable polyolefin Solder: Sn63 Pb37 Flux: ROL1 per ANSI-J-004 (RMA flux) Solder: Sn50 Pb32 Cd18 Flux: ROM1 per ASNS-J-004 (RA flux) Meltable thermoplastic Typical Performance Voltage drop Tensile strength Dielectric strength Temperature rating (CWT) Temperature rating (D-110, D-1744) Insulation resistance 2.0 mV Exceeds strength of conductor 2.0 kV -55C to +125C [-67F to +257F] -55C to +150C [-67F to +302F] 1000 megohms Series CWT D-110 D-1744 Agency UL E87681 UL E87681 NAS-1744 Electrical Interconnect Products Specifications/Approvals Material Insulation (D-110, D-1744) Insulation (CWT) Solder and flux (D-110, D-1744) Solder and flux (CWT) Meltable inserts (CWT, D-1744) Raychem D-5023 RT-1404 RT-1404 8-11 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderGrip Closed End Connector Splices Product Facts n Soldered connection Electrical insulation n Sealed for immersion (SGRS) n Excellent strain relief n Simple installation n 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 controlledsoldering technology provides dependable electrical termination of multiple wire combinations. SolderGrip terminators consist of a heat-shrinkable thermoplastic sleeve containing a spiral-wound copper 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 hightemperature insulation. The termination is environmentally protected and strain relieved. SolderGrip splice terminators are color-coded for easy identification. Product Options Available in: Americas Europe Asia Pacific n n n Product Series SGRP SGRS Environmental Protection Splashproof Sealed Max. Operating Temp. 125C [257F] 125C [257F] 8-12 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderGrip Closed End Connector Splices (Continued) 1. From the Product Options table on the previous page, select the product series appropriate for your application. Product Selection Process Example: For connecting a bundle with one 12 AWG wire (1 #12) and two 14 AWG wires (+2 #14), you need an SGRP3 connector. For sealed parts, select the SGRS series. 2. Determine the wire combination (number of wires and size) of the wire bundle you wish to splice. 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. *If the wire combination is not listed in Table C, use the CMA (mm2) method of determining wire bundle size (see "CMA/ mm2 Calculation" on page 8-14). Using Table B (page 8-14, select the smallest size connector that will fit your total wire CMA (mm2) value. 3. Use Table C (page 8-15) to select the correct connector for AWG wire combinations.* For mm2 wire combinations use Table A to select a SolderGrip part number. 5. Verify that the total amperage to be applied does not exceed the maximum amp rating for the part. Insulated and Sealed Closed-End Connectors (SGRS series) Insulated Closed-End Connectors (SGRP series) L L OA OA Sealing insert Table A - Product Dimensions and Part Number Descriptions Color Code SGRP-1 Green SGRP-2 Red SGRP-3 Blue SGRP-4 Yellow Product Dimensions (Min.) Wire Range (Min.-Max.) OA CMA/mm2 1.370 .120 1400 - 4800 [34.8] [2.9] [0.7 - 2.4] 1.350 .150 4000 - 8000 [34.2] [3.7] [2.0 - 4.0] 1.610 .200 7000 - 18000 [3.5 - 8.0] [5.1] [41.0] 1.650 .270 15000 - 30000 [42.0] [6.8] [7.5 - 12.0] L Part No. Color Code SGRS-1 Green SGRS-2 Red SGRS-3 Blue SGRS-4 Yellow L 1.370 [34.8] 1.350 [34.2] 1.650 [42.0] 1.630 [41.5] Product Dimensions (Min.) Wire Range (Min.-Max.) OA CMA/mm2 0.130 1400 - 4800 [3.4] [0.7 - 2.4] 0.190 4000 - 8000 [4.8] [2.0 - 4.0] 0.290 7000 - 16000 [7.3] [3.5 - 8.0] 0.360 15000 - 24000 [9.1] [7.5 - 12.0] 8 Electrical Interconnect Products Part No. 8-13 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderGrip Closed End Connector Splices (Continued) CMA/mm2 Calculation To calculate the total circular mil or mm area of the wire bundle to be terminated, follow these steps: 2 1. Choose either CMA or mm2 as your unit of measure for selection purposes and continue to use it for all your selection criteria. (Both measures provide the same results.) Wire Number 2. In the workspace below, list the CMA or mm2 for each conductor in the bundle. (Table B provides the CMA of typical conductors.) 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). CMA mm2 1 2 3 4 5 6 7 8 9 10 Solder Grip Part No. Total CMA/mm2 Example OD Bundle 22 AWG/.38 CMA 754 Insulation 22 AWG/.38 CMA 754 18 AWG/.95 CMA 1900 Conductor 16 AWG/1.21 CMA 2426 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 mm2 of 2.92): SGRP-2or SGRS-2 Table B. CMA of Typical Copper Conductors AWG CMA mm2 30 112 0.05 28 177 0.09 26 304 0.15 24 475 0.24 22 754 0.38 20 1216 0.61 18 1900 0.95 16 2426 1.21 14 3831 1.92 12 5874 2.94 10 9354 4.74 8 16983 8.61 8-14 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderGrip Closed End Connector Splices (Continued) Table C. SolderGrip Wire Combinations Splashproof SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-4 SGRP-4 SGRP-4 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-4 SGRP-4 SGRP-4 SGRP-3 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-4 SGRP-3 Sealed SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-4 SGRS-4 SGRS-4 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-4 SGRS-4 SGRS-4 SGRS-3 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-4 SGRS-3 Wire Combinations 1 # 14 + 3 # 20 1 # 14 + 4 # 20 1 # 14 + 1 # 18 1 # 14 + 1 # 18 + 1 # 20 1 # 14 + 2 # 18 1 # 14 + 3 # 18 1 # 14 + 4 # 18 1 # 14 + 5 # 18 1 # 14 + 1 # 16 1 # 14 + 1 # 16 + 1 # 20 1 # 14 + 1 # 16 + 1 # 18 1 # 14 + 1 # 16 + 2 # 18 1 # 14 + 1 # 16 + 3 # 18 1 # 14 + 1 # 16 + 4 # 18 1 # 14 + 2 # 16 1 # 14 + 2 # 16 + 1 # 18 1 # 14 + 2 # 16 + 2 # 18 1 # 14 + 2 # 16 + 3 # 18 1 # 14 + 3 # 16 1 # 14 + 3 # 16 + 1 # 18 1 # 14 + 3 # 16 + 2 # 18 1 # 14 + 4 # 16 1 # 14 + 4 # 16 + 1 # 18 1 # 14 + 5 # 16 2 # 14 2 # 14 + 1 # 16 2 # 14 + 1 # 16 2 # 14 + 1 # 16 2 # 14 + 1 # 16 2 # 14 + 2 # 16 2 # 14 + 2 # 16 2 # 14 + 3 # 16 2 # 14 + 4 # 16 3 # 14 3 # 14 + 1 # 16 3 # 14 + 2 # 16 3 # 14 + 3 # 16 4 # 14 Splashproof SGRP-2 SGRP-3 SGRP-2 SGRP-2 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-2 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-4 SGRP-3 SGRP-3 SGRP-4 SGRP-4 SGRP-3 Sealed SGRS-2 SGRS-3 SGRS-2 SGRS-2 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-4 SGRS-3 SGRS-3 SGRS-4 SGRS-4 SGRS-3 Wire Combinations 2 # 16 + 1 # 18 + 3 # 20 2 # 16 + 1 # 18 + 2 # 20 2 # 16 + 1 # 18 + 1 # 20 2 # 16 + 1 # 18 2 # 16 + 4 # 20 2 # 16 + 3 # 20 2 # 16 + 2 # 20 2 # 16 + 1 # 20 2 # 16 1 # 16 + 5 # 18 1 # 16 + 4 # 18 + 1 # 20 1 # 16 + 4 # 18 1 # 16 + 3 # 18 + 2 # 20 1 # 16 + 3 # 18 + 1 # 20 1 # 16 + 2 # 18 + 3 # 20 1 # 16 + 2 # 18 + 1 # 20 1 # 16 + 2 # 18 1 # 16 + 1 # 18 + 4 # 20 1 # 16 + 1 # 18 + 3 # 20 1 # 16 + 1 # 18 + 2 # 20 1 # 16 + 1 # 18 + 1 # 20 1 # 16 + 1 # 18 1 # 16 + 4 # 20 1 # 16 + 3 # 20 1 # 16 + 1 # 20 + 1 # 22 1 # 16 + 1 # 20 1 # 16 + 3 # 22 1 # 16 + 2 # 22 1 # 16 + 1 # 22 1 # 18 + 1 # 22 1 # 18 + 2 # 22 1 # 18 + 3 # 22 1 # 18 + 1 # 20 1 # 18 + 1 # 20 + 1 # 22 1 # 18 + 1 # 20 + 2 # 22 1 # 18 + 2 # 20 1 # 18 + 3 # 20 1 # 18 + 4 # 20 Splashproof SGRP-3 SGRP-3 SGRP-2 SGRP-2 SGRP-3 SGRP-3 SGRP-2 SGRP-2 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-2 SGRP-2 SGRP-3 SGRP-2 SGRP-2 SGRP-2 SGRP-1 SGRP-2 SGRP-2 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-2 SGRP-2 Sealed SGRS-3 SGRS-3 SGRS-2 SGRS-2 SGRS-3 SGRS-3 SGRS-2 SGRS-2 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-2 SGRS-2 SGRS-3 SGRS-2 SGRS-2 SGRS-2 SGRS-1 SGRS-2 SGRS-2 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-2 SGRS-2 8 Electrical Interconnect Products Wire Combinations 1 # 8 + 1 # 12 1 # 8 + 1 # 16 2 # 8 + 2 # 16 1 # 8 + 1 # 14 1 # 8 + 1 # 14 + 1 # 16 1 # 10 + 1 # 18 1 # 10 + 2 # 18 1 # 10 + 3 # 18 1 # 10 + 1 # 16 1 # 10 + 1 # 16 + 1 # 18 1 # 10 + 1 # 16 + 2 # 18 1 # 10 + 2 # 16 1 # 10 + 3 # 16 1 # 10 + 4 # 16 1 # 10 + 5 # 16 1 # 10 + 1 # 14 1 # 10 + 1 # 14 + 1 # 18 1 # 10 + 1 # 14 + 1 # 16 1 # 10 + 1 # 14 + 2 # 16 1 # 10 + 1 # 14 + 3 # 16 1 # 10 + 2 # 14 1 # 10 + 3 # 14 1 # 10 + 1 # 12 1 # 10 + 1 # 12 + 1 # 14 1 # 10 + 2 # 12 2 # 10 2 # 10 + 1 # 16 1 # 12 + 1 # 18 1 # 12 + 2 # 18 1 # 12 + 3 # 18 1 # 12 + 4 # 18 1 # 12 + 5 # 18 1 # 12 + 1 # 16 1 # 12 + 1 # 16 + 1 # 18 1 # 12 + 1 # 16 + 2 # 18 1 # 12 + 1 # 16 + 3 # 18 1 # 12 + 1 # 16 + 4 # 18 1 # 12 + 2 # 16 8-15 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderGrip Closed End Connector Splices (Continued) Table C. SolderGrip Wire Combinations (Continued) Wire Combinations 1 # 12 + 2 # 16 + 1 # 18 1 # 12 + 2 # 16 + 2 # 18 1 # 12 + 3 # 16 1 # 12 + 4 # 16 1 # 12 + 5 # 16 1 # 12 + 1 # 14 + 1 # 18 1 # 12 + 1 # 14 + 2 # 18 1 # 12 + 1 # 14 + 3 # 18 1 # 12 + 1 # 14 + 1 # 16 1 # 12 + 1 # 14 + 2 # 16 1 # 12 + 1 # 14 + 3 # 16 1 # 12 + 1 # 14 + 4 # 16 1 # 12 + 2 # 14 1 # 12 + 2 # 14 + 1 # 18 1 # 12 + 2 # 14 + 1 # 16 1 # 12 + 2 # 14 + 2 # 16 1 # 12 + 2 # 14 + 3 # 16 1 # 12 + 3 # 14 1 # 12 + 3 # 14 + 1 # 16 1 # 12 + 4 # 14 2 # 12 2 # 12 + 1 # 18 2 # 12 + 1 # 18 2 # 12 + 1 # 16 2 # 12 + 2 # 16 + 1 # 18 2 # 12 + 3 # 16 2 # 12 + 1 # 14 + 1 # 18 2 # 12 + 1 # 14 + 1 # 16 3 # 12 + 1 # 14 2 # 12 + 2 # 14 3 # 12 + 1 # 18 3 # 12 + 1 # 16 1 # 14 + 1 # 22 1 # 14 + 1 # 20 1 # 14 + 2 # 20 Splashproof SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-4 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-4 SGRP-4 SGRP-3 SGRP-3 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-3 SGRP-3 SGRP-3 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-1 SGRP-2 SGRP-2 Sealed SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-4 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-4 SGRS-4 SGRS-3 SGRS-3 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-3 SGRS-3 SGRS-3 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-1 SGRS-2 SGRS-2 Wire Combinations 4 # 14 + 1 # 16 4 # 14 + 2 # 16 5 # 14 5 # 14 + 1 # 16 1 # 16 + 3 # 18 1 # 16 + 2 # 18 + 2 # 20 1 # 16 + 5 # 20 1 # 16 + 2 # 20 6 # 16 5 # 16 + 1 # 18 5 # 16 + 1 # 20 5 # 16 4 # 16 + 2 # 18 4 # 16 + 1 # 18 + 1 # 20 4 # 16 + 1 # 18 4 # 16 + 2 # 20 4 # 16 + 1 # 20 4 # 16 3 # 16 + 3 # 18 3 # 16 + 2 # 18 + 1 # 20 3 # 16 + 2 # 18 3 # 16 + 1 # 18 + 2 # 20 3 # 16 + 1 # 18 + 1 # 20 3 # 16 + 1 # 18 3 # 16 + 3 # 20 3 # 16 + 2 # 20 3 # 16 + 1 # 20 3 # 16 2 # 16 + 4 # 18 2 # 16 + 3 # 18 + 1 # 20 2 # 16 + 3 # 18 2 # 16 + 2 # 18 + 2 # 20 2 # 16 + 2 # 18 + 1 # 20 2 # 16 + 2 # 18 -- Splashproof SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-3 SGRP-3 SGRP-3 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 -- Sealed SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-3 SGRS-3 SGRS-3 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 -- Wire Combinations 1 # 18 + 5 # 20 2 # 18 2 # 18 + 1 # 22 2 # 18 + 1 # 20 2 # 18 + 2 # 20 2 # 18 + 3 # 20 2 # 18 + 4 # 20 3 # 18 3 # 18 + 1 # 20 3 # 18 + 2 # 20 3 # 18 + 3 # 20 4 # 18 4 # 18 + 1 # 20 4 # 18 + 2 # 20 5 # 18 5 # 18 + 1 # 20 6 # 18 1 # 20 + 1 # 22 1 # 20 + 2 # 22 1 # 20 + 3 # 22 1 # 20 + 4 # 22 2 # 20 2 # 20 + 1 # 22 2 # 20 + 2 # 22 2 # 20 + 3 # 22 3 # 20 3 # 20 + 1 # 22 4 # 20 5 # 20 6 # 20 3 # 22 4 # 22 5 # 22 6 # 22 -- Splashproof SGRP-2 SGRP-1 SGRP-1 SGRP-2 SGRP-2 SGRP-2 SGRP-3 SGRP-2 SGRP-2 SGRP-3 SGRP-3 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-2 SGRP-2 SGRP-2 SGRP-1 SGRP-1 SGRP-1 SGRP-1 -- Sealed SGRS-2 SGRS-1 SGRS-1 SGRS-2 SGRS-2 SGRS-2 SGRS-3 SGRS-2 SGRS-2 SGRS-3 SGRS-3 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-2 SGRS-2 SGRS-2 SGRS-1 SGRS-1 SGRS-1 SGRS-1 -- 8-16 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderGrip Closed End Connector Splices (Continued) Product Characteristics Material Insulation Solder preform with flux Sealing insert (SGRS) Spiral wound insert Radiation-crosslinked, transparent heat-shrinkable polyvinylidene fluoride Sn 60, Pb 40, ROM1 flux per ANSI-J-STD-004 (RA flux). Hot melt adhesive Copper alloy Physical Dimensions Unit inches Method of test RB-109 Requirement See product dimensions. Electromechanical Dielectric withstand voltage Static heating Unit kilovolts degrees Method of test RB-109 RB-109 Typical values 2.0 Less than 50C rise Environmental* Insulation resistance after water immersion (SGRS only) Contact resistance after testing Unit megohms milliohms Method of test RB-109 RB-109 Requirement 100 Less than 6 milliohms Operating condition Temperature rating Voltage rating Unit -- volts Method of test -- -- Value -55C to 125C [-67F to 257F] 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. Approvals and Reference Documents Agency Approvals Reference documents UL, CUL E87681 Raychem Specification RB-109 for splices Specification Control Drawings Splices--Non Sealed (SGRP-X), Splices--Sealed (SGRS-X) 8 The SolderGrip product is pushed onto the conductors with a twisting motion. With the product in place, installation can be completed with the proper selection and use of heating tools and reflectors. Either of the following Raychem heating tools is recommended: n HL1802E n CV-1981 Electrical Interconnect Products Installation Refer to Raychem installation procedure RPIP 820-00 for detailed instructions and recommended reflector attachments. You will find ordering information for these tools in Section 10. 8-17 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing DuraSeal Heat-Shrinkable, Environmentally Sealed, Nylon-Insulated Crimp Splices Product Facts n Protects splices from water, condensation, salt, and corrosion n Provides strain relief n Protects against vibration in rugged environments n Completely insulates and protects electrical connections n Has adhesive lining for protection that is more reliable than conventional splices n UL, CUL, and Lloyd's listed R Applications n n n Automotive/truck wiring repair and maintenance. n Marine electronics. n Fleet maintenance. Automotive accessory installations. n OEM automotive/truck/RV wire harness fabrication. n Commercial wiring (pumps/pools/spas). Appliances. Specifications/Approvals Series D-406 -- Agency UL and CUL listed 91J4, File E87681 Lloyd's listed, File 65 247 HH 02-93 Raychem RB-107 -- L Product Dimensions Butt Splices OA min. Part No. Available in: Americas Europe Asia Pacific n n n D-406-0001 D-406-0002 D-406-0003 Butt Splice Dimensions A L Min. Nom. 3.68 [.145] 31.75 [1.25] 4.57 [.180] 31.75 [1.25] 6.35 [.250] 38.10 [1.50] Color Conductor Red Blue Yellow 22-18 16-14 12-10 Wire Dimensions Insulation Insulation O.D. (Max.) O.D. (Min.) 3.56 [.140] 1.40 [.055] 4.45 [.175] 2.03 [.080] 6.22 [.245] 2.79 [.110] 8-18 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing DuraSeal Heat-Shrinkable, Environmentally Sealed, Nylon-Insulated Crimp Splices (Continued) Product Selection Process 1. Determine wire size. 2. Select part number. Product Characteristics (Typical) Wire Size AWG 22-18 16-14 12-10 Operating temperature Shrink ratio Physical properties Chemical properties Electrical properties mm2 Part No. Color 0.38-0.95 1.2-2.5 3-6 D-406-0001 D-406-0002 D-406-0003 Red Blue Yellow -55C to 125C [-67F to 257F] 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 160C [320F] Solvent resistance: isopropyl alcohol, trichloroethylene, gasoline, battery acid, diesel fuel, motor oil, antifreeze, brake fluid, 5% salt water Dielectric strength: 2500 Vac Insulation resistance: 1000 megohms at 100 Vdc Installation Requirements Installation For proper installation of these devices, the correct crimp tool and a heating tool with a reflector attachment must be used. The Raychem AD-1522 crimp tool and HL1802E heating tool are recommended. 1. Select splice of appropriate size. Strip wire 7.5 mm (5/16 in). Insert into crimp barrel. You will find ordering information for these tools in Section 10. Refer to Raychem installation procedure RPIP 821-00 for detailed instructions. 2. Crimp using Raychem AD-1522 crimp tool for preinsulated crimps. 8 Electrical Interconnect Products 3. Heat crimped splice with heat gun until tubing recovers and adhesive flows. 8-19 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing PolyCrimp Heat-Shrinkable Polyethylene Crimp Splices Product Facts n One-piece product reduces inventory management n Translucent tubing allows visual inspection n Color coded for easy selection of correct AWG n Dual wall polyethylene tubing provides strain relief and protection against environment Applications n Alarms. n Marine electronics. n Mass transit signal wire. n Telecom aerial splices. n n n Traffic light junction boxes. Commercial wiring (pumps). Heavy industrial environments. Specifications/Approvals Series C203 Raychem D5203 Product Dimensions Butt Splices LL min. dia. AOA min. Part No. Available in: Americas Europe Asia Pacific n n n C-203-01 C-203-02 C-203-03 Butt Splice Dimensions A L Min. Nom. 3.68 [.145] 31.75 [1.25] 4.57 [.180] 31.75 [1.25] 6.35 [.250] 38.10 [1.50] Color Conductor Red Blue Yellow 22-18 16-14 12-10 Wire Dimensions Insulation Insulation O.D. (Max.) O.D. (Min.) 3.56 [.140] 1.40 [.055] 4.45 [.175] 2.03 [.080] 6.22 [.245] -- 8-20 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing PolyCrimp Heat-Shrinkable Polyethylene Crimp Splices (Continued) Product Selection Process 1. Determine wire size. 2. Select part number. Product Characteristics (Typical) Wire Size AWG 22-18 16-14 12-10 mm2 Part No. Color 0.38-0.95 1.2-2.5 3-6 C-203-01 C-203-02 C-203-03 Red Blue Yellow Operating temperature Shrink ratio -55C to 125C [-67F to 257F] Approximately 2:1 Physical properties 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. Dielectric strength: 2500 Vac Insulation resistance: 1000 megohms at 100 Vdc Voltage rating: 600 Volts max. Electrical properties 8 Electrical Interconnect Products 8-21 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing MiniSeal High-Performance, Immersion-Resistant Crimp Splices Product Facts n Immersion-resistant crimp splices are on QPL for MIL-S-81824 n MIL-Spec approval n Small size n Light weight n Insulation and strain relief n Easy installation Applications Product Selection Process MiniSeal wire-to-wire splicing products offer solutions for hundreds of aerospace and defense applications. These environment-resistant splices provide excellent reliability, long term performance, MIL-S-81824/1 qualification, and a low installed cost. 1. Determine the type of splice required. MiniSeal crimp splices consist of a plated copper crimp barrel and a separate, heat-shrinkable, transparent sealing sleeve. They can be used on a combination of wires, from 1:1 to 10:10. MiniSeal splices are one of the smallest, lightest, and most environmentresistant splices available. They preserve the electrical integrity of the splice by preventing the penetration of liquids and the resulting chemical and galvanic corrosion. n Stub (parallel) splice: 2 2 n Butt (in-line) splice: 2. Determine which crimp barrel plating is required: n n Tin plating, recommended for tin or silverplated wire Nickel plating, recommended for nickel-plated wire, or silver-plated wire in applications above 150C [302F]. 3. Calculate the size of crimp barrel required. Using the CMA/mm2 worksheet on the next page, calculate the total cross section to be spliced by adding the circular mil area (CMA) or square millimeters (mm ) of each wire. 2 Stub splice: Add the CMA or mm of all wires together. 2 Butt splice: Calculate each side separately (see example on the worksheet). Available in: Americas Europe Asia Pacific Table A provides the CMA of typical conductors. (Both CMA and mm give the same results, so choose either CMA or mm as your unit of measure for selection purposes and continue to use it for all your selection criteria.) n n n 4. Select the color code for the size crimp barrel required. Using Table B (page 8-23), select the crimp barrel--colorcoded red, blue, or yellow--for the CMA or mm you calculated. 2 Stub splice: Select the barrel that will accommodate the total cross section. Butt splice: Select the smallest barrel that will accommodate the largest CMA/mm2 required. (Refer to the example in the worksheet for a more specific description.) If the CMA/mm2 of the smaller side of a butt splice is too small for the size barrel required to fit the larger side, increase the CMA/mm2 --either by doubling back one wire (stripping the conductor twice the length you would ordinarily strip it and then folding it back) or by adding a filler wire. 5. Determine the type of sealing sleeve required. Some wire insulations will not fit in the holes of the sealing sleeve inserts, so be sure to compare the internal diameter of each hole with the outer diameter of the wire(s) you intend to insert in that hole. To create a reliable seal, place a maximum of two wires in any hole of the sealing sleeve. 6. Select the part number. Turn to the MiniSeal part number selection tables (Tables C and D, page 8-23 and 8-24) and find the table for the type of splice (stub or butt) required. Using the appropriate table, find the crimp barrel size range and the size and number of wires for your application. Then select the part number for the type of plating required. The color code accompanying that part number should match the color code you arrived at in Table B, confirming that the part number you have selected is correct. 8-22 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued) Table A. CMA of Typical Conductors Strands AWG CMA mm2 Table B. Crimp Barrel Color Code Selection CMA Range 304-1510 779-2680 1900-6755 7 28 177 0.09 19 26 304 0.15 19 24 475 0.24 19 22 754 0.38 19 20 1216 0.61 mm2 Range 0.15-0.75 0.39-1.34 0.95-3.37 19 18 1900 0.95 19 16 2426 1.21 1:1 Splice (AWG Size) 26-20 20-16 18-12 19 14 3831 1.92 37 12 5874 2.94 Color Code Red Blue Yellow Example: CMA/mm2 Worksheet The other side, where the CMA for AWG 18 is 1900, is calculated as: Application: A butt splice with three AWG 22 wires in one side and one AWG 18 wire in the other side: The CMA for AWG 22 wire in Table A is 754 (0.38 mm2). Side one is therefore calculated as follows: CMA = 3 x 754 = 2262 (mm2 = 3 x 0.38 = 1.14) Wire Number 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. CMA mm2 1 2 3 4 5 6 8 7 8 10 Electrical Interconnect Products 9 Part Number: Total Table C. Stub (Parallel) Splices Part No. Illustration Crimp Barrel Size Range CMA [mm2] Min.-Max. I.D.dimensions Side 1 Sealing Insert Tin Plated Nickel Plated D-436-0128 Red D-436-0119 Red 304-1510 [0.15-0.75] 2.16 [.085] D-436-58 Blue D-436-75 Blue 779-2680 [0.39-1.34] 4.56 [.180] D-436-59 Yellow D-436-76 Yellow 1900--6755 [0.95-3.37] 4.56 [.180] D-436-60 Blue D-436-77 Blue 779-2680 [0.39-1.34] D-436-61 Yellow D-436-78 Yellow 1900-6755 [0.95-3.37] 2.03 [.080] 2.03 [.080] Side 2 Max. No. of Wires 2 2 Sealing Insert 1.01 [.040] 2.28 [.090] 2 Max. No. of Wires 2 2 2 2.28 [.090] 10 (2 per hole) 10 (2 per hole) 2 6.35 [.250] 2 6.35 [.250] 8-23 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued) Table D. Butt (in-line) splices Part No. Illustration Tin Plated Nickel Plated Crimp Barrel Size Range CMA [mm2] Min.-Max. I.D.dimensions Side 1 Side 2 Sealing Insert Max. No. of Wires D-436-36* Red D-436-82 Red 304-1510 [0.15-0.75] 2.16 [.085] D-436-37* Blue D-436-83 Blue 779-2680 [0.39-1.34] 2.79 [.110] D-436-38* Yellow D-436-84 Yellow 1900-6755 [0.95-3.37] 4.32 [.170] D-436-0110 Red D-436-85 Red 304-1510 [0.15-0.75] D-436-52 Blue D-436-86 Blue 779-2680 [0.39-1.34] D-436-53 Yellow D-436-87 Yellow 1900-6755 [0.95-3.37] D-436-0115 Red D-436-88 Red 304-1510 [0.15-0.75] D-436-42 Blue D-436-89 Blue 779-2680 [0.39-1.34] D-436-43 Yellow D-436-90 Yellow 1900-6755 [0.95-3.37] 2 2 Sealing Insert 2.16 [.085] 2.79 [.110] 2 Max. No. of Wires 2 2 2 4.32 [.170] 6 2.36 [.093] 2 4.06 [.160] 2 2.36 [.093] 6 (2 per hole) 4.06 [.160] 2.36 [.093] 6 (2 per hole) 4.06 [.160] 2.36 [.093] 6 (2 per hole) 2.36 [.093] 6 (2 per hole) 2.36 [.093] 6 (2 per hole) 2.36 [.093] 6 (2 per hole) 2.36 [.093] 6 (2 per hole) 2.36 [.093] 6 (2 per hole) 2 *Qualified to MIL-S-81824/1. Table E. Crimp Barrel Only Type Butt (in-line) Butt (in-line) Butt (in-line) Stub (Parrel) Stub (Parrel) Stub (Parrel) Color Code Red Blue Yellow Red Blue Yellow Tin-Plated D-609-06 D-609-07 D-609-08 D-609-03 D-609-04 D-609-05 Nickel Plated D-609-09 D-609-10 D-609-11 D-609-12 D-609-13 D-609-14 Crimp Barrel Size Range CMA [mm2] Min. - Max. 304-1510 [0.15-0.75] 779-2680 [0.39-1.34] 1900-6755 [0.95-3.37] 304-1510 [0.15-0.75] 779-2680 [0.39-1.34] 1900-6755 [0.95-3.37] Table F. Sealing Sleeve Only L max. A min. L Max. 29.2 [1.15] 29.2 [1.15] 29.2 [1.15] Part No. D-436-0096 D-436-0097 D-436-0098 Color Code Red Blue Yellow Catalog 1654025 Revised 12-04 Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. A Min. 2.16 [0.085] 2.8 [0.110] 4.32 [0.170] 8-24 www.tycoelectronics.com Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued) Product Characteristics Specifications/Approvals Installation Material Insulation Crimp barrel Meltable inserts Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride Tin- or nickel-plated copper Meltable thermoplastic Typical Performance Voltage drop Tensile strength Dielectric strength Temperature rating Insulation resistance 6.9 mV at 4.5 A vs 8.1 mV for an equal length of wire Exceeds strength of conductor 2.5 kV -55C to 150C [-67F to 302F] 5000 megohms Military MIL-S-81824/1 for D-436-36/37/38 Series D-436 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: n HL1802E n AA-400 Super Heater You will find ordering information for these tools in Section 10. Refer to Raychem installation procedure RCPS 20020 for detailed instructions and recommended reflector attachments. 8 Electrical Interconnect Products 8-25 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects Introduction Raychem insulated electrical terminal products provide reliable, repeatable, and rugged examples of terminals available. We start on the front end with terminal sizes and configurations that meet or exceed industry 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: n DuraSeal heat-shrinkable nylon crimp products, which protect against water, condensation, salt, and corrosion. Their tough, heat-shrinkable nylon tubing resists abrasion and cut-through 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 accommodate a wide range of wire sizes and are colorcoded for easy identification, yet are transparent for visual inspection of the finished splice. n SolderGrip heat-shrinkable twist-on products, which utilize 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 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 SolderGrip technology is a reliable means of terminating 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 successfully demonstrated using this product. DuraSeal product delivers protected electrical joints on industry standard terminals and is suitable for harsh environments. 8-26 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects DuraSeal Heat-Shrinkable Environmentally Sealed, Nylon Insulated Crimp Terminals and Disconnects Product Facts n Resistance to moisture and abrasion n Strain relief n Protection from wire pull-out n Easy installation n UL and CUL listed R Applications DuraSeal products insulate and protect electrical connections from mechanical abuse, wire pull-out, and abrasion while resisting water, salt, and other contaminants. Approvals and Reference Documents Agency approvals Reference documents Available in: Americas Europe Asia Pacific 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. 8 Electrical Interconnect Products DuraSeal devices provide a tough, environmentally sealed wire connection. Their crimp barrel or terminal, 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 impactresistance long after similar products have become brittle. UL listed component, file E87681, terminals except quick connect terminals; file E157833, quick connect terminals Raychem specifications RB-108, Specification DuraSeal crimp terminals DuraSeal selection guide (H54153) DuraSeal installation guidelines (H54154) n n n 8-27 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects DuraSeal Heat-Shrinkable Environmentally Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued) Product Characteristics Physical Electrical Chemical Environmental (Fluid) Operating conditions Property Dimensions Tensile strength Unit Inches Pounds Requirement None 8 to 40 lbs depending on AWG Method of Test See product dimensions UL486C, IEC512-8 Property Voltage drop Insulation resistance Dielectric withstand voltage Unit Millivolts Megohms Kilovolts Typical value Less than equal length of wire 103 min. 2.5 Method of Test MIL-S-81824, IEC512-2 MIL-STD-202 method 302 MIL-STD-202F method 301, IEC512-2 Property Diesel fuel Brake fluid Antifreeze 5% salt water Motor oil Humidity Immersion Vibration Bending Thermal shock Heat aging (168h @ 85C [185F) Salt spray Temperature rating Minimum shrink temperature Voltage rating Unit Requirement Method of Test ASTM D 3032, ESA-603D -- Meet electrical test listed above after conditioning. -- Meet electrical test listed above after conditioning. -- -55C to +125C [-67F to -257F] 180C [356F] 600 Volt max MIL-STD-202F method 106, IEC68-2-30 MIL-STD-202F condition C, IEC68-2-14 test NC MIL-STD-202F method 201, IEC68-2-6 UL486C, IEC512-8 MIL-STD-202F method 107, IEC68-2-14 test N MIL-STD-202F, IEC68-2-2 MIL-STD-202F method 101, IEC68-2-11 None None None Fork Terminals L max. OA min. OB nom. C nom. Fork Terminal Dimensions Part No. B-106-2401 B-106-2402 B-106-2403 B-106-2502 B-106-2503 A Min. 3.81 4.57 6.35 4.57 6.35 Stud Size [.15] [.18] [.25] [.18] [.25] Metric M4 M4 M4 M5 M5 C Nom. Imperial 8 8 8 10 10 7.87 [.31] 7.87 [.31] 7.87 [.31] 9.91 [.39] 9.91 [.39] L Max. 32.00 35.05 38.10 35.05 40.15 [1.26] [1.38] [1.50] [1.38] [1.58] Color Insulation Conductor (AWG) Red Blue Yellow Blue Yellow 22-18 16-14 12-10 16-14 12-10 Wire Dimensions Insulation O.D. O.D. (Min.) (Max.) 3.81 4.45 6.35 4.45 6.35 [.150] [.175] [.250] [.175] [.250] 1.40 2.00 2.79 2.00 2.79 [.055] [.080] [.110] [.080] [.110] 8-28 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects DuraSeal Heat-Shrinkable Environmentally Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued) Ring Terminals L max. OA min. Part No. B-106-1401 B-106-1501 B-106-1601 B-106-1801 B-106-1991 B-106-1402 B-106-1502 B-106-1602 B-106-1802 B-106-1992 B-106-1403 B-106-1503 B-106-1603 B-106-1803 B-106-1993 A Min. 3.81 3.81 3.81 3.81 3.81 4.57 4.57 4.57 4.57 4.57 6.35 6.35 6.35 6.35 6.35 [.15] [.15] [.15] [.15] [.15] [.18] [.18] [.18] [.18] [.18] [.25] [.25] [.25] [.25] [.25] Fork Terminal Dimensions Stud C Size Nom. Metric Imperial M4 8 7.88 [.31] M5 10 9.91 [.39] M6 1/4 11.94 [.47] M8 5/16 13.97 [.55] M10 3/8 17.78 [.70] M4 8 7.88 [.31] M5 10 9.91 [.39] M6 1/4 11.94 [.47] M8 5/16 13.97 [.55] M10 3/8 17.78 [.70] M4 8 7.88 [.31] M5 10 9.91 [.39] M6 1/4 11.94 [.47] M8 5/16 13.97 [.55] M10 3/8 17.78 [.70] B nom. L Max. 32.00 34.04 36.07 39.12 43.18 33.02 35.05 36.58 40.13 43.94 38.10 40.13 41.66 45.21 46.99 [1.26] [1.34] [1.42] [1.54] [1.70] [1.30] [1.38] [1.44] [1.58] [1.73] [1.50] [1.58] [1.64] [1.78] [1.85] Color Red Red Red Red Red Blue Blue Blue Blue Blue Yellow Yellow Yellow Yellow Yellow OC nom. Wire Dimensions Insulation Insulation Conductor O.D. (AWG) (Max.) 22-18 22-18 22-18 22-18 22-18 16-14 16-14 16-14 16-14 16-14 12-10 12-10 12-10 12-10 12-10 3.81 3.81 3.81 3.81 3.81 4.45 4.45 4.45 4.45 4.45 6.35 6.35 6.35 6.35 6.35 [.150] [.150] [.150] [.150] [.150] [.175] [.175] [.175] [.175] [.175] [.250] [.250] [.250] [.250] [.250] O.D. (Min.) 1.40 1.40 1.40 1.40 1.40 2.00 2.00 2.00 2.00 2.00 2.79 2.79 2.79 2.79 2.79 [.055] [.055] [.055] [.055] [.055] [.080] [.080] [.080] [.080] [.080] [.110] [.110] [.110] [.110] [.110] 8 Electrical Interconnect Products 8-29 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects DuraSeal Heat-Shrinkable Environmentally Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued) Push-on Terminals L max. C nom. A min. B nom. Push-on Terminal Dimensions Part No. B-106-3631 B-106-3632 B-106-3633 B-106-3281 B-106-3481 Tab Size (inches) .250 x .032 .250 x .032 .250 x .032 .110 x .020 .187 x .020 A Min. 3.81 4.57 6.35 3.81 3.81 [.150] [.180] [.250] [.150] [.150] B Nom. 6.35 6.35 6.35 2.79 4.75 C Nom. [.250] [.250] [.250] [.110] [.187] .81 .81 .81 .51 .51 L Max. [.032] [.032] [.032] [.020] [.020] 30.48 32.00 33.02 22.86 30.48 [1.200] [1.260] [1.300] [.900] [1.200] Color Insulation Conductor (AWG) Red Blue Yellow Red Red 22-18 16-14 12-10 22-18 22-18 Wire Dimensions Insulation O.D. O.D. (Min.) (Max.) 3.81 [.150] 1.40 [.055] 4.45 [.175] 2.00 [.080] 6.35 [.250] 2.79 [.110] 3.81 [.150] 1.40 [.055] 3.81 [.150] 1.40 [.055] Tab Terminals L max. C nom. OA min. B nom. Tab Terminal Dimensions Part No. B-106-4631 B-106-4632 Tab Size (inches) .250 x .032 .250 x .032 A Min. B Nom. C Nom. L Max. Color Insulation Conductor (AWG) 3.81 [.150] 4.57 [.180] 6.35 [.250] 6.35 [.250] .81 [.032] .81 [.032] 30.48 [1.20] 32.00 [1.26] Red Blue 22-18 16-14 Wire Dimensions Insulation O.D. O.D. (Min.) (Max.) 3.81 [.150] 1.40 [.055] 4.45 [.175] 2.00 [.080] 8-30 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects DuraSeal Heat-Shrinkable Environmentally Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued) Pin Terminals L max. OA min. OB Wire Dimensions Insulation O.D. (Max.) 3.81 [.150] Pin Terminal Dimensions Part No. B-106-6201 A Min. B Nom. L Max. Color Conductor (AWG) 3.81 [.150] 2.00 [.080] 30.99 [1.220] Red 22-18 Insulation O.D. (Min.) 1.40 [.055] Bullet Terminals L max. B nom. OA min. Fig. 1 L max. OA min. Fig. 2 OC min. OB Bullet Terminal Dimensions Part No. Fig. Type B-106-7401 B-106-7502 B-106-8401 B-106-8502 1 1 2 2 M M F F A Min. 3.81 4.57 3.81 4.57 [.150] [.180] [.150] [.180] B Nom. 3.81 5.08 3.81 5.08 [.150] [.200] [.150] [.200] C Min. -- -- 5.59 [.220] 6.10 [.240] L Max. 33.53 34.54 30.48 32.51 [1.32] [1.36] [1.20] [1.28] Color Conductor (AWG) Red Blue Red Blue 22-18 16-14 22-18 16-14 Wire Dimensions Insulation Insulation O.D. O.D. (Max.) (Min.) 3.81 [.150] 1.40 [.055] 4.45 [.175] 2.00 [.080] 3.81 [.150] 1.40 [.055] 4.45 [.175] 2.00 [.080] 8 Electrical Interconnect Products 8-31 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects DuraSeal Heat-Shrinkable Environmentally Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued) Product Characteristics (Typical) Operating temperature Shrink ratio Physical properties -55C to 125C [-67F to 257F] Approximately 2:1 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 160C [320F] Solvent resistance: isopropyl alcohol, trichloroethylene, gasoline, battery acid, diesel fuel, motor oil, antifreeze, brake fluid, 5% salt water Dielectric strength: 1000 V Insulation resistance: 10 megohms Chemical properties Electrical properties Specifications/Approvals Agency UL and CUL 91J4, File E87681 Lloyd's listed, File 65 247 HH 02-93 UL and CUL E157833 (B-106-3XXX/B-106-4XXX) Series B-106 Installation Raychem RB-108 1. Select appropriate size. For terminal and disconnect terminations, strip wire 6.5 mm (1/4 inch). 2. Crimp using Raychem AD-1522 crimp tool for preinsulated crimps. 3. Heat terminal or disconnect 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 installation procedure RPIP 684-00 for detailed instructions. 8-32 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects SolderGrip Self-Fixturing Insulated Terminals Product Facts n Transparent insulation sleeve provides encapsulation, inspectability, strain relief, and insulation n Spiral copper coil grips and compresses the conductors for optimum solder connection n Prefluxed solder preform provides a controlled soldering process. n One-piece design for easy installation n Accommodates a wide variety of conductor types, quantities, sizes, and plating types unmatched by any other termination technique n Parts meet the performance requirements of MIL-T-7928G Product option Environmental Protection Splashproof Product Series SGRT Product Selection Process 1. Determine the wire combination (number of wires and size) of the wire bundle you wish to terminate. Applications Used for terminating multiple wires to terminals. 3. Determine the correct stud size. Table A. Part Number Selection Available in: Americas Europe Asia Pacific n n n 5. Verify that the wire bundle (with wire insulation) does not exceed the maximum diameter allowed for the part you selected. Simply check the bundle's diameter against the maximum diameter that Table A lists for that part. SolderGrip Part No. Stud Size Maximum Bundle Diameter Maximum Amp Rating SGRT-1-02 2 [2] 4.1 [.161] 12.5 A SGRT-2-03 3 [6] 5.0 [.195] 15 A SGRT-2-04 4 [8] -- 15 A SGRT-2-05 5 [10] -- 15 A SGRT-2-06 6 [1/4] -- 15 A SGRT-3-06 6 [1/4] 6.5 [.255] 33 A SGRT-3-08 8 [5/16] -- 33 A SGRT-4-06 6 [1/4] 9.0 [.355] 56 A SGRT-4-08 8 [5/16] -- 56 A 6. Verify that the total amperage to be applied does not exceed the maximum amp rating for the part as specified in Table A. *If the wire combination is not listed in Table B, use the CMA (mm2) method of determining wire bundle size (see "CMA/mm2 Calculation" on page 8-34). 8 Using Table B, select the smallest size part that will fit your total wire CMA (mm2) value. Wire Range (Min.-Max.) CMA [mm2] 1400-5000 [0.7-2.5] 2400-6000 [1.2-3.0] 2400-6000 [1.2-3.0] 2400-6000 [1.2-3.0] 2400-6000 [1.2-3.0] 5000-13,200 [2.5-6.6] 5000-13,200 [2.5-6.6] 12,000-22,400 [6.0-11.2] 12,000-22,400 [6.0-11.2] Electrical Interconnect Products 2. Use Table C to select the correct terminal for AWG wire combination.* Example: For connecting a bundle with one 12 AWG wire (1 #12) and two 18 AWG wires (+ 2 #18) to a terminal, you need an SGRT-4-XX terminal. 4. Select the correct part number from Table A for that stud size in the terminal series and size you selected in Step 2. Example: If the stud size is 1/4, select part number SGRT-4-06. Typical Length 38 [1 1/2] 38 [1 1/2] 38 [1 1/2] 38 [1 1/2] 38 [1 1/2] 44.5 [1 3/4] 51.0 [2] 44.5 [1 3/4] 51 [2] Maximum bundle diameter is measured over wire insulation. 8-33 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects SolderGrip Self-Fixturing Insulated Terminals (Continued) CMA/mm2 Calculation To calculate the total circular mil or mm2 area of the wire bundle to be terminated, follow these steps: 1. Choose either CMA or mm2 as your unit of measure for selection purposes and continue to use it for all your selection criteria. (Both measures provide the same results.) 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). 2. In the workspace below, list the CMA or mm2 for each conductor in the bundle. (Table B provides the CMA of typical conductors.) Wire Number CMA mm2 1 2 3 4 5 6 7 8 9 10 Solder Grip Part No. Total CMA/mm2 Example OD Bundle 22 AWG/.38 CMA 754 Insulation 22 AWG/.38 CMA 754 Conductor 18 AWG/.95 CMA 1900 16 AWG/1.21 CMA 2426 Total CMA = 5834 Total mm2 = 2.92 Correct part number (based on CMA of 5834 or mm2 of 2.92): SGRT-2-XX if bundle OD is less than 5.0 mm (0.195 in). Bundle diameter must not exceed 5.0 mm [0.195 in] for this example 8-34 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects SolderGrip Self-Fixturing Insulated Terminals (Continued) Table B. CMA of Typical Copper Conductors Strands AWG CMA mm2 7 28 177 0.09 19 26 304 0.15 19 24 475 0.24 19 22 754 0.38 19 20 1216 0.61 19 18 1900 0.95 19 16 2426 1.21 19 14 3831 1.92 37 12 5874 2.94 Table C. SolderGrip Wire Combinations (see Table A for Terminal Size [-XX]) Part No. SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX Wire Combinations 1 # 12 + 1 # 16 + 4 # 18 1 # 12 + 2 # 16 1 # 12 + 2 # 16 + 1 # 18 1 # 12 + 2 # 16 + 2 # 18 1 # 12 + 3 # 16 1 # 12 + 4 # 16 1 # 12 + 5 # 16 1 # 12 + 1 # 14 + 1 # 18 1 # 12 + 1 # 14 + 2 # 18 1 # 12 + 1 # 14 + 3 # 18 1 # 12 + 1 # 14 + 1 # 16 1 # 12 + 1 # 14 + 2 # 16 1 # 12 + 1 # 14 + 3 # 16 1 # 12 + 1 # 14 + 4 # 16 1 # 12 + 2 # 14 1 # 12 + 2 # 14 + 1 # 18 1 # 12 + 2 # 14 + 1 # 16 1 # 12 + 2 # 14 + 2 # 16 1 # 12 + 2 # 14 + 3 # 16 1 # 12 + 3 # 14 1 # 12 + 3 # 14 + 1 # 16 1 # 12 + 4 # 14 2 # 12 + 1 # 18 2 # 12 + 1 # 16 2 # 12 + 2 # 16 + 1 # 18 2 # 12 + 3 # 16 2 # 12 + 1 # 14 + 1 # 18 2 # 12 + 1 # 14 + 1 # 16 2 # 12 + 2 # 14 3 # 12 + 1 # 18 3 # 12 + 1 # 16 3 # 12 + 1 # 14 1 # 14 1 # 14 + 1 # 22 1 # 14 + 1 # 20 1 # 14 + 2 # 20 1 # 14 + 3 # 20 Part No. SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX Wire Combinations 1 # 14 + 4 # 20 1 # 14 + 1 # 18 1 # 14 + 1 # 18 + 1 # 20 1 # 14 + 2 # 18 1 # 14 + 3 # 18 1 # 14 + 4 # 18 1 # 14 + 5 # 18 1 # 14 + 1 # 16 1 # 14 + 1 # 16 + 1 # 20 1 # 14 + 1 # 16 + 1 # 18 1 # 14 + 1 # 16 + 2 # 18 1 # 14 + 1 # 16 + 3 # 18 1 # 14 + 1 # 16 + 4 # 18 1 # 14 + 2 # 16 1 # 14 + 2 # 16 + 1 # 18 1 # 14 + 2 # 16 + 2 # 18 1 # 14 + 2 # 16 + 3 # 18 1 # 14 + 3 # 16 1 # 14 + 3 # 16 + 1 # 18 1 # 14 + 3 # 16 + 2 # 18 1 # 14 + 4 # 16 1 # 14 + 4 # 16 + 1 # 18 1 # 14 + 5 # 16 2 # 14 2 # 14 2 # 14 2 # 14 2 # 14 2 # 14 + 1 # 16 2 # 14 + 1 # 16 2 # 14 + 1 # 16 2 # 14 + 1 # 16 2 # 14 + 2 # 16 2 # 14 + 2 # 16 2 # 14 + 3 # 16 2 # 14 + 4 # 16 3 # 14 Part No. SGRT-3-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX 8 Electrical Interconnect Products Wire Combinations 1#8 1 # 8 + 1 # 16 2 # 8 + 2 # 16 1 # 8 + 1 # 14 1 # 10 1 # 10 + 1 to 3 # 18 1 # 10 + 2 # 18 1 # 10 + 3 # 18 1 # 10 + 1 # 16 1 # 10 + 1 # 16 + 1 # 18 1 # 10 + 1 # 16 + 2 # 18 1 # 10 + 2 # 16 1 # 10 + 3 # 16 1 # 10 + 4 # 16 1 # 10 + 5 # 16 1 # 10 + 1 # 14 1 # 10 + 1 # 14 + 1 # 18 1 # 10 + 1 # 14 + 1 # 16 1 # 10 + 1 # 14 + 2 # 16 1 # 10 + 1 # 14 + 3 # 16 1 # 10 + 2 # 14 1 # 10 + 3 # 14 1 # 10 + 1 # 12 1 # 10 + 1 # 12 + 1 # 14 1 # 10 + 2 # 12 2 # 10 2 # 10 + 1 # 16 1 # 12 1 # 12 + 1 # 18 1 # 12 + 2 # 18 1 # 12 + 3 # 18 1 # 12 + 4 # 18 1 # 12 + 5 # 18 1 # 12 + 1 # 16 1 # 12 + 1 # 16 + 1 # 18 1 # 12 + 1 # 16 + 2 # 18 1 # 12 + 1 # 16 + 3 # 18 8-35 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects SolderGrip Self-Fixturing Insulated Terminals (Continued) Table C. SolderGrip Wire Combinations (see Table A for Terminal Size [-XX]) (Continued) Wire Combinations 3 # 14 + 1 # 16 3 # 14 + 2 # 16 3 # 14 + 3 # 16 4 # 14 4 # 14 + 1 # 16 4 # 14 + 2 # 16 5 # 14 5 # 14 + 1 # 16 1 # 16 1 # 16 + 1 # 22 1 # 16 + 2 # 22 1 # 16 + 3 # 22 1 # 16 + 1 # 20 1 # 16 + 1 # 20 + 1 # 22 1 # 16 + 2 # 20 1 # 16 + 3 # 20 1 # 16 + 4 # 20 1 # 16 + 5 # 20 1 # 16 + 1 # 18 1 # 16 + 1 # 18 + 1 # 20 1 # 16 + 1 # 18 + 2 # 20 1 # 16 + 1 # 18 + 3 # 20 1 # 16 + 1 # 18 + 4 # 20 1 # 16 + 2 # 18 1 # 16 + 2 # 18 + 1 # 20 1 # 16 + 2 # 18 + 2 # 20 1 # 16 + 2 # 18 + 3 # 20 1 # 16 + 3 # 18 1 # 16 + 3 # 18 + 1 # 20 1 # 16 + 3 # 18 + 2 # 20 1 # 16 + 4 # 18 1 # 16 + 4 # 18 + 1 # 20 1 # 16 + 5 # 18 2 # 16 2 # 16 + 1 # 20 2 # 16 + 2 # 20 2 # 16 + 3 # 20 Part No. SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-2-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX Wire Combinations 2 # 16 + 4 # 20 2 # 16 + 1 # 18 2 # 16 + 1 # 18 + 1 # 20 2 # 16 + 1 # 18 + 2 # 20 2 # 16 + 1 # 18 + 3 # 20 2 # 16 + 2 # 18 2 # 16 + 2 # 18 + 1 # 20 2 # 16 + 2 # 18 + 2 # 20 2 # 16 + 3 # 18 2 # 16 + 3 # 18 + 1 # 20 2 # 16 + 4 # 18 3 # 16 3 # 16 + 1 # 20 3 # 16 + 2 # 20 3 # 16 + 3 # 20 3 # 16 + 1 # 18 3 # 16 + 1 # 18 + 1 # 20 3 # 16 + 1 # 18 + 2 # 20 3 # 16 + 2 # 18 3 # 16 + 2 # 18 + 1 # 20 3 # 16 + 3 # 18 4 # 16 4 # 16 + 1 # 20 4 # 16 + 2 # 20 4 # 16 + 1 # 18 4 # 16 + 1 # 18 + 1 # 20 4 # 16 + 2 # 18 5 # 16 5 # 16 + 1 # 20 5 # 16 + 1 # 18 6 # 16 1 # 18 + 1 # 22 1 # 18 + 2 # 22 1 # 18 + 3 # 22 1 # 18 + 1 # 20 1 # 18 + 1 # 20 + 1 # 22 -- Part No. SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX -- Wire Combinations 1 # 18 + 1 # 20 + 2 # 22 1 # 18 + 2 # 20 1 # 18 + 3 # 20 1 # 18 + 4 # 20 1 # 18 + 5 # 20 2 # 18 2 # 18 + 1 # 22 2 # 18 + 1 # 20 2 # 18 + 2 # 20 2 # 18 + 3 # 20 2 # 18 + 4 # 20 3 # 18 3 # 18 + 1 # 20 3 # 18 + 2 # 20 3 # 18 + 3 # 20 4 # 18 4 # 18 + 1 # 20 4 # 18 + 2 # 20 5 # 18 5 # 18 + 1 # 20 6 # 18 1 # 20 + 2 # 22 1 # 20 + 3 # 22 1 # 20 + 4 # 22 2 # 20 2 # 20 + 1 # 22 2 # 20 + 2 # 22 2 # 20 + 3 # 22 3 # 20 3 # 20 + 1 # 22 4 # 20 5 # 20 6 # 20 4 # 22 5 # 22 6 # 22 -- Part No. SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX -- 8-36 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Solder Style SolderGrip Self-Fixturing Insulated Terminals (Continued) Installation The SolderGrip product is pushed onto the conductors with a twisting motion. With the product in place, installation can be completed with the proper selection and use of heating tools and reflectors. Refer to Raychem installation procedure RPIP 820-01 for detailed instructions and recommended reflector attachments. You will find ordering information for these tools in Section 10. Either of the following Raychem heating tools is recommended: Product Characteristics n HL1802E n CV-1981 Material Insulation Solder and flux Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride (Kynar(R)) Sn60 Pb40 with RA flux Typical Performance Tensile strength Temperature rating Voltage Drop Dielectric Withstanding Voltage Exceeds strength of individual wires -55C to +150C [-67F to +302F] Not to exceed that of equivalent length of wire by more than 1 mV Current leakage less than 2 mA (1.5 kV) 8 Electrical Interconnect Products 8-37 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 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 150C [302F], the products in this section include SolderSleeve discrete wire terminators, which are heat-shrinkable thermoplastic sleeves containing a precisely engineered fluxed solder preform. SolderSleeve terminators are also available on carrier tape, spaced precisely to match connector terminal spacing, enabling termination 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, provide reliability and economical installation for greater productivity. They can be supplied either in bulk or on carrier tape. 8-38 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire Termination to Pin/Post/Tab SolderSleeve Discrete Wire Terminators Product Facts n Transparent polyvinylidene fluoride or polyolefin insulation sleeve provides encapsulation, inspectability, strain relief, and insulation n Prefluxed solder preform offers a controlled soldering process n One-piece design means easy installation and low installed cost n Optional tape carrier provides convenience and ease of installation n UL and CUL Recognized R Applications Installation Used for terminating wires to component terminals, such as motor tabs, connector pins, and switch terminals. 1. Determine the application operating temperature. 6. Select part number from the appropriate table: 2. From the Product Options table on the next page, select the product series appropriate for the application, based on the temperature required. For CWT series (applications with lowtemperature wires-- below 125C [257F]), use Table A. n n 3. Determine your component connection point type (pin, post, or tab) and dimensions. For D-129/141/71X series (applications with wires rated higher than 125C [257F]), use Table B. 4. Determine your wire gauge. Available in: Americas Europe Asia Pacific 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: n HL1802E n AA-400 Super Heater Refer to Raychem installation procedure RCPS 20012 (for D-129, D-141, D-71X) or RPIP 824-00 (for CWT) for detailed instructions and recommended reflector attachment. 8 Electrical Interconnect Products Product selection process 5. Optional: Select tape carrier center-to-center spacing (D-71X series only). This should match center spacing of component terminals. You will find ordering information for these tools see section 10. n n n 8-39 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire Termination to Pin/Post/Tab SolderSleeve Discrete Wire Terminators (Continued) Product Options Product Series CWT D-129, D-141, D-71X Note: Max. Operating Temperature 125C [257F] 150C [302F] Min. Wire Temperature Rating 85C [185F] 125C [257F] Cadmium-free option (B-152 series) is available for operating temperature of 125C [257F]. Consult Tyco Electronics for details. Table A. CWT Series (125C [257F] rated) Connection-point Type and Size W pin W post Terminal Dimensions Wire AWG/mm2 Part No. W = up to 0.63 [.025] 24 [0.24] 20 [0.61] CWT-1501 CWT-1502 W = 0.63 [.025] to 0.89 [0.035] 24 [0.24] 22 [0.38] 20 [0.61] CWT-1501 CWT-1502 CWT-1503 W = 0.89 [0.035] to 1.14 [.045] 24-22 [0.24-0.38] 20-18 [0.61-0.95] CWT-1502 CWT-1503 W = 1.14 [.045] to 1.52 [.060] 24-22 [0.24-0.38] 20-18 [0.61-0.95] CWT-1503 CWT-1504 W = up to1.52 [.060] 24-20 [0.24-0.61] CWT-1501 W = 1.27 [.050] to 2.28 [.090] 24-18 [0.24-0.95] CWT-1502 W = 1.77 [.070] to 2.79 [.110] 24-18 [0.24-0.95] CWT-1503 W = 2.54 [.100] to 3.80 [.150] 24-18 [0.24-0.95] CWT-1504 W = 2.28 [.090] to 4.70 [.187] 22-16 [0.38-1.21] CWT-1505 W tab 8-40 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire Termination to Pin/Post/Tab SolderSleeve Discrete Wire Terminators (Continued) Table B. D-129/141/71X Series (up to 150C [302F] rated) Connection-point Type and Size Tape Carrier Spacing of Sleeves (Center-to-Center) 1.27 2.54 3.17 None [0.050] [0.100] [0.125] Wire Terminal Dimensions 4.0 [0.156] AWG mm 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 0.81 [.032] 20 [0.61] D-141-31 -- D-711-04 D-711-07 D-711-08 W = 0.76 [.030] to 1.27 [.050] 24-20 [0.24-0.61] D-141-56 -- -- -- -- W = up to 1.52 [.060] 24-20 [0.24-0.61] D-129-05 -- D-714-01 -- -- W = 1.27 [.050] to 2.28 [.090] 24-20 [0.24-0.61] D-129-03 -- -- -- D-714-00 W = 2.28 [.090] to 3.55 [.140] 24-20 [0.24-0.61] D-129-0043 -- -- -- -- W 2 W = up to 0.61 [.024] pin W post W tab For Fine Wire Terminations 0.15 mm2 (26 AWG) and Smaller* Inside Diameter As Supplied** 1.0 [0.040] 1.0 [0.040] 0.75 x 1.65 [0.030 X 0.065] 0.75 x 1.65 [0.030 X 0.065] 0.75 x 1.65 [0.030 X 0.065] Fully Recovered 0.6 [0.025] 0.6 [0.025] 0.75 [0.030] 0.75 [0.030] 0.75 [0.030] Length 16.0 [0.630] 9.0 [0.360] 4.7 [0.185] 6.0 [0.240] 9.5 [0.375] 8 Electrical Interconnect Products Part No.* D-110-0062 D-110-0217 D-141-13 D-141-22 D-141-30 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 combined 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. 8-41 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire Termination to Pin/Post/Tab SolderSleeve Discrete Wire Terminators (Continued) Product Characteristics Specifications/Approvals Material Insulation [D-129, D-141, D-71X] Insulation [CWT] Solder and flux [D-129, D-141, D-71X] Solder and flux [CWT] Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride Radiation-crosslinked, heat-shrinkable polyolefin Solder: Sn63 Pb37 Flux: ROL1 per ANSI -J - 004 [RMA flux] Solder: Sn50 Pb32 Cd 18 Flux: ROM1 per ANSI -J - 004 [RA flux] Typical Performance Voltage drop Tensile strength Dielectric strength Temperature rating [CWT] Temperature rating [D-129, D-141, D-71X] Insulation resistance 2.0 mV Exceeds strength of conductor 2.0 kV -55C to 125C [-67F to 257F] -55C to 150C [-67F to 302F] 1000 megohms Series CWT D-129, D-141 Agency UL and CUL E87681 UL and CUL E87681 Raychem D-5023 RT-1404 8-42 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shield Termination Introduction Raychem SolderSleeve shield grounding terminators provide an environmentally 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 -65C to 200C [-85F to 392F], the products in this section include: n CWT-X SolderSleeve terminators, designed for low-temperature cables with operating temperatures up to 125C [257F] and suitable for most commercial environments. n MIL-S-83519 SolderSleeve terminators, which are immersion resistant and available with or without a preinstalled ground lead. n SO 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 Electrical Interconnect Products 8-43 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shield Termination SolderSleeve Shield Terminators Product Facts n Transparent insulation sleeve provides encapsulation, inspectability, strain relief, and insulation n Prefluxed solder preform provides a controlled soldering process n One-piece design offers easy installation and lower installed cost n Optional preinstalled ground leads provide convenience and ease of installation Applications Product Selection Process Used for shield-to-ground termination. 1. Select product series from the Product Options table below. 4. Select part number (use the selection table indicated for your product series in the Product Options table below). 2. Determine cable dimensions. 5. Refer to Table H on page 8-49 for cross-reference information. 3. Optional: Select preinstalled wire lead type (see Table G on page 8-47 for type descriptions). Jacket OD (max.) Shield OD (min.) Product Options (Refer to Table G on Page 8-47 for Additional Information) Product Series CWT SO63* S01/S02**, S03 SO96*** SO175**** System Oper. Temperature (Max.) 125C [257F] 150C [302F] 150C [302F] 175C [347F] 175C [347F] Used on Cables Rated (Min.) 85C [185F] 125C [257F] 125C [257F] 150C [302F] 150C [302F] Environmental Protection Solder Alloy Flux Type Insulation Material Splash resistant Immersion resistant Immersion resistant Immersion resistant Immersion resistant Cd18 Sn63 Sn63 Sn96 Sn96 RA RMA RMA RA RA Polyolefin Polyvinylidene fluoride Polyvinylidene fluoride Polyvinylidene fluoride Polyvinylidene fluoride Part No. Selection Table A B C, D E 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 125C [257F]. Consult Tyco Electronics for details. Available in: Americas Europe Asia Pacific n n n 8-44 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shield Termination SolderSleeve Shield Terminators (Continued) Table A. CWT Series (125C [257F] rated) Cable OD Part Nos. Shield OD Min. 0.9 [.035] 1.1 [.043] 1.5 [.059] 2.0 [.079] 3.3 [.130] 3.3 [.130] 4.5 [.177] 4.5 [.177] 7.0 [.276] Jacket OD Max. 1.7 [.065] 1.95 [.075] 2.7 [.105] 4.5 [.180] 6.0 [.235] 7.0 [.275] 8.7 [.340] 10.7 [.420] 13.0 [.510] No Preinstalled Lead CWT-3801 CWT-3802 CWT-3 CWT-5 CWT-6 CWT-7 CWT-9 CWT-11 CWT-13 With Preinstalled Lead (22AWG/0.38 mm2 green) -- -- CWT-3-W122-5 CWT-5-W122-5 CWT-6-W122-5 CWT-7-W122-5 CWT-9-W122-5 CWT-11-W122-5 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 85C [185F] to 125C [257F]) with bare copper or tin plating. Table B. SO63 Series BiAlloy Temperature Indication System This system greatly enhances the reliability and repeatability of SO63 series terminators while reducing installed cost. The heat-shrinkable thermoplastic sleeve contains a precisely 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. Jacket OD Max. Shield OD Min. 1.95 [0.075] 2.7 [0.105] 4.3 [0.170] 6.0 [0.235] 7.0 [0.275] 0.90 [.035] 1.40 [.055] 2.15 [.085] 3.30 [.130] 4.30 [.170] Electrical Interconnect Products Cable OD 8 Part Nos. No Preinstalled Lead SO63-1-00 SO63-2-00 SO63-3-00 SO63-4-00 SO63-5-00 Preinstalled Lead Option* 20 AWG 22 AWG SO63-1-55-20-90 SO63-2-55-20-90 SO63-3-55-20-90 SO63-4-55-20-90 SO63-5-55-20-90 SO63-1-55-22-90 SO63-2-55-22-90 SO63-3-55-22-90 SO63-4-55-22-90 SO63-5-55-22-90 24 AWG SO63-1-55-24-90 SO63-2-55-24-90 SO63-3-55-24-90 SO63-4-55-24-90 SO63-5-55-24-90 Braid Strap 26 AWG SO63-1-55-26-90 SO63-2-55-26-90 SO63-3-55-26-90 SO63-4-55-26-90 SO63-5-55-26-90 Nickel Plated Tin Plated SO63-1-01 SO63-2-01 SO63-3-01 SO63-4-01 SO63-5-01 SO63-1-9030 SO63-2-9030 SO63-3-9030 SO63-4-9030 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) . 8-45 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shield Termination SolderSleeve Shield Terminators (Continued) Table C. S01/S02 M83519 Series Thermochromic Temperature Indicator The M83519 (S01 and S02) series terminators contain a colored 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. Cable OD Part No. (MIL Part Number and Raychem Part No.) by Lead Option Preinstalled Lead Option* No Preinstalled Lead Jacket OD Max Shield OD Min MIL Raychem MIL Raychem MIL Raychem 1.95 [0.075] 2.7[0.105] 4.3 [0.170] 6.0 [0.235] 7.0 [0.275] 0.9 [.035] 1.40 [.055] 2.15 [.085] 3.30 [.130] 4.30 [.170] M83519/1-1 M83519/1-2 M83519/1-3 M83519/1-4 M83519/1-5 S01-01-R S01-02-R S01-03-R S01-04-R S01-05-R M83519/2-1 M83519/2-2 M83519/2-3 M83519/2-4 M83519/2-5 S02-01-R S02-02-R S02-03-R S02-04-R S02-05-R M83519/2-6 M83519/2-7 M83519/2-8 M83519/2-9 M83519/2-10 S02-06-R S02-07-R S02-08-R S02-09-R S02-10-R Jacket OD Max. Shield OD Min. 1.95 [0.075] 2.7 [0.105] 4.3[0.170] 6.0 [0.235] 7.0 [0.275] 0.9 [.035] 1.40 [.055] 2.15 [.085] 3.30 [.130] 4.30 [.170] 20 AWG 22 AWG Preinstalled Lead Option* 24 AWG M83519/2-11 M83519/2-12 M83519/2-13 M83519/2-14 M83519/2-15 26 AWG M83519/2-16 M83519/2-17 M83519/2-18 M83519/2-19 M83519/2-20 S02-11-R S02-12-R S02-13-R S02-14-R S02-15-R S02-16-R S02-17-R S02-18-R S02-19-R 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 termination and inspection. The Raychem part number is permanently marked on the sleeve. Table D. S03 Series Thermochromic Temperature Indicator The S03 series terminators contain a colored 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. Cable OD Part No. Jacket OD Max. Shield OD Min. Tin plated Braid Strap Nickel plated Braid Strap 1.95 [0.075] 2.7 [0.105] 4.3 [0.170] 6.0 [0.235] 7.0 [0.275] 0.9 [.035] 1.40 [.055] 2.15 [.085] 3.30 [.130] 4.30 [.170] S03-01-R S03-02-R S03-03-R S03-04-R S03-05-R S03-06-R S03-07-R S03-08-R S03-09-R S03-10-R Preinstalled Lead Option* *See Table G for lead description. 8-46 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shield Termination SolderSleeve Shield Terminators (Continued) Table E. SO96 Series (175C [347F] rated) Thermochromic Temperature Indicator The SO96 series terminators contain a colored 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. Cable OD Part No. Jacket OD Max. Shield OD Min. No Preinstalled Lead 22 AWG Preinstalled Lead Option* Braid Strap 1.95 [0.075] 2.7 [0.105] 4.3 [0.170] 6.0 [0.235] 7.0 [0.275] 0.9 [.035] 1.40 [.055] 2.15 [.085] 3.30 [.130] 4.30 [.170] SO96-1-00 SO96-2-00 SO96-3-00 SO96-4-00 SO96-5-00 SO96-1-55-22-90 SO96-2-55-22-90 SO96-3-55-22-90 SO96-4-55-22-90 SO96-5-55-22-90 SO96-1-01 SO96-2-01 SO96-3-01 SO96-4-01 SO96-5-01 *See Table G for lead description. The SO96 series is designed for high-temperature applications with operating temperature requirements up to 200C [392F]. This series features a thermochromic temperature indicator and meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) . The solder is Sn96 with RA flux compatible with nickel-plated shields. Table F. SO175 Series (175C [347F] 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 very minimum amount of heat. Cable OD Part No. Shield OD Min. 1.95 [0.075] 2.7 [0.105] 4.3 [0.170] 6.0 [0.235] 7.0 [0.275] 0.90 [0.035] 1.40 [0.055] 2.15 [0.085] 3.30 [0.130] 4.30 [0.170] 8 Preinstalled Lead Option* No Preinstalled Lead 22 AWG Braid Strap SO175-1-00 SO175-2-00 SO175-3-00 SO175-4-00 SO175-5-00 SO175-1-1-55-22-90 SO175-2-1-55-22-90 SO175-3-1-55-22-90 SO175-4-1-55-22-90 SO175-5-1-55-22-90 SO175-1-01 SO175-2-01 SO175-3-01 SO175-4-01 SO175-5-01 Electrical Interconnect Products Jacket OD Max. *See Table G for lead description. Table G. Preinstalled Lead Description Series M83519, SO63 SO96, SO175 SO63, SO96, S03 CWT SO63, S03 Lead Type 55A0111 55A0813 Braid strap XL polyethylene Braid Strap Remarks MIL-W-22759/32 MIL-W-22759/41 Uninsulated UL Listed Uninsulated Plating Tin Nickel Nickel Tin Tin Stranding Stranded Stranded 40 x 38 AWG Stranded (W1) Stranded Min. Length 150 [6.00] 150 [6.00] 150 [6.00] 150 [6.00] 150 [6.00] 8-47 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shield Termination SolderSleeve Shield Terminators (Continued) Product Characteristics Material Insulation SO, M83519 CWT Solder and flux SO63, M83519, S03 SO96, SO175 series CWT Ground lead CWT series SO, M83519, SO175 Typical Performance Voltage drop Tensile strength Dielectric strength Temperature rating CWT SO63/M83519/S03 SO96/SO175 series Insulation resistance Specifications/Approvals Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride Radiation-crosslinked, heat-shrinkable polyolefin Solder: Sn63 Pb37 Solder: Sn96 Ag4 Solder: Sn50 Pb32 Cd18 Flux: ROL1 per ANSI - J - 004 (RMA Flux) Flux: ROM1 per ANSI - J - 004 (RA Flux) Flux: ROM1 per ANSI - J - 004 (RA Flux) XL polyethylene MIL-W-22759/32 or /41 2.5 mV Exceeds strength of ground lead 1.0 kV immersed -55C to 125C [-67F to 257F] -55C to 150C [-67F to 302F] -55C to 175C [-67F to 347F] 1000 megohms Agency -- NAS 1747 MIL-S-83519/1&/2 NAS 1747 Series CWT SO63* M83519** SO96*** SO175 Raychem D-5023 RT-1404 RT-1404 RT-1404 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. 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: 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 n HL1802E M83519 (S01/S02) RCPS 100-70 n AA-400 Super Heater SO96 RCPS 100-70 n CV-1981 S03 RCPS 100-70 n MiniRay SO175 RCPS-100-70 n IR-1759 You will find ordering information for these tools in section 10. 8-48 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 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. Comment Part No. D-1744-01 1744-1 D-1744-02 1744-2 1744-3 D-1744-03 1744-4 D-1744-04 D-1744-05 1744-5 D-1744-06 1744-6 D-1744-07 1744-7 1744-8 D-1744-08 1745-1 D-144-25 Inactive, Use SAE-AS83519/1-1 (formerly MIL-S-83519) D-100-00 Inactive, Use SAE-AS83519/1-2 (formerly MIL-S-83519) 1745-2 D-101-00 Inactive, Use SAE-AS83519/1-3 (formerly MIL-S-83519) 1745-3 D-103-00 Inactive, Use SAE-AS83519/1-5 (formerly MIL-S-83519) 1745-4 1745-5 D-144-26 1745-6 D-100-31 D-101-31 1745-7 D-103-31 1745-8 Obsolete - Use NAS1745-13 1745-9 1745-10 Obsolete - Use NAS1745-14 1745-11 Obsolete - Use NAS1745-15 Obsolete - Use NAS1745-16 1745-12 D-142-83 Inactive, Use SAE-AS83519/1-1 (formerly MIL-S-83519) 1745-13 D-142-50 Inactive, Use SAE-AS83519/1-2(formerly MIL-S-83519) 1745-14 1745-15 D-142-51 Inactive, Use SAE-AS83519/1-3 (formerly MIL-S-83519) D-142-52 Inactive, Use SAE-AS83519/1-5 (formerly MIL-S-83519) 1745-16 1745-17 D-107-00 Inactive, Use SAE-AS83519/1-4 (formerly MIL-S-83519) D-104-00 1745-18 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 SO63-2-55-20-90 S02-02-R M83519/2-2 M83519/2-3 S02-03-R SO63-3-55-20-90 M83519/2-4 S02-04-R SO63-4-55-20-90 SO63-5-55-20-90 S02-05-R M83519/2-5 M83519/2-6 S02-06-R SO63-1-55-22-90 SO63-2-55-22-90 S02-07-R M83519/2-7 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 S02-11-R SO63-1-55-24-90 M83519/2-11 M83519/2-12 S02-12-R SO63-2-55-24-90 SO63-3-55-24-90 S02-13-R M83519/2-13 SO63-4-55-24-90 S02-14-R M83519/2-14 M83519/2-15 S02-15-R SO63-5-55-24-90 SO63-1-55-26-90 S02-16-R M83519/2-16 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 Electrical Interconnect Products 8-49 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination Introduction Raychem SolderSleeve coaxial cable terminators allow reliable, easy terminations in a variety of coaxial cable applications, including 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 150C [302F], the products in this section include: n SolderSleeve coaxial cable terminators, which allow reliable, economical attachment of coaxial cable to connector terminals, printed wiring assemblies, or solderless wrap terminals. n n One-piece SolderSleeve PCB coaxial cable terminators, which permit quick, easy, and costeffective terminations of coaxial cable to printed circuit boards. RF one-step BNC/TNC connectors, which are single-piece assemblies for terminating the center conductor and the braid of a broad range of coaxial cables. They are fully intermateable with MIL-C39012C 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 terminations. 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. 8-50 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination SolderSleeve Coaxial Cable Terminators Product Facts n Transparent polyvinylidene fluoride or polyolefin insulation sleeve provides encapsulation, inspectability, strain relief (eliminates center conductor breakage), and insulation. n Prefluxed solder preform provides a controlled soldering process n One-piece design provides easy installation and lower installed cost n Preinstalled termination leads provide convenience and ease of installation Applications Product Selection Process Used for terminating coaxial cable to component terminals, contacts, printed circuit boards, and solderless wrap terminals. 1. Select product series from the product options table below. 3. Determine cable RG number or dimensions. 4. Select part number from Table A (CWT series) or Table B (B-02X/B-04X series) on the next page. 2. Select preinstalled lead type from the table below. Product Options Product Series CWT B-02X/B-04X D-181 D-184 Max. Operating Temp. 125C [257F] 150C [302F] 150C [302F] 125C [257F] Use on Cables Rated (Min) 85C [185F] 125C [257F] 125C [257F] 85C [185F] Cable Shield Plating Tin, copper Tin, silver Tin, silver Tin Part No. Selection Table A B C D Design 2-pc. 1-pc. 2-pc. 2-pc. Preinstalled Lead Descriptions Lead Type XL polyethelene M81822/13 (solderless wrap) M81822/13 (solderless wrap) M81822/13 (solderless wrap) 55A0111 (MIL-W-22759/32) 55A0111 (MIL-W-22759/32) 55A0111 (MIL-W-22759/32) 55A0111 (MIL-W-22759/32) 55A0111 (MIL-W-22759/32) 55A0111 (MIL-W-22759/32) M81822/13 M81822/13 55A0111 (MIL-W-22759/32) Plating Tin Silver Silver Silver Tin Tin Tin Tin Tin Tin Silver Silver Tin Stranding Stranded (W1) Solid-OFHC Solid-OFHC Solid-OFHC Stranded Stranded Stranded Stranded Stranded Stranded Solid Solid Stranded AWG 22 24--30 24--30 24--30 20--30 20--30 20--30 20--30 20--30 20--30 26 - 30 26 - 30 20 - 26 Length 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] Color White (cntr), green (grnd) White (cntr), blue (grnd) White (cntr), blue (grnd) White (cntr), blue (grnd) White (cntr), blue (grnd) White (cntr), blue (grnd) White (cntr), blue (grnd) White (cntr), white w/black stripe (grnd) White (cntr), white w/black stripe (grnd) White (cntr), white w/black stripe (grnd) White (cntr), blue (grnd) White (cntr), blue (grnd) White (cntr), white w/black stripe (grnd) 8 Electrical Interconnect Products Series CWT B-021 B-041 B-043 B-020 B-040 B-044 D-181-12XX D-181-22XX D-181-32XX D-181-18XX D-181-28XX D-184 Product Characteristics Available in: Americas Europe Asia Pacific n n n Material Insulation (B-02X/B-04X, D-181, D-184) Insulation (CWT series) Solder and flux (B-02X/B-04X, D-181) Solder and flux (CWT series, D-184) Typical Performance Voltage drop Tensile strength Dielectric strength Temperature rating (CWT, D-184) Temperature rating (B-02X/B-04X, D-181) Insulation resistance Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride Radiation-crosslinked, heat-shrinkable polyolefin Solder: Sn63 Pb37 Flux: ROL1 per ANSI-J-004 (RMA Flux) Solder: Sn50 Pb32 Cd18 Flux: ROM1 per ANSI-J-004 (RA Flux) 2.0 mV Exceeds strength of conductor 2.0 kV -55C to 125C [-67F to 257F] -55C to 150C [-67F to 302F] 1000 megohms 8-51 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination SolderSleeve Coaxial Cable Terminators (Continued) Table A. CWT Series Part Numbers Part No. With Preinstalled Lead AWG/0.38 mm2 Green/White) CWT-4174-W122-5/9 CWT-4058-W122-5/9 CWT-4059-W122-5/9 Dimensions Cable RG Number 174 58, 122 59 Table B. B-02X/B-04X Series Part Numbers Dielectric OD Jacket OD 0.80-2.30 [.032-.091] 2.00-2.80 [.079-.110] 2.80-3.30 [.110-.130] 1.30-2.80 [.051-.110] 2.50-4.40 [.100-.173] 3.20-6.00 [.125-.235] Part 1: Coaxial Product Group Selection Typical Compatible Part No. Raychem RG Cable Cable Number Description Dimension Range Jacket OD (Max.) Shield OD Dielectric OD Conductor OD One-Piece Coaxial Product Group RG178, RG404 5030A13XX 5028A13XX 3.40 [.134] 1.30-2.30 [.051-.091] 0.50-1.70 [.019-.067] 0.30-0.80 [.011-.032] Group 1 RG179, RG316 5024A13XX 7530A13XX 7526A13XX 9530A13XX 4.40 [.173] 1.50-2.80 [.060-.110] 1.20-2.50 [.047-.100] 0.30-1.60 [.011-.063] Group 2 RG180, RG302, RG303 9527A13XX 9528A13XX 6.30 [.248] 2.40-4.60 [.094-.181] 1.40-4.30 [.055-.169] 0.30-2.80 [.011-.110] Group 3 Part 2: Product Part Number Selection One-Piece Coaxial Product Group Group 1 Group 2 Group 3 Preinstalled Wire Type Preinstalled Wire Size 24 26 AWG AWG 20 AWG 22 AWG 28 AWG 30 AWG Stranded (M22759) -- B-044-22-N B-044-24-N B-044-26-N -- -- Solid (M81822) -- -- B-043-24-N B-043-26-N B-043-28-N B-043-30-N Stranded (M22759) B-040-20-N B-040-22-N B-040-24-N B-040-26-N B-040-28-N B-040-30-N Solid (M81822) -- -- B-041-24-N B-041-26-N B-041-28-N B-041-30-N Stranded (M22759) B-020-20-N B-020-22-N B-020-24-N B-020-26-N -- -- Solid (M81822) -- -- -- B-021-26-N -- -- 1. The B-02X/B-04X series uses a one-piece design to terminate coaxial cables rated at 125C minimum. 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 C. D-181 Series Part Numbers E min. F min. L1 max. L2 max. A min. D min. B min. C min. Table D. D-184 Series Part Numbers E min. F min. L1 max. L2 max. A min. D min. B min. C min. Product Name D-181-1220-90/9 D-181-1222-90/9 D-181-1224-90/9 D-181-1226-90/9 D-181-1826-6/9 D-181-1830-6/9 D-181-2220-90/9 D-181-2222-90/9 D-181-2224-90/9 D-181-2226-90/9 D-181-2826-6/9 D-181-2830-6/9 D-181-3220-90/9 D-181-3222-90/9 D-181-3224-90/9 D-181-3226-90/9 D-181-3826-6/9 D-181-3830-6/9 Product Name D-184-1220-90/9 D-184-1222-90/9 D-184-1224-90/9 D-184-1226-90/9 D-184-2220-90/9 D-184-2222-90/9 D-184-2224-90/9 D-184-2226-90/9 Product Dimensions D E min. min. A min. B min. C min. F min. L1 max. L2 max. 3.7 [0.145] 3.2 [0.125] 2.7 [0.105] 2.4 [0.095] 2.3 [0.09] 0.71 [0.028] 17 [0.67] 21.5 [0.85] 4.5 [0.18] 4 [0.16] 3.45 [0.135] 2.9 [0.115] 3 [0.12] 1.1 [0.045] 17 [0.67] 22.7 [0.895] 5.2 [0.205] 4.7 [0.185] 4.45 [0.175] 3.95 [0.155] 4 [0.16] 1.3 [0.055] 17 [0.67] ] 21.5 [0.85] A B min. min. F min. L1 max. L2 max. 3.7 [0.145] 3.2 [0.125] 2.7 [0.105] 2.4 [0.095] 2.3 [0.09] 0.71 [0.028] 17 [0.67] 21.5 [0.85] 4.5 [0.18] 4 [0.16] 3.45 [0.135] 2.9 [0.115] 3 [0.12] 1.1 [0.045] 17 [0.67] 22.7 [0.895] Product Dimensions D E min. min. min. C Wire AWG 20 22 24 26 26 30 20 22 24 26 26 30 20 22 24 26 26 30 Wire AWG 20 22 24 26 20 22 24 26 8-52 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination SolderSleeve PCB/Coaxial Cable Terminators Product Facts n Provides a completely shielded, low-resistance, matched-impedance termination with very low VSWR (D-607 series only) n Transparent polyvinylidene fluoride insulation sleeve provides encapsulation, inspectability, strain relief, and insulation n Prefluxed solder preform provides a controlled soldering process n One-piece design offers easy installation and lower installed cost n Preinstalled PCB termination body provides convenience and ease of installation Applications Installation Product Selection Process Used for terminating coaxial cable to printed circuit boards. 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: 1. Select product series from the Product Options table below. n HL1802E n AA-400 Super Heater n IR-1759 MiniRay 3. Select the appropriate part number from Table A (D-607 series) or Table B (B-046 series). n CV-1981 2. Determine cable RG number or outside diameter dimensions. n You will find ordering information for these tools in Section 10. Available in: Americas Europe Asia Pacific A B C n D 8 Electrical Interconnect Products Refer to Raychem installation procedure ES61139 for detailed instructions and recommended reflector attachments. For D-607 (matched impedance) series, determine straight or rightangle entry to PCB and grid pattern, then select the appropriate part number from Table A on the next page. For B-046 (PinPak, or pin to ground) series, determine hole spacing and diameter. Refer to Table B for product selection (see illustration below for cable dimensions). n n n Product Options Product Series D-607 B-046 Typical Application Performance Matched impedance up to 2.3 GHz Effective transmission up to 100 MHz Shield Method Metal body Pin to ground Part No. Selection Table A B 8-53 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination SolderSleeve PCB/Coaxial Cable Terminators (Continued) Specifications/Approvals Raychem RT-1404 RT-1404 Series D-607 B-046 Table A. D-607 Series Part Numbers Cable Dimensions (mm/in) Max. Outside Diameter Jacket Shield Dielectric Straight grid 5.08 [.200] Part No. Entry to PCB Right-Angle Grid 5.08 [.200] 1.5-3.55 [.060-.140] 1.1-3.15 [.045-.125] 0.60-2.25 [.025-.090] D-607-09 D-607-10 RG Cable No. 174, 178, 179, 316, 404 Straight Grid 2.54 [.100] D-607-40* Table B. B-046 Series Part Numbers Cable Dimensions RG Cable No. Pin Diameter Part No. Spacing Between Pins 2.54 [.100] A B C D Max. 178, 404 0.30-0.80 [.011-.032] 0.5-1.7 [.019-.067] 1.3-2.3 [.050-.091] 3.4 [.134] 0.6 [.023] 0.8 [.031] B-046-14-N 179, 316 0.3-1.6 [.011-.063] 1.2-2.5 [.047-.100] .1.5-2.8 [.060-.110] 4.4 [.173] 0.6 [.023] 0.8 [.031] B-046-15-N 5.08 [.200] 6.35 [.250] B-046-10-N B-046-11-N B-046-66-N B-046-68-N B-046-12-N B-046-13-N B-046-16-N B-046-18-N Product Characteristics Material Insulation Solder and flux Termination body/pin Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride Solder: Sn63 Pb37 Flux: ROL1 per ANSI - J - 004 (RMA flux) Copper alloy, solder-plated Typical Performance Voltage drop Tensile strength Dielectric strength Temperature rating Insulation resistance 2.0 mV Exceeds strength of conductor 2.0 kV -55C to 150C [-67F to 302F] 1000 megohms Electrical Performance (typical) D-607 Series Only Frequency 350 MHz 700 MHz 2.3 GHz VSWR (D-607-09, -40) 1.04 max. 1.05 max. 1.09 max. VSWR (D-607-10) 1.04 max. 1.09 max. 1.12 max. 8-54 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination RF One-Step BNC/TNC Connectors Product Facts n Easy, quick installation Outstanding cable-retention force n Solder-solder connection type (center conductor and braid) n One-step termination for easy, quick installation and lower installed cost n Exceptional cable retention force to withstand high vibration and frequent mates and unmates n Fully soldered center conductor and braid n Excellent built-in strain relief against vibration and excessive handling n Long-term reliability n Controlled soldering termination n Use with standard RG/U cables and Raychem Cheminax cables n Three product sizes to accommodate a wide range of cables n Meets performance requirements of MIL-C-39012 up to 2.8 GHz n Applications One-Step BNC/TNC connectors 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. 8 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: * Steinel (R) Model HL1802E * CV-1981 Raychem RB-115 Available in: Americas Europe Asia Pacific Electrical Interconnect Products Specifications Refer to Raychem installation procedure RPIP 683-00 for detailed instructions. n n n 8-55 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination RF One-Step BNC/TNC Connectors (Continued) Product Options and Part Numbering System RXX - XX - X - XX Connector Style Dash No. -XX Connector Type Style TNC BNC 24.5 Max. [.965] -00 24.5 max. [.965] Straight plug 31.5 max. [1.23] 33.5 Max. [1.32] Male Right-angle plug -01 Male 28 [1.09] 28 [1.09] 25.4 Max. [1.0] 25.4 max. [1.0] Straight bulkhead jack -02 25.4 Max. [1.0] 25.4 max. [1.0] -03 Straight jack Female 25.4 Max. [1.0] 25.4 Max. [1.0] -04 Female Straight panel jack 4 x M2.5 x 0.45 4 x M2.5 x 0.45 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. 8-56 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination RF One-Step BNC/TNC Connectors (Continued) Product Characteristics Solder Insulation Sleeve Transition Shield Center Contact Dielectric Insulator Connector Body Insulation Sleeve and Solder Material Gold-plated beryllium copper (female) Gold-plated brass (male) PTFE Silver-plated brass Nickel-plated brass Sn63Pb37, RMA flux Tin-plated copper wire per ASTM B3 Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride, transparent blue Radiation-crosslinked, heat-shrinkable modified polyolefin with adhesive, black Center contact Dielectric insulator Transition Connector body Solder and flux Braided shield Insulation sleeve Strain relief/sealing sleeve Typical Performance Dielectric withstand voltage Insulation resistance Temperature rating Contact resistance-straight Contact resistance -- right-angle Cable retention force Voltage rating Connector durability 1500 V 5000 megohms -55C to 150C [-67F to 302F] Inner = 1.5 milliohms, outer = 1.0 milliohm Inner = 2.5 milliohms, outer = 1.5 milliohms 295N (66 lb) to 822N (196 lb) 500 V RMS 500 mating cycles minimum Electrical Performance Nominal impedance Frequency range 50 and 75 ohms Up to 2.8 GHz 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. D E F G 8-57 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination RF One-Step BNC/TNC Connectors (Continued) D (Min.-Max.) Cable Dimensions E F (Min.-Max.) (Max.) G (Max.) 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 1.50-5.00 [.060-.217] 3.50-7.00 [.138-.276] 5.00-.12.50 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 5 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.126] 7.3 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.1-9.50 [.161-.375] 0.9-3.00 [.035-.118] 2.1-5.00 [.083-.197] 4.1-9.50 [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.146] 7.30 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 1.50-5.00 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 5 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.146] 7.30 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.146] 7.30 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.5o [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.146] 7.30 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] Cable Type Impedance (ohms) RG Cables BNC Straight Plugs, Male Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-58, RG-141, RG-142, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 Raychem Cables 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 RG-179, RG-187 7530A1317 75 -- 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- 75 BNC Right-Angle Plugs, Male Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-58, RG-141, RG-142, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 RG-179, RG-187 7530A1317 75 -- 524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- 75 BNC Straight Bulkhead Jacks, Female Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-58, RG-141, RG-142, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 75 RG-179, RG-187 7530A1317 75 -- 75 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- BNC Straight Jacks, Female Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-58, RG-141, RG-142, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 75 RG-179, RG-187 7530A1317 75 -- 75 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- BNC Straight Panel Jacks, Female Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-58, RG-141, RG-142, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 75 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 RG-179, RG-187 7530A1317 75 -- 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- Part No. RBD-50-S-00 RBD-50-M-00 RBD-50-L-00 RBD-75-S-00 RBD-75-M-00 RBD-75-L-00 RBD-50-S-01 RBD-50-M-01 RBD-50-L-01 RBD-75-S-01 RBD-75-M-01 RBD-75-L-01 RBD-50-S-02 RBD-50-M-02 RBD-50-L-02 RBD-75-S-02 RBD-75-M-02 RBD-75-L-02 RBD-50-S-03 RBD-50-M-03 RBD-50-L-03 RBD-75-S-03 RBD-75-M-03 RBD-75-L-03 RBD-50-S-04 RBD-50-M-04 RBD-50-L-04 RBD-75-S-04 RBD-75-M-04 RBD-75-L-04 8-58 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination RF One-Step BNC/TNC Connectors (Continued) TNC Coaxial Connectors D (Min.-Max.) Cable Dimensions E F (Min.-Max.) (Max.) G (Max.) 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.146] 7.30 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] 1.5-5.5 [.060-.217] 3.5-7.0 [.138-.276] 5.0-12.5 [.197-.500] 1.5-5.5 [.060-.217] 3.5-7.0 [.138-.276] 5.0-12.5 [.197-.500] 0.9-3.0 [.035-.118] 2.1-5.0 [.083-.197] 4.1-9.5 [.161-.375] 0.9-3.0 [.035-.118] 2.1-5.0 [.083-.197] 4.1-9.5 [.161-.375] 1.55 [.060] 3.0 [.118] 7.3 [.287] 1.55 [.060] 3.7 [.146] 7.3 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] 1.5-5.5 [.060-.217] 3.5-7.0 [.138-.276] 5.0-12.5 [.197-.500] 1.5-5.5 [.060-.217] 3.5-7.0 [.138-.276] 5.0-12.5 [.197-.500] 0.9-3.0 [.035-.118] 2.1-5.0 [.083-.197] 4.1-9.5 [.161-.375] 0.9-3.0 [.035-.118] 2.1-5.0 [.083-.197] 4.1-9.5 [.161-.375] 1.55 [.060] 3.0 [.118] 7.3 [.287] 1.55 [.060] 3.7 [.146] 7.3 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] Cable Type Impedance (ohms) RG Cables TNC Straight Plugs, Male Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-141, RG-142, RG-58, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 Raychem Cables 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 75 RG-179, RG-187 7530A1317 75 -- 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- TNC Straight Jacks, Female Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-58, RG-141, RG-142, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 RG-179, RG-187 7530A1317 75 -- 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- 75 TNC Straight Panel Jacks, Female Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-58, RG-141, RG-142, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 75 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 RG-179, RG-187 7530A1317 75 -- 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- Part No. RTD-50-S-00 RTD-50-M-00 RTD-50-L-00 RTD-75-S-00 RTD-75-M-00 RTD-75-L-00 RTD-50-S-03 RTD-50-M-03 RTD-50-L-03 RTD-75-S-03 RTD-75-M-03 RTD-75-L-03 RTD-50-S-04 RTD-50-M-04 RTD-50-L-04 RTD-75-S-04 RTD-75-M-04 8 RTD-75-L-04 Electrical Interconnect Products 8-59 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination RF One-Step BNC/TNC Connectors (Continued) TNC Coaxial Connectors Panel thickness: 3.2 [.125] max. RBD-XX-X-04 RTD-XX-X-04 12.7 [.5] 12.7 [.5] RBD-XX-X -02 RTD-XX-X -02 20.5 [.8] min. = = 12 [.47] 11.2 [.44] = = 3 [.12] 12.9 [.51] 18 [.7] min. D (Min.-Max.) Cable Dimensions E F (Min.-Max.) (Max.) G (Max.) 1.50-5.50 [.060-.217] 3.5-7.0 [.138-.276] 5.0-12.5 [.197-.500] 1.5-5.5 [.060-.217] 3.5-7.0 [.138-.276] 5.0-12.5 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.146] 7.30 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.0-12.5 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.146] 7.30 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] Cable Type Impedance (ohms) RG Cables TNC Straight Bulkhead Jacks, Female Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-58, RG-141, RG-142, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 75 Raychem Cables 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 RG-179, RG-187 7530A1317 75 -- 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- TNC Right-Angle Plugs, Male Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-58, RG-141, RG-142, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 75 RG-179, RG-187 7530A1317 75 -- 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- Part No. RTD-50-S-02 RTD-50-M-02 RTD-50-L-02 RTD-75-S-02 RTD-75-M-02 RTD-75-L-02 RTD-50-S-01 RTD-50-M-01 RTD-50-L-01 RTD-75-S-01 RTD-75-M-01 RTD-75-L-01 8-60 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 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 consisting of a flux-coated, solderimpregnated copper shield braid encased in a heatshrinkable insulation sleeve. SolderShield cable-to-cable splice kits, designed for single-conductor or multiconductor 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 Electrical Interconnect Products 8-61 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable-to-Cable Splicing SolderShield Shielded and Coaxial Cable Splices Product Facts n Flux-coated, solderimpregnated copper shield braid encased in a transparent heat-shrinkable insulation sleeve provides a controlled soldering process, encapsulation, inspectability, strain relief, and insulation n One-piece design provides easy installation and lower installed cost n Circumferential (360) shielding results in EMI protection and shield continuity equal to or better than the original cable n Conductor splices are made using Raychem MiniSeal crimp products, which are recognized by MIL-S-81824 and MIL-W-5088 Applications Product Selection Process Used for splicing a wide range of cables, including coaxial and multiconductor cables. For splicing multiconductor cables refer to Table A. SolderShield devices can be used to repair or splice shielded or coaxial cables. These products consist of a MiniSeal crimp splice plus a flux-coated, solderimpregnated 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. 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: n HL1802E n IR-1759 MiniRay n CV-1981 Refer to Raychem installation procedure RCPS 15002 (D-150 series) and RPIP 699-00 (B-202 series) for detailed instructions and recommended reflector attachment. You will find ordering information for most of these tools in Section 10. Specifications/Approvals Series Military US: M81824 (conductor splice only) UK: RAF AP 1130-2008-1 D-150 Available in: Americas Europe Asia Pacific Raychem RT-1404 n n n 8-62 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable-to-Cable Splicing SolderShield Shielded and Coaxial Cable Splices (Continued) L1 L3 Table A. Multiconductor Cable Splices L2 Crimp Splice SolderShield Splice L1 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. L3 L2 I.D. SolderShield Product Dimensions Dimensions Part No. Tin Plated Nickel Plated L1 Max. L2 Nom. L3 Min. ID Min. D-150-0168 D-150-0228 D-150-0169 D-150-0229 D-150-0170 D-150-0230 D-150-0174 D-150-0231 D-150-0175 D-150-0232 D-150-0176 D-150-0233 D-150-0177 D-150-0234 D-150-0178 D-150-0235 D-150-0179 D-150-0236 D-150-0180 D-150-0237 D-150-0181 D-150-0238 80.50 [3.17] 80.50 [3.17] 80.50 [3.17] 10.60 [4.17] 10.60 [4.17] 10.60 [4.17] 10.60 [4.17] 10.60 [4.17] 10.60 [4.17] 10.60 [4.17] 10.60 [4.17] 50.00 [1.97] 50.00 [1.97] 50.00 [1.97] 75.00 [2.95] 75.00 [2.95] 75.00 [2.95] 75.00 [2.95] 75.00 [2.95] 75.00 [2.95] 75.00 [2.95] 75.00 [2.95] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 3.00 [.118] 4.00 [.157] 5.00 [.197] 4.00 [.157] 5.00 [.197] 6.00 [.236] 9.00 [.356] 4.00 [.157 ] 5.00 [.197] 6.00 [.236] 9.00 [.353] Conductor Splice Size Range CMA [mm2] Min.-Max. 304-1510 [0.15-0.75] 779-2680 [0.39-1.34] 1900-6755 [0.95-3.37] 304-1510 [0.15-0.75] 779-2680 [0.39-1.34] 1900-6755 [0.95-3.37] 304-1510 [0.15-0.75] 304-1510 [0.15-0.75] 779-2680 [0.39-1.34] 1900-6755 [0.95-3.37] 1900-6755 [0.95-3.37] Color Code Quantity Per Kit Red 1 Blue 1 Yellow 1 Red 2 Blue 2 Yellow 2 Yellow 2 Red 4 Red 4 Blue 4 Yellow 4 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 conductors. All the kits have environmental-sealing capability. The cable temperature rating must be 125C minimum. To find 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. 8 Electrical Interconnect Products 8-63 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable-to-Cable Splicing SolderShield Shielded and Coaxial Cable Splices (Continued) L1 Table B. Coaxial Cable Splices 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. L2 Crimp Splice SolderShield Splice L1 L3 L2 I.D. RG Cable No. Raychem Cable Description 8A, 9B, 11 13, 26, 31 115, 144, 149 165, 213, 214 216, 235, 391 393, 397 178, 196, 179, 187, 188, 316, 404, M17/138-00001, M17/136-00001 180, 195 M17/137-00001 M17/139-00001 -- 124, 140, 141 159, 302, 303 -- -- -- 29, 30, 55B 58, 223 -- 59, 62, 71 -- -- 5012A3311 5012E1339 7518A1311 -- -- -- 5028A1317 7528A1317 5030A1317 7530A1317 5024A1311 7526A1311 9527A1318 9530E1014 5020A1311 5022A1311 7522A1311 7523D1331 7524A1311 5019D3318 5021D1331 5022A1311 7523D1331 7524A1311 9524A1311 SolderShield Dimensions L2 Min ID Min Conductor Splice Qty/Kit Part No. 1 D-150-0214 80.50 [3.170] 50.00 [1.970] 12.00 [.472] 1 D-150-0094 80.50 [3.170] 50.00 [1.970] 3.00 [.118] 1 D-150-0095 80.50 [3.170] 50.00 [1.970] 4.00 [.157] 1 D-150-0096 80.50 [3.170 ] 50.00 [1.970] 5.00 [.236] 1 B-202-81* 56.00 [2.200] 23.00 [.900] 7.00 [.275] 1 B-202-82* 56.00 [2.200 ] 23.00 [.900] 7.00 [.275] L1 Max *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. 8-64 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable-to-Cable Splicing SolderShield Shielded and Coaxial Cable Splices (Continued) Product Characteristics Materials Insulation sleeve Meltable inserts Radiation-crosslinked polyvinylidene fluoride Fluorocarbon-based thermoplastic Base metal: Copper alloy C10200 per ASTM B75 Plating: Tin per MIL-T-10727 or nickel per QQ-N-290 Base metal: Tin-plated copper wire braid per ASTM B3 Solder and flux coating: Type Sn63 Pb37. Flux: ROM1 per ANSI - J - STD - 004 (RA flux) MiniSeal crimp splice SolderShield shield splice Test Method Parameter Electromechanical Performance Dielectric strength (shield connection) Dielectric strength (conductor connection) Voltage drop Insulation resistance (shield connection) Insulation resistance (conductor connection) Tensile strength for MiniSeal Tensile strength for SolderShield -- -- MIL-S-81824 -- -- MIL-S-81824 MIL-S-81824 Temperature rating Environmental Resistance Salt spray Heat aging Temperature cycling Altitude immersion -- MIL-STD-202 M101 750 hours at 150C [302F] MIL-STD-202 M107C Immersion at 22,860m [75,000 ft] Corrosion resistance -- Requirement No breakdown or arcing at 1000 Vac (RMS) 2.5 kV Less than 2.0-millivolt increase 1000 megohms minimum at 500 Vdc 5000 megohms Exceed yield strength (pounds) of wire. 75% of strength (pounds) of unspliced cable -55C to 150C [-67F to 302F] Meet voltage drop requirement. Meet all electromechanical requirements. Meet all electromechanical requirements. Meet insulation-resistance requirement. No evidence of corrosion after testing in accordance with MIL-STD-202, Method 101, Test Condition A 8 Electrical Interconnect Products 8-65 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts Introduction Raychem SolderTacts shielded contacts are designed to provide reliable, one-piece solder terminations for use with circular and rectangular connectors. These controlled 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 are available to terminate coaxial cable and twisted wire pairs in both military and commercial applications. 8-66 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts Product Facts n n n n n Reliable one-piece solder contacts: through-connector shielding reduces crosstalk, and improves signal transmission One-step installation Solder joints are strong and reliable Terminations are fully inspectable Termination for coax cables, shielded wires, twisted pairs, triaxial cables, for a variety of commercial and military connectors Applications Controlled Soldering SolderTacts contacts provide 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 provide 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 suited to military applications, along with commercial aerospace, instrumentation and computers. SolderTacts products are compatible with most standard connector cavities. SolderTacts contacts are intermateable and intermountable with contacts qualified to the indicated specification. 8 Electrical Interconnect Products One-piece controlled-soldering SolderTacts contacts connectors are designed to terminate coaxial cables, shielded wires, and twisted pairs faster and more reliably than any other method. SolderTacts contacts eliminate the variables associated with hard-to-handle crimping. Their one-step installation accelerates production while reducing handling and installed costs. SolderTacts shielded contacts can be terminated with standard Raychem heating tools. Once terminated, they can be installed into connector cavities with standard insertion and extraction tools. They are replaceable without cutting and restripping or shortening the cable. Specifications/Approvals Available in: Americas Europe Asia Pacific n n n Raychem D-6002 Series D-602 8-67 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) Jacket (JOD) Shield (SOD) Dielectric (DOD) Conductor (COD) SolderTacts Product Construction, MIL-C-26482 Series SolderTacts Series: MIL-C-26482 Contact Military Specification Cable Diameter JOD SOD DOD COD 1.78-4.70 [.070-.185] 1.78-4.70 [.070-.185] 1.52-3.30 [.060-.130] 1.52-3.30 [.060-.130] 1.65-2.79 [.065-.110] 1.65-2.79 [.065-.110] 1.68-2.13 [.066-.089] 1.68-2.13 [.066-.089] -- -- -- -- -- -- .76-2.03 [.030-.080] .76-2.03 [.030-.080] .91-1.75 [.036-.069] .91-1.75 [.036-.069] .76-1.24 [.030-.049] .76-1.24 [.030-.049] .23-.51 [.009-.020] .23-.51 [.009-.020] .30-.66 [.012-.026] .30-.66 [.012-.026] .28-.79 [.011-.031] .28-.79 [.011-.031] MIS-20067/5-001 MIS-20067/6-001 -- -- Wire (AWG) Raychem SolderTacts Part No. Size Polarity Cable Type 24-32 D-602-16 12 S Coaxial 24-32 D-602-17 12 P Coaxial 24-30 D-602-46 16 P Coaxial 26-32 D-602-47 16 S Coaxial 24-30 D-602-56 16 P Twinax 24-30 D-602-57 16 S Twinax These SolderTacts contacts are on qualified parts list for indicated specification. Tooling Selection Guide Part Numbers D-602-46/47 D-602-56/57 D-602-16/17 Engineering Standard (Termination Instructions) ES61137 ES61138 ES61161 Convection (Hot Air) Heating AT-1319 Adapter AT-1319-17 -- -- Repair Wand Contact Insertion Tool Contact Removal Tool * -- -- AD-1525 (M81969/17-04) -- AD-1526 (M81969/19-08) -- *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(R) General Purpose Hot-Air Heating Tool shown on page 10-13. 8-68 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) SolderTacts Series: MIL-C-28748 Series Jacket (JOD) Shield (SOD) Dielectric (DOD) Conductor (COD) SolderTacts product construction, MIL-C-28748 Series Cable Diameter Contact Military Specification MIS-20067/2-002a MIS-20067/1-001a MIS-20067/4-001a SOD DOD COD 1.52-3.35 [.060-.132] 1.52-3.35 [.060-.132] 1.68-2.13 [.066-.084] 1.68-2.13 [.066-.084] -- -- .91-1.78 [.036-.070] .91-1.78 [.036-.070] .76-1.24 [.030-.049] .76-1.24 [.030-.049] .91-1.68 [.036-.066] .91-1.68 [.036-.066] .91-1.68 [.036-.066] .91-1.68 [.036-.066] .76-1.24 [.030-.049] .76-1.24 [.030-.049] .91-1.78 [.036-.070] .91-1.78 [.036-.070] 1.40-3.15 [.055-.124] 1.40-3.15 [.055-.124] .23-.89 [.009-.035] .23-.89 [.009-.035] .28-.79 [.011-.031] .28-.79 [.011-.031] .30-.66 [.012-.026] .30-.66 [.012-.026] .30-.66 [.012-.026] .30-.66 [.012-.026] .28-.79 [.011-.031] .28-.79 [.011-.031] .23-.46 [.009-.018] .23-.46 [.009-.018] .64-1.57 [.025-.062] .64-1.57 [.025-.062] MIS-20067/3-001a -- -- M39029/79b 1.52-3.35 [.060-.132] 1.52-3.35 [.060-.132] 1.52-3.35 [.060-.132] 1.52-3.35 [.060-.132] 1.68-2.13 [.066-.084] 1.68-2.13 [.066-.084 ] 1.68-2.13 [.066-.084 ] 1.68-2.13 [.066-.084 ] -- -- -- -- -- -- -- 1.52-3.35 [.060-.132] 1.52-3.35 [.060-.132] 1.68-2.13 [.066-.084 ] 1.68-2.13 [.066-.084 ] MIS-20067/8-001a -- -- MIS-20067/7-001a -- -- M39029/80b M39029/40b M39029/41b MIS-20067/2-001, 003a Raychem Wire (AWG) SolderTacts Part No. Size Polarity Cable Type 26-32 D-602-44 16 P Coaxial 26-32 D-602-45 16 S Coaxial 24-30 D-602-54 16 P Twisted pair 24-30 D-602-55 16 S Twisted pair 26-32 D-602-72 16 P Coaxial 26-32 D-602-73 16 S Coaxial 26-32 D-602-76 16 P Coaxial 26-32 D-602-77 16 S Coaxial 24-30 D-602-0126 16 P Twisted pairc 24-30 D-602-0127 16 S Twisted pairc 28-32 D-602-0172 16 P Coaxial 28-32 D-602-0173 16 S Coaxial 16-20 D-610-09 16 P Power 16-20 D-610-10 16 S Power 8 Electrical Interconnect Products JOD a These SolderTacts contacts are on the qualified parts list for indicated specification. b These SolderTacts contacts are intermateable and intermountable with contacts qualified to the indicated specification; they replace crimp-style termination. c These SolderTacts contacts are designed for twisted-pair cable per MIL-STD-1553B. 8-69 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) Tooling Selection Guide: MIL-C-28748 Series 748 SolderTacts Series 748 D-602-44/45 D-602-0172/0173 D-602-54/55 D-602-0126/0127 ES61133 ES61240 ES61132 ES61199 Convection (Hot Air) Heating AT-1319 Repair Wand Adapter AT-1319-14 AD-1480 -- -- -- -- -- -- 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 Part No. SolderTacts Series Contact Insertion Tool * Engineering Standard (Termination Instructions) Contact Removal Tool AD-1447 Special Tools AD-1457A (bushing tool) AD-1464 (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(R) General Purpose Hot-Air Heating Tool shown on page 10-13. 8-70 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) SolderTacts Series: MIL-C-38999, Series I, II, III, IV Circular Connectors SolderTacts Product Construction, MIL-C-38999 Series Jacket (JOD) Contact Military Specification United States Air Force Drawing No. Cable Diameter JOD SOD DOD COD 3.81-5.94 [.150-.234] 3.81-5.94 [.150-.234] 1.27-2.62 [.050-.103] 1.27-2.62 [.050-.103] 3.10-4.32 [.150-.170] 3.10-4.32 [.150-.170] 1.68-2.13 [.066-.084] 1.68-2.13 [.066-.084] -- -- 1.52-3.84 [.060-.151] 1.52-3.84 [.060-.151] .91-1.73 [.036-.068] .91-1.73 [.036-.068] .64-1.09 [.025-.043] .64-1.09 [.025-.043] 1.12-2.03 [.044-.080] 1.12-2.03 [.044-.080] .74-1.45 [.029-.057] .74-1.45 [.029-.057] 1.27-2.62 [.050-.103] 1.27-2.62 [.050-.103] .76-1.24 [.030-.049] .76-1.24 [.030-.049] .91-1.78 [.036-.070] .91-1.78 [.036-.070] .76-1.24 [.030-.049] .76-1.24 [.030-.049] .64-1.29 [.029-.051] .64-1.29 [.029-.051] .48-1.09 [.019-.043] .48-1.09 [.019-.043] .23-.58 [.009-.023] .23-.58 [.009-.023] .23-.58 [.009-.023] .23-.58 [.009-.023] .48-.89 [.019-.035] .48-.89 [.019-.035] .48-.89 [.019-.035] .48-.89 [.019-.035] .48-.89 [.019-.035] .48-.89 [.019-.035] .27-.79 [.011-.031] .27-.79 [.011-.031] .23-.89 [.009-.035] .23-.89 [.009-.035] .27-.79 [.011-.031] .27-.79 [.011-.031] .27-.74 [.011-.029] .27-.74 [.011-.029] Shield (SOD) Dielectric (DOD) Conductor (COD) Wire (AWG) Raychem SolderTacts Part Number Size Polarity Cable Type 22-24 D-602-0122 8 P Coaxial 22-24 D-602-0123 8 S Coaxial 26-30 D-602-0140 16 P Coaxial 26-30 D-602-0141 16 S Coaxial 26-30 D-602-0142 16 P Twisted pair 26-30 D-602-0143 16 S Twisted pair 24-32 D-602-0144 12 P Coaxial 24-32 D-602-0145 12 S Coaxial 22-26 D-602-0146 12 P Twisted pair 22-26 D-602-0147 12 S Twisted pair 22, 28 D-602-0150 12 P Coaxial 22, 28 D-602-0151 12 S Coaxial 24-26 D-602-1108 8 S Twisted pairb 24-26 D-602-1109 8 P Twisted pairb 22-26 D-602-1110 8 S Triaxial 22-26 D-602-1111 8 P Triaxial 24-26 D-602-1112 8 S Twisted pairb 24-26 D-602-1113 8 P Twisted pairb 24-26 DK-602-0156-N-1 8 P Twinaxialc 24-26 DK-602-0156-N-2 8 P Twinaxialc Series I, III, and IV a M39029/60 a M39029/59 a M39029/76 a M39029/77 a M39029/76 a M39029/77 a M39029/28 a M39029/75 a M39029/28 a M39029/75 a M39029/28 -- 915304-1 915305-1 915304-2 915305-2 -- -- 915307-1 1.47-3.10 [.058-.122] 1.47-3.10 [.058-.122] 1.68-2.39 [.066-.094] 1.68-2.39 [.066-.094] -- -- 915308-1 915307-3 915308-3 -- -- 915307-2 1.90-3.81 [.075-.150] 1.90-3.81 [.075-.150] 2.49-3.42 [.098-.135] 2.49-3.42 [.098-.135] 2.49-3.76 [.098-.148] 2.49-3.76 [.098-.148] 2.49-3.42 [.098-.135] 2.49-3.42 [.098-.135] 3.68 [.145 ] Max. 4.11 [.162] Max. 2.54-2.97 [.100-.117] 2.54-2.97 [.100-.117] 1.68-3.05 [.066-.120] 1.68-3.05 [.066-.120] 1.68-3.30 [.066-.130] 1.68-3.30 [.066-.130] 1.68-3.05 [.066-.120] 1.68-3.05 [.066-.120] M39029/75 915308-2 -- 8340712-OS-01 -- 8340713-OS-01 -- -- -- -- -- 8340712-OL-01 -- 8340713-OL-01 a M39029/90 a M39029/90 8912020-OS-01 8912020-DL-01 -- -- 8 Electrical Interconnect Products a -- a These SolderTacts contacts are intermateable and intermountable with contacts qualified to indicated specification; they replace crimp-style termination. b These SolderTacts contacts are designed for shielded twisted pair cable per MIL-STD-1553B. c These SolderTacts contacts are designed for databus contacts per MIL-STD-1553B. 8-71 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) SolderTacts Series: MIL-C-38999, Series I, II, III, IV Circular Connectors (Continued) Contact Military Specification United States Air Force Drawing No. Cable Diameter (in inches) Wire (AWG) Raychem SolderTacts Part Number Size Polarity Cable Type JOD SOD DOD COD 4.50 max. [.177] 3.68 max. [.145] 4.12 max. [.162] 4.50 max. [.177] 4.67 max. [.184] 4.67 max. [.184] -- .74-1.30 [.029-.051] .74-1.30 [.029-.051] .74-1.30 [.029-.051] .74-1.30 [.029-.051] .24-.74 [.011-.029] .24-.74 [.011-.029] .24-.74 [.011-.029] .24-.74 [.011-.029] 24-26 DK-602-0156-N-3 8 P Twinaxialc 24-26 DK-602-0157-N-1 8 S Twinaxialc 24-26 DK-602-0157-N-2 8 S Twinaxialc 24-26 DK-602-0157-N-3 8 S Twinaxialc -- -- -- 20 DK-602-0169-1 8 P Twinaxialc -- -- -- 20 DK-602-0170-1 8 S Twinaxialc .23-.58 [.009-.023] .23-.58 [.009-.023] .23-.58 [.009-.023] .23-.58 [.009-.023] 26-30 D-602-0140 16 P Coaxial 26-30 D-602-0171 16 S Coaxial 26-30 D-602-0142 16 P Twisted pair 26-30 D-602-0174 16 S Twisted pair Series I, III, and IV a M39029/90 a M39029/91 a M39029/91 a M39029/91 a M39029/90 a M39029/91 8912020-EL-01 8912019-OS-01 8912019-DL-01 8912019-EL-01 8912020-OL-01 8912019-OL-01 -- -- -- Series II a M39029/76 a M39029/77 a M39029/76 a M39029/77 915304-1 915306-1 1.27-2.62 [.050-.103] 1.27-2.62 [.050-.103] 915304-2 -- 915306-2 -- 1.68-2.13 .91-1.73 [.066-.084] [.036-.068] 1.68-2.13 .91-1.73 [.066-.084] [.036-.068] .64-1.09 -- [.025-.043] .64-1.07 -- [.025-.042] a These SolderTacts contacts are intermateable and intermountable with contacts qualified to indicated specification; they replace crimp-style termination. b These SolderTacts contacts are designed for shielded twisted pair cable per MIL-STD-1553B. c These SolderTacts contacts are designed for databus contacts per MIL-STD-1553B. Tooling Selection Guide SolderTacts Series 999 Size 16 999 Size 12 999 Size 8 Part Numbers (D-602-) 0140/0141 0142/0143 0171 0174 0144/0145 0146/0147 0150/0151 0122/0123 1108/1109 1110/1111 1112/1113 0156/0157-X 0169/0170-X Engineering Standard (Termination Instructions) ES61226 ES61224 ES61226 ES61224 ES61206 ES61218 ES61223 ES61179 ES61172 ES61172 ES61184 ES61231 ES61235 Convection (Hot Air) Heating AT-1319 Adapter AT-1319-78 -- AT-1319-27 -- AT-1319-24 -- -- AT-1319-22 AT-1319-22 and AT-1319-14 Repair Wand AD-1565 -- AD-1572 -- AD-1566 -- -- AD-1568 -- AD-1568 and AD-1480 Contact Insertion Tool Contact Removal Tool* M81969/8-07 or M81969/14-03 M81869/8-08 or M81969/14-03 M81969/8-09 or M81969/14-04 M81969/8-10 or M81969/14-04 -- M81969/14-06 or Astro ATBX-2277 *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(R) General Purpose Hot-Air Heating Tool shown on page 10-13. 8-72 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) SolderTacts Series: Subminiature* SolderTacts Product Construction, Submin Series Jacket (JOD) Shield (SOD) Dielectric (DOD) Conductor (COD) Raychem Cable Diameter SolderTacts Size Polarity Cable Type D-602-0278 16 P Coaxial D-602-0279 16 S D-602-0288 16 D-602-0289 16 Coaxial JOD 1.52-2.92 [.060-.115] 1.52-2.92 [.060-.115] SOD 1.85-2.18 [.073-.086] 1.85-2.18 [.073-.086] P Twisted pair -- -- S Twisted pair -- -- Cable Diameter DOD .64-1.91 [.025-.075] .64-1.91 [.025-.075] .74-1.40 [.029-.055] .74-1.40 [.029-.055] COD .23-.74 [.009-.029] .23-.74 [.009-.029] .23-.74 [.009-.029] .23-.74 [.009-.029] (AWG) 24-32 24-32 24-32 24-32 *These SolderTacts contacts belong to the Raychem "Subminiature" series of contacts, which are designed for use in commercial connectors. 8 Electrical Interconnect Products Tooling Selection Guide SolderTacts Series Part Numbers (D-602-) Submin -- 0278/0279 0288/0289 Engineering Standard (Termination Instructions) ES61170 ES61414 Convection (hot air) Heating AT-1319 Adapter AT-1319-12 -- Repair Wand Contact Insertion Tool Contact Removal Tool AD-1481 -- * -- AD-1447 -- *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(R) General Purpose Hot-Air Heating Tool shown on page 10-13. 8-73 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) SolderTacts Series: MIL-C-83723 Contact Military Specification* M39029/74-400 M39029/73-397 Cable Diameter JOD SOD DOD COD 2.39-3.56 [.094-.140] 2.39-3.56 [.094-.140] 1.96-2.49 [.077-.098] 1.96-2.49 [.077-.098] -- -- 1.32-2.06 [.052-.081] 1.32-2.06 [.052-.081] .74-1.45 [.029-.057] .74-1.45 [.029-.057] 2.36-2.67 [.093-.105] 2.36-2.67 [.093-.105] .28-.74 [.011-.029] .28-.74 [.011-.029] .28-.74 [.011-.029] .28-.74 [.011-.029] .28-.74 [.011-.029] .28-.74 [.011-.029] M39029/74-401 M39029/73-398 -- -- M39029/74-399 3.05-3.68 [.120-.145] 3.05-3.68 [.120-.145] 3.10-3.15 [.122-.124] 3.10-3.15 [.122-.124] M39029/73-396 Wire (AWG) Raychem SolderTacts Size Polarity Cable Type 24-32 D-602-0094 12 P Coaxial 24-32 D-602-0095 12 S Coaxial 24-32 D-602-0104 12 P Twisted pair 24-32 D-602-0105 12 S Twisted pair 24-32 D-602-0106 12 P Large coaxial 24-32 D-602-0107 12 S Large coaxial * These SolderTacts contacts are on qualified parts list for indicated specification. Tooling Selection Guide Raychem SolderTacts Part Number D-602-0094/0095 D-602-0106/0107 D-602-0104/0105 Engineering Standard (Termination Instructions) ES61128 ES61134 ES61129 Convection (Hot Air) Heating AT-1319 Adapter AT-1319-19 Rev. D -- Repair Wand Contact Insertion Tool Contact Removal Tool Special Tools AD-1494 Rev. C -- AD-1527 (M81969/14-04) -- AD-1527 (M81969/14-04) -- AD-1496 (twisted) -- Note: AA-400 SuperHeater Compressed Air Heating Tool shown on page 10-2 can be used for installation. Another option is the Steinel(R) General Purpose Hot-Air Heating Tool shown on page 10-13. SolderTacts Series: DOD-C-83527 Raychem SolderTacts Size Polarity Reference D-602-0185 16 socket D-602-0094 12 pin D-602-0093* 12 socket D-602-0106 12 pin D-602-0189* 12 socket *These SolderTacts contacts are intermateable with M39029/73, but are not on QPL. Cable Type Coaxial Coaxial Coaxial Coax (large) Coax (large) Contact Military Specification -- M39029/74 M39029/73 M39029/74 M39029/73 SolderTacts Series: DOD-C-83527 (data bus contacts)** Raychem SolderTacts Reference D-602-0186 D-602-0187 DK-602-0186-2 DK-602-0187-2 Size Polarity Cable Type 8 8 8 8 pin socket pin socket Twisted pair Twisted pair Sh. twisted pair Sh. twisted pair Contact Military Specification M39029/96 M39029/95 M39029/96 M39029/95 ** These SolderTacts contacts are designed for shielded twisted pair cable per MIL-STD-1553B. 8-74 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) SolderTacts Series: Grommets Raychem SolderTacts Reference D-600-0071 D-600-0116 D-600-0125 Performance Size -- For size 8 DOD-C-83527 series For size 8 MIL-C-38999 series, for twisted pair Polarity For shielded twisted pair -- -- The performance of SolderTacts contacts is defined by the applicable Raychem specification control drawing (SCD) and Raychem Specification D-6002. Products on qualified 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. 8 Electrical Interconnect Products 8-75 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Introduction The full line of Raychem data bus products offers a complete system of interconnection hardware for all MIL-STD-1553B multiplexing needs. Available components include: n n n n n n n n n Couplers (micros, boxes, flat packs) Data bus cables Triax connectors and contacts with strain relief One-piece triaxial contacts for MIL-C-38999 connectors (size 8 cavity) Raychem MIL-STD-1553B data bus components are also specified in the Air Force drawings listed in Air Force Drawing 8340707. Tyco Electronics also supplies 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. Bus and stub terminators Cable marker sleeves (TMS) Lightweight couplers (see pages 8-82 to 8-84) Space components (see pages 8-95 to 8-97) Harness design (HarnWare) All Raychem data bus components offer: n n n High packaging density and weight savings Design flexibility High performance (to 150C [302F] rating) 8-76 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Cables Product Facts n Light weight Highly flexible n Flame resistant n Chemical resistant to all aircraft fluids n Solder iron resistant n Defined shielding levels n Applications Tyco Electronics manufactures a line of Raychem SPEC 55 data bus cables that meet or exceed the performance requirements of MIL-STD-1553B. 8 Electrical Interconnect Products SPEC 55 insulation is a high-temperature, radiationcrosslinked, modified ETFE material that can be used in wire constructions rated up to 200C [392F]. Note: Tyco Electronics will build harnesses with any customer specified cables and/or connectors. 8-77 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Cables (Continued) Specifications/Approvals Product Selection Series SPEC 55 insulation Military MIL-W-22759/32-/35 MIL-W-22759/41-/46 Cable Type Part No. 24 AWG Single Optimized Shield 10612 24 AWG Double Optimized Shield 10613 24 AWG EMP Hardened 10614 24 AWG Flat Shield, Unfilled 7724 H 0664 8-78 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components In-Line Microcouplers: One- and Two-Stub Product Facts n Environmental sealing No connectors n Very small size n Light weight (1 stub: 10 g max.; 2 stubs: 15 g max.) n In-line profile that makes wire bundle mounting possible n 360 continuous lowimpedance cable-shield terminations n Reliable solder termination of all components n Potted circuit elements for maximum durability and inuse reliability n Ease of installation n Altitude immersion resistance n Optional eyelet configurations for bulkhead mounting n Mean time between failures > 1,000,000 hours n 8 Electrical Interconnect Products 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 Europe Asia Pacific including EMP-hardened versions. They are also available assembled with other components into a complete data bus harness. Series D-500-04 Military MIL-STD-1553B Raychem D-6020 n n n 8-79 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components In-Line Microcouplers: One- and Two-Stub (Continued) Product Selection 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 8-80 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components In-Line Microcouplers: One- and Two-Stub (Continued) Microcoupler Part Numbering System D-500-04 W W - X- YYY - ZZZ 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 8 Electrical Interconnect Products 8-81 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub Product Facts n Environmental sealing No connectors n Very small size n Ultra Light weight (1 stub: 6.5 g max.; 2 stubs: 9.5 g max.) n In-line profile that makes wire bundle mounting possible n 360 continuous lowimpedance cable-shield terminations n Reliable solder termination of all components n Potted circuit elements for maximum durability and in-use reliability n Ease of installation n Altitude immersion resistance n Mean time between failures > 1,000,000 hours n Applications Building on over 20 years of experience and continuous improvement in data bus, including pioneering in-line microcouplers, Tyco Electronics introduces a new family of ultra lightweight 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 6stub, and minimize weight there is no option with a mounting eyelet. Combined with Raychem 24 AWG data bus cables, these ultra light couplers allow designers to significantly reduce weight. An unfilled flat braid cable is available for additional weight savings. They are also available assembled with other customer specified components into a complete factory-built and tested data bus harness. Specifications/approvals Series D-500-L4xx Available in: Americas Europe Asia Pacific Military MIL-STD-1553B Raychem D-6020 (same as current microcouplers) n n n 8-82 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub (Continued) Lightweight In-Line Couplers Part Numbering System D-500-L4 5 W -X -YYY -ZZZ Cable Length 012 = 12 in 079 = 79 in 078 = 78 in 120 = 120 in 236 = 236 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 8 Electrical Interconnect Products 8-83 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub (Continued) Product Selection D-500-L455-X-YYY-ZZZ End View Left Side D-500-L456-X-YYY-ZZZ End View Right Side End View Left Side End View Right Side 1 stub 1 stub 2 stub 2 stub 3 stub 3 stub 4 stub 4 stub 5 stub 5 stub 6 stub 6 stub D-500-L457-X-YYY-ZZZ End View Left Side D-500-L458-X-YYY-ZZZ End View Right Side End View Right Side End View Left Side 1 stub 1 stub 2 stub 2 stub 3 stub 3 stub 4 stub 4 stub 5 stub 5 stub 6 stub 6 stub Legend Bus cable Stub cable 8-84 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Box Couplers Product Facts n Light, robust coupler modules with connector versatility n Up to eight stub connectors can be arrayed on the "face" of the box coupler. Bus connectors can also be on the "face" or on the "side" of the box n Designed with Raychem D-621 series corrosionresistant threaded-type or bayonet-type connectors Applications The multiport capability of these couplers (up to eight stubs) enables avionics system designers to interconnect black boxes with minimum wire runs. Box couplers are supplied with Raychem triaxial threaded or bayonet connectors. 8 Electrical Interconnect Products Note: Tyco Electronics also designs and manufactures customized Raychem data bus box couplers. Specifications/Approvals Available in: Americas Europe Asia Pacific Series D-500-0255 Military MIL-STD-1553 Raychem D-6021 n n n 8-85 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Box Couplers (Continued) Product Selection Coupler Type Part No. Face - 1 Stub Face - 2 Stub Face - 3 Stub Face - 4 Stub Face - 5 Stub Face - 6 Stub Face - 7 Stub Face - 8 Stub Threaded D-500-0255-511-1 D-500-0255-521-1 D-500-0255-531-1 D-500-0255-541-1 D-500-0255-551-1 D-500-0255-561-1 D-500-0255-571-1 D-500-0255-581-1 Bayonet A* D-500-0255-513-1 D-500-0255-523-1 D-500-0255-533-1 D-500-0255-543-1 D-500-0255-553-1 D-500-0255-563-1 D-500-0255-573-1 D-500-0255-583-1 Bayonet B* D-500-0255-515-1 D-500-0255-525-1 D-500-0255-535-1 D-500-0255-545-1 D-500-0255-555-1 D-500-0255-565-1 D-500-0255-575-1 D-500-0255-585-1 Bayonet C* D-500-0255-517-1 D-500-0255-527-1 D-500-0255-537-1 D-500-0255-547-1 D-500-0255-557-1 D-500-0255-567-1 D-500-0255-577-1 D-500-0255-587-1 Side - 1 Stub Side - 2 Stub Side - 3 Stub Side - 4 Stub Side - 5 Stub Side - 6 Stub Side - 7 Stub Side - 8 Stub D-500-0255-512-1 D-500-0255-522-1 D-500-0255-532-1 D-500-0255-542-1 D-500-0255-552-1 D-500-0255-562-1 D-500-0255-572-1 D-500-0255-582-1 D-500-0255-513-2 D-500-0255-523-2 D-500-0255-533-2 D-500-0255-543-2 D-500-0255-553-2 D-500-0255-563-2 D-500-0255-573-2 D-500-0255-583-2 D-500-0255-515-2 D-500-0255-525-2 D-500-0255-535-2 D-500-0255-545-2 D-500-0255-555-2 D-500-0255-565-2 D-500-0255-575-2 D-500-0255-585-2 D-500-0255-517-2 D-500-0255-527-2 D-500-0255-537-2 D-500-0255-547-2 D-500-0255-557-2 D-500-0255-567-2 D-500-0255-577-2 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 8-86 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Discrete Connectors Product Facts n Compliance with MIL-STD-1553B hardware requirements n Light weight n Removable pin or socket contacts n Termination with Raychem MIL-STD-1553B data bus cables, including EMPhardened versions n Continuous 360 shield coverage n Rugged constructions n Termination time of 1 to 2 minutes n Inspectable solder terminations n Low-skill assembly n Reworkable and repairable terminations n Strain relief built into the design n Low-voltage drop and high reliability because of precisely controlled solder terminations n Threaded and bayonet coupling styles n Low total installed cost n 1000-hour salt spray resistance n Lower-cost connectors, for benchtop and mock-up Available in: Americas Europe Asia Pacific Designed specifically for MIL-STD-1553B data bus applications, the D-621 connector is intended to be a perfect match for the Raychem airworthy data bus cable. Together they provide durable, reliable, and reworkable interconnection hardware for the MIL-STD-1553B market. Series DK-621 8 Military MIL-STD-1553B Electrical Interconnect Products Specifications/Approvals Applications Raychem D-6025 n n n 8-87 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Discrete Connectors (Continued) Connector Kit Part Numbering System DK-621-04 XX-XX Contact (supplied in DK-621 kits only) P = Pin S = Socket Polarization (bayonet styles only) (jack view) 1=A 2=B 4=D 3=C 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 Example: DK-621-0434-1P = D-621 connector, kitted with accessories, jack bayonet style with A polarization and pin contact. 8-88 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Accessories Product Facts n A single source for all harness components n Products designed to work together 8 Available in: Americas Europe Asia Pacific n n n Electrical Interconnect Products These include: Applications Tyco Electronics manufactures all the products needed to build a MIL-STD1553B data bus network. In addition to the main components (couplers, connectors, contacts, and cables), Tyco Electronics supplies the accessory components that may be necessary to complete a data bus system. n n n n n Bus and stub terminators (spliced-in and connectorized D-621 series). Cable splice kits. EMI/environment-resistant connector caps. Braid terminators and strain relief tubing (for rework applications). Cable marking materials. 8-89 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Accessories (Continued) Product Selection D-621 Plug D-621 plug D-621 Jack D-621 jack Splice-in Splice-in Bus and Stub Terminators Spliced-in 77-ohm 10612 cable 77-ohm 10613 cable 77-ohm 10614 cable 77-ohm 7724H0664 cable 12-inch Cable D-500-0463-612 D-500-0463-613 D-500-0463-614 D-500-0463-H06 D-621 Series--Plug 77-ohm pin contact 77-ohm socket contact 3000-ohm pin contact 3000-ohm socket contact 1 = A 2 = B 3 = C 4 = D Threaded D-621-0413 D-621-0415 D-621-0417 D-621-0407 Bayonet A D-621-0453 D-621-0469 D-621-0457 D-621-0473 Bayonet B D-621-0454 D-621-0470 D-621-0458 D-621-0474 Bayonet C D-621-0455 D-621-0471 D-621-0459 D-621-0475 Bayonet D D-621-0456 D-621-0472 D-621-0476 D-621-0460 D-621 Series--Jack 77-ohm pin contact 77-ohm socket contact 3000-ohm pin contact 3000-ohm socket contact Threaded D-621-0418 D-621-0406 D-621-0423 D-621-0424 Bayonet A D-621-0477 D-621-0461 D-621-0481 D-621-0465 Bayonet B D-621-0478 D-621-0462 D-621-0482 D-621-0466 Bayonet C D-621-0479 D-621-0463 D-621-0483 D-621-0467 Bayonet D D-621-0480 D-621-0464 D-621-0484 D-621-0468 D-621 Series--L Lanyard 7" -- -- -- -- Connector Caps D-621 Series Plug cap for jack connector Supplied with 7" Lanyard Threaded Bayonet A Bayonet B Bayonet C Bayonet D D-600-0083 D-600-0068 D-600-0068 D-600-0068 D-600-0065 Cable Splice Kits Cables All data bus cables Flexible Crimp D-150-0708-5 8-90 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Accessories (Continued) Terminator and Connector and Compatibility -- Bayonet and Threaded Connectors Panel Thickness Connector Contact Terminator Reference Standard Connector Mate with Long Reach Connector Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket D-621-0453(-L) D-621-0469(-L) D-621-0477(-L) D-621-0461(-L) D-621-0457(-L) D-621-0473(-L) D-621-0481(-L) D-621-0465(-L) DK-621-0434-1S DK-621-0434-1P DK-621-0433-1S DK-621-0433-1P DK-621-0434-1S DK-621-0434-1P DK-621-0433-1S DK-621-0433-1P DK-621-0550-1S DK-621-0550-1P -- -- DK-621-0550-1S DK-621-0550-1P -- -- Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket D-621-0454-(-L) D-621-0470-(-L) D-621-0478-(-L) D-621-0462-(-L) D-621-0458-(-L) D-621-0474-(-L) D-621-0482-(-L) D-621-0466-(-L) DK-621-0436-2S DK-621-0436-2P DK-621-0435-2S DK-621-0435-2P DK-621-0436-2S DK-621-0436-2P DK-621-0435-2S DK-621-0435-2P DK-621-0548-2S DK-621-0548-2P -- -- DK-621-0548-2S DK-621-0548-2P -- -- Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket D-621-0455(-L) D-621-0471(-L) D-621-0479(-L) D-621-0463(-L) D-621-0459(-L) D-621-0475(-L) D-621-0483(-L) D-621-0467(-L) DK-621-0438-3S DK-621-0438-3P DK-621-0437-3S DK-621-0437-3P DK-621-0438-3S DK-621-0438-3P DK-621-0437-3S DK-621-0437-3P DK-621-0546-3S DK-621-0546-3P -- -- DK-621-0546-3S DK-621-0546-3P -- -- Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket D-621-0456(-L) D-621-0472(-L) D-621-0480(-L) D-621-0464(-L) D-621-0460(-L) D-621-0476(-L) D-621-0468(-L) D-621-0484(-L) DK-621-0440-4S DK-621-0440-4P DK-621-0439-4S DK-621-0439-4P DK-621-0440-4S DK-621-0440-4P DK-621-0439-4S DK-621-0439-4P DK-621-0551-4S DK-621-0551-4P -- -- DK-621-0551-4S DK-621-0551-4P -- -- Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket D-621-0413(-L) D-621-0415(-L) D-621-0418(-L) D-621-0406(-L) D-621-0417(-L) D-621-0407(-L) D-621-0423(-L) D-621-0424(-L) DK-621-0412-S DK-621-0412-P DK-621-0411-S DK-621-0411-P DK-621-0412-S DK-621-0412-P DK-621-0411-S DK-621-0411-P DK-621-0512-S DK-621-0512-P -- -- DK-621-0512-S DK-621-0512-P -- -- Bayonet Connectors Polarity A 77 Ohm bus terminator 3K Ohm stub terminator Polarity B 77 Ohm bus terminator 3K Ohm stub terminator Polarity C 77 Ohm bus terminator 3K Ohm stub terminator 8 Polarity D 3K Ohm stub terminator Electrical Interconnect Products 77 Ohm bus terminator Threaded Connectors 77 Ohm bus terminator 3K Ohm stub terminator 8-91 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Accessories (Continued) Triaxial Connectors and Terminator Compatibility -- Bayonet and Threaded Connectors Panel Thickness Connector Contact Connector Reference Connector Mate with 77 Ohm Bus Terminator Standard 2.4mm max. Long Reach Plug Plug Jack Jack Jack Pin Socket Pin Socket Pin DK-621-0433-1P DK-621-0433-1S DK-621-0434-1P DK-621-0434-1S DK-621-0550-1P DK-621-0434-1S DK-621-0434-1P DK-621-0433-1S DK-621-0433-1P DK-621-0433-1S D-621-0461(-L) D-621-0477(-L) D-621-0461(-L) D-621-0453(-L) D-621-0469(-L) D-621-0465 (-L) D-621-0481(-L) D-621-0473(-L) D-621-0457(-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) Standard 2.4mm max. Long Reach Plug Plug Jack Jack Jack Pin Socket Pin Socket Pin DK-621-0435-2P DK-621-0435-2S DK-621-0436-2P DK-621-0436-2S DK-621-0448-2P DK-621-0436-2S DK-621-0436-2P DK-621-0435-2S DK-621-0435-2P DK-621-0435-2S D-621-0462(-L) D-621-0478(-L) D-621-0470(-L) D-621-0454(-L) D-621-0470(-L) D-621-0474 (-L) D-621-0458(-L) D-621-0474(-L) D-621-0458(-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) Standard 2.4mm max. Long Reach Plug Plug Jack Jack Jack Pin Socket Pin Socket Pin DK-621-0437-3P DK-621-0437-3S DK-621-0438-3P DK-621-0438-3S DK-621-0446-3P DK-621-0438-3S DK-621-0438-3P DK-621-0437-3S DK-621-0437-3P DK-621-0437-3S D-621-0463(-L) D-621-0479(-L) D-621-0471(-L) D-621-0455(-L) D-621-0471(-L) D-621-0467(-L) D-621-0483(-L) D-621-0475(-L) D-621-0459(-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) Plug Plug Jack Jack Jack Pin Socket Pin Socket Pin DK-621-0439-4P DK-621-0439-4S DK-621-0440-4P DK-621-0440-4S DK-621-0551-4P DK-621-0440-4S DK-621-0440-4P DK-621-0439-4S DK-621-0439-4P DK-621-0439-4S D-621-0464(-L) D-621-0480(-L) D-621-0472(-L) D-621-0456(-L) D-621-0472(-L) D-621-0468(-L) D-621-0484(-L) D-621-0476(-L) D-621-0460(-L) D-621-0476(-L) Jack Socket DK-621-0551-4S DK-621-0439-4P D-621-0456(-L) D-621-0460(-L) Standard 2.4mm max. Long Reach Plug Plug Jack Jack Jack Pin Socket Pin Socket Pin DK-621-0411-P DK-621-0411-S DK-621-0412-P DK-621-0412-S DK-621-0412-P DK-621-0412-S DK-621-0412-P DK-621-0411-S DK-621-0411-P DK-621-0411-S D-621-0406(-L) D-621-0418(-L) D-621-0415(-L) D-621-0413(-L) D-621-0415(-L) D-621-0424(-L) D-621-0423(-L) D-621-0407(-L) D-621-0417(-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) 3K Ohm Stub Terminator Bayonet Connectors Polarity A Polarity B Polarity C Polarity D Standard 2.4mm max. Long Reach 12.5mm max. Threaded Connectors 8-92 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Accessories (Continued) Triaxial Connectors and Terminator Compatibility -- to European norme 3716 Panel Thickness Connector Contact Connector Reference Connector Mate with 77 Ohm Bus Terminator 3K Ohm Stub Terminator Plug Plug Plug Plug Jack Jack Jack Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket Pin DK-3716-F101-TP DK-3716-F101-TS DK-3716-F201-TP DK-3716-F201-TS DK-3716-E102-TP DK-3716-E102-TS DK-3716-E202-TP DK-3716-E202-TS DK-3716-E112-TP DK-621-E102-TS DK-621-E102-TP DK-621-E202-TS DK-621-E202-TP DK-621-F101-TS DK-621-F101-TP DK-621-F201-TS DK-621-F201-TP DK-621-F101-TS D-621-E077-S D-621-E077-P D-621-E077-S D-621-E077-P D-621-F077-S D-621-F077-P D-621-F077-S D-621-F077-P D-621-F077-S D-621-E03K-S D-621-E03K-P D-621-E03K-S D-621-E03K-P D-621-F03K-S D-621-F03K-P D-621-F03K-S D-621-F03K-P D-621-F03K-S Jack Jack Jack Socket Pin Socket DK-3716-E112-TS DK-3716-E212-TP DK-3716-E212-TS DK-621-F101-TP DK-621-F201-TS DK-621-F201-TP D-621-F077-P D-621-F077-S D-621-F077-P D-621-F03K-P D-621-F03K-S D-621-F03K-P Triaxial Connectors Standard 2.4mm max. Long Reach 12.5mm max. Panel Thickness Mate with Connector Contact Terminator Reference Standard Connector Long Reach Connector Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket DK-3716-F077-P DK-3716-F077-S DK-3716-F077-P DK-3716-F077-S DK-3716-E03K-P DK-3716-E03K-S DK-3716-E03K-P DK-3716-E03K-S DK-3716-E#02-TS DK-3716-E#02-TP DK-3716-E#01-TS DK-3716-E#01-TP DK-3716-E#02-TS DK-3716-E#02-TP DK-3716-E#01-TS DK-3716-E#01-TP DK-3716-E#12K-TS DK-3716-E#12K-TP -- -- DK-3716-E#12K-TS DK-3716-E#12K-TP -- -- Terminators 77 Ohm bus terminator 3K Ohm stub terminator 8 Electrical Interconnect Products 8-93 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Triaxial Size 8 Contacts Product Facts n One-step termination Termination time of 1 to 2 minutes n No requirements for special termination tools n No requirements for special skills n Reworkable and repairable terminations n Strain relief n Continuous 360 shield coverage n Triaxial mating face for least susceptibility to damage n Rugged construction, because only two parts are being soldered together n Inspectable solder terminations n Low voltage drop and high reliability due to precisely controlled solder termination n Applications Contacts provide full shield coverage with a simple, quick, and reliable termination system. 24 AWG twisted-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. Specifications/Approvals Product Selection Available in: Americas Europe Asia Pacific 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 termination, and intermateability with more cumbersome crimp contacts. Series Size 8 These contacts provide a fast and convenient method of implementing MIL-STD-1553B connections in MIL-STD-1760 applications. Raychem D-6002 Cable Type 10612 10613 10614 Pin DK-602-0156-N-1 DK-602-0156-N-2 DK-602-0156-N-3 Socket DK-602-0157-N-1 DK-602-0157-N-2 DK-602-0157-N-3 n n n 8-94 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Space-Grade Data Bus Components Product Facts n Complete line of spacequalified MIL-STD-1553B components n Low outgassing levels that meet NASA requirements n Light weight n Rugged construction Figure 1. In-line couplers and terminators Applications Figure 2. Threaded triaxial connectors Figure 3. Bayonet triaxial connectors Raychem space-grade components are designed in a variety of configurations and are currently available either as discrete items or as Raychem- assembled harnesses. Using factorybuilt harnesses eliminates unnecessary splices and connectors, reducing the cost and increasing the reliability of the networks. Figure 4. Splice kit Specification control drawings describe the design Available in: Americas Europe Asia Pacific features and performance characteristics of Raychem space-grade couplers, terminators, connectors, and splices. The spacegrade data bus couplers, terminators, and connectors have tin/nickel-plated metallic 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 polymeric environmental covers. 8 Electrical Interconnect Products Tyco Electronics full line of Raychem data bus products 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 outerspace applications. 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. n n n 8-95 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Space-Grade Data Bus Components (Continued) Specifications/Approvals Series Space-grade data bus components Raychem D-6022 Space-Grade In-Line Coupler Part Numbering System D-500-94 W W -X -YYY -ZZZ 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 8-96 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Space-Grade Data Bus Components (Continued) Space-Grade Connectors Part Numbering System DK-621 -09 XX -X X 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) 1=A 2=B 4=D 3=C 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 8 Electrical Interconnect Products Space-Grade Terminators Part Numbering System D-500-9463- ZZZ 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) Space-Grade Splice Kit = D-150-9708-5 8-97 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Customer-Specified Harness Assemblies and HarnWare Harness Design Software Tyco Electronics supplies complete Raychem data bus networks in accordance with customer harness drawings, with any customer-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 to draw a data bus harness in a matter of minutes, while selecting Raychem or others' components; a bill of materials is automatically generated. Sample Drawing WHEELBAY 10 WHEEL BAY 2 1 12 D-600-XXXX ISSUE x LOT N XXXX 4 1 3 NOSE 12 1 NOSE DATA BUS COUPLER Raychem Raychem Raychem DATA BUS COUPLER DATA BUS COUPLER 2 5 12 11 6 2 12 CMC1 2 12 12 8 STBD CMC2 CMC 1 7 9 CMC 2 STBD Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 Description Data bus Cable Data bus Cable Data bus Coupler Data bus Coupler Data bus Coupler Data bus Terminator Data bus Contact Data bus Contact Data bus Connector Data bus Connector Data bus Connector Marker Sleeve Part No. 10613-9 10613-96 D-500-0455-1 D-500-0455-2 D-500-0457-1 D-621-0469-L DK-602-0156-N-2 DK-602-0157-N-2 DK-621-0411-P DK-621-0412-P DK-621-0434-1P TMS-SCE-3/16-2.0-9 Spec/Remarks Raychem Raychem Raychem Raychem Raychem Raychem Raychem Raychem Raychem Raychem Raychem Raychem Qty 5.3 7 1 1 1 1 1 1 1 1 1 6 Unit M M Pc Pc Pc Pc Pc Pc Pc Pc Pc Pc 8-98 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC/EMI Adapters Introduction Product Facts n Superior EMC/EMI Shielding Performance n Simple installation n Easy reentry n Simplified maintenance and repair n Excellent mechanical and environmental resistance n Efficient strain relief n Flexibility n Versatility Applications Tyco Electronics, a longtime leader in harnessing technology, has written a new chapter in EMC shielding with the introduction of the Raychem HexaShield EMC adapter. n n n HexaShield adapters are simple to install, easy to Designed to corresponding connector specifications. Principal points and features n n n n n Easy reentry: To insert or remove ferrules from the HexaShield adapter, simply loosen the back nut. Superior protection: No degradation of shielding performance. Up to four shielded cables accommodated by each ferrule. Mechanical and environmental protection equal to backshells complying with MIL-C-85049 Category 3B. Strain relief on each individual cable. Two Platings Available Electroless nickel (MIL-DTL-26074) Olive drab cadmium (QQ-P-416 Type II Class 3) n n n Weight reduction, by possibly eliminating the need for overall shielding. Compact size - not exceeding outer diameter of connector. Available in straight, 45 and 90 angles, as well as swept and long bodies. 8 Simple assembly and installation 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. Electrical Interconnect Products Available in: Americas Europe Asia Pacific Designed to provide EMC protection solutions for both commercial and military applications, HexaShield adapters represent a significant improvement over pigtail termination methods. By providing 360-degree EMC shielding on the termination area of each individual cable, HexaShield adapters provide outstanding shielding effectiveness. maintain, and dependably resistant to mechanical and environmental stresses. Raychem Product Specifications RB-110 and RB-114 -- *Contact Tyco Electronics for additional platings. Installation Procedures Installation procedure for HET-A-02X and HET-A-04X (RPIP-696-00) Installation procedure for HET-03X (RPIP-696-03) 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) General procedure for cylindrical connectors, right-angle body (RPIP-696-07) -- -- 8-99 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC/EMI Adapters Kit Descriptions Hexashield Adapters for Circular Connectors: Straight, 45and 90 Assemblies Item 1 2 3 4 5 6 7 8 Description Straight adapter assembly Conic ring assembly Star Plain (Standard) Drilled (Option) Split (Option) _ Straight adapter assembly - "L" version - nominally 0.5" [12.7] longer body 45 adapter assembly - welded 45 adapter assembly - swept 90 adapter assembly - welded 90 adapter assembly - swept Standard products shown. Variants available on request. 1 1 2 2 3 3 c 4 Split star assemblies are shown on relevant S.C.D's where applicable. Item -1 -2 -3 -C HexaShield Version Back Nut Tinel adapter assembly Tinel-Lock ring for single braid Bandstrap adapter assembly Conduit adapter 5 6 7 8 HexaShield Adapters for ARINC 404/600 Connectors: Sizes 1, 2, 3 and 4 Assemblies Item 1 2 3 4 5 6 7 Description Left side support Right side support Retention bars Body assemblies Body Holding nut Conic ring assembly Star _ Back nut Cavity plug assemblies Plug Holding nut Pan head screws - 4-40 UNC Spring washers ARINC 600 Size 2 shown Stars are available as plain, drilled or split. See relevant S.C.D's for further information 8-100 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC Adapters Ordering Information Part Numbering for Standard Products HexaShield Adapter for Circular Connectors HEXYY L -AY -00 S -YY -AY -Y -DS 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 8 Electrical Interconnect Products 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 8-101 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC Adapters Ordering Information (Continued) HexaShield Adapter for Collins Connectors HEXDB-AC-00-A9-1 00 = Straight body 90 = Right-angle body HexaShield Adapter for ARINC 600 Connectors HEXA6-AY-00-YY-AY-Y 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. Part Numbering of Ferrule Kits* HET-A-02X for small-size cable with SolderShield terminator HET-A-03X for connection of unshielded cables ferrules with heat-shrinkable 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 Type of Plating: B = Cadmium plated C = Electroless nickel *Not all part numbers are standard; your local Tyco Electronics representative will assist you in selecting the appropriate standard product 8-102 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC Adapters EMC Performance Product Facts Transfer Impedance n 75 10 85 95 Zt (m/m) 1.0 105 115 .1 125 .01 .01 .1 1.0 10 Frequency (MHz) 100 Shielding effectiveness (dB) Outperforms traditional pigtail termination, especially in HIRF performance n Withstands 10-kA peak current lightning transients of SAE AE4L-87-3 135 1000 HexaShield size: 23 Cable: Raychem 5024H8424 (one cable installed) Test method: CEI 96-1 Protection Level Generalized system performance (Actual system performance in any one test method may differ.) 100 HexaShield terminated, shielded, twisted pairs without overbraid 80 8 dB 60 40 20 0 Frequency spectrum of threats Electrical Interconnect Products Pigtailed, shielded twisted pairs Pigtailed, shielded twisted pairs with overbraid 0 10 100 MHz 1000 10,000 Lightning EMP Cross talk HIRF Frequency spectrum of test methods Lightning Surface transfer impedance Bulk cable injection Radiated susceptibility Stirred mode 8-103 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC Adapters EMC Performance (Continued) Typical HexaShield Applications 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) HexaShield Product Range 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. 8-104 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts Introduction Product Facts n Low-profile rectangular design for high packaging density n Environmental sealing for aerospace applications n Modular components for design versatility and logistics savings n Lightweight materials for weight savings n Quick-disconnect mating hardware 8 The Raychem MTC product line is a complete modular connector system consisting of lightweight, environmentally sealed miniature rectangular connectors (shell housings with removable inserts) and individually removable rear-release contacts. Components Available in: Americas Europe Asia Pacific n n n MTC connectors are now available with quickdisconnect mating hardware, EME shielding accessories, and modular inserts that can accommodate a mix of signal and power crimp contacts and coaxial contacts. The need for special termination tooling has been minimized, while the ease of manufacturing and maintenance has been improved. Configurations MTC rectangular connectors using jack screws or quickdisconnect hardware can be stacked or panel-mounted next to each other without any provision for grip space, a feature that can save significant panel area. MTC connectors are available 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. Electrical Interconnect Products System Inserts MTC inserts are available in 20-cavity and 5-cavity versions. The 20-cavity insert accepts size 20-22 (24 AWG to 20 AWG wire) crimp contacts. The 5-cavity insert accepts 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. 8-105 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts 20-Cavity Inserts 2-inch shell with inserts 27 max. Raychem A2 Raychem 20 A1 15 1 10 5 27 max. Raychem A2 15 10 5 20 1 MTCP-122-20 inserts are used with MTC100 1-inch and 2-inch shells. The 1-inch shell takes: n One MTCP-122-20P (pin contact) or n One MTCP-122-20S (socket contact) The 2-inch shell takes: 2 x 20 Cavity Inserts (Size 20-22)--2-Inch Shell n One MTCP-122-20P1 and one MTCP-122-20P2 (pin contact) or n One MTCP-122-20S1 and one MTCP-122-20S2 (socket contact) Pin Insert MTCP-122-20P1 MTCP-122-20P2 Socket Insert MTCP-122-20S1 MTCP-122-20S2 8-106 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts 20-Cavity Inserts (Continued) 1 x 20 Cavity Inserts (Size 20-22)--1-Inch Shell 1-inch shell with insert 27 max. 27 max. Raychem A Raychem 10 3 A 1 1 Pin Insert MTCP-122-20P 5 10 Socket Insert MTCP-122-20S Contacts for 20-Cavity Inserts The contacts for 20-cavity inserts must be ordered separately. They are: n CTA-0166--pin contact n CTA-0165--socket contact 8 Contacts accept 24 AWG to 20 AWG wires. Tools Positioner for pin contact Installation process Contact removal tool (plastic) Extraction tool for MTCP inserts Electrical Interconnect Products Socket Contact CTA-0165 Pin Contact CTA-0166 CE-1605900 ES-61413 CTA-1160 CTA-0161 Tools Positioner for socket contact Installation process Contact removal tool (plastic) Extraction tool for MTCP inserts CE-1606000 ES-61413 CTA-1160 CTA-0161 8-107 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts 5-Cavity Inserts 5-Cavity Inserts (Size 16) A B C D E 27 max. 27 max. A1 A B C D E A B C D E F G H J K A2 A2 A B C D E A B C D E F G H J K F G H J K MTCP-116-05 inserts are used with MTC100 1-inch and 2-inch shells. The 1-inch shell takes: n One MTCP-116-05-P1 (pin contact) or n One MTCP-116-05-S1 (socket contact) The 2-inch shell takes: n One MTCP-116-05P1 and one MTC-116-05P2 (pin contact) or n One MTCP-116-05-S1 and one MTCP-116-05-S2 (socket contact) 5-Cavity Inserts (Size 16) Pin Insert MTCP-116-05P1 MTCP-116-05P2 Contacts for 5-Cavity Inserts Socket Insert MTCP-116-05S1 MTCP-116-05S2 The contacts for 5-cavity inserts must be ordered separately. They include: n CTA-0079 - pin contact (MS 27493-16) (MIL-C-39029/58 intermateable) n CTA-0078 - socket contact (MS 27491-16) (MIL-C-39029/57 intermateable) n D-602-0140 - coaxial pin contact (MIL-C-39029/76 intermateable) n D-602-0171 - coaxial socket contact (MIL-C-39029/78 intermateable) Other contacts designed for M38999 Series II connectors can be used. Pin Contact D-602-0140 (coaxial) CTA-0079 (power) Socket Contact D-602-0171 (coaxial) CTA-0078 (power) 8-108 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts Hybrid Inserts 1 A1 10 1 B1 10 A B C D E Plug F G H J K 11 A2 20 11 B2 20 Receptacle 1" = 2.00 2" = 3.00 1" = 1.75 2" = 2.75 .39 max. A Raychem 1.09 .34 MTC100-JH1-P32 XXXX MTC100-JH1-R32 XXXX .34 1.09 Raychem A .394 max. flangeless .60 max. flanged 1" = 1.75 2" = 2.75 1" = 1.75 flanged 2" = 2.75 1" = 2.06 flangeless 2" = 3.06 Hybrids Hybrid insert combinations of size 22 and size 16 contact cavities are also possible. 2-Inch Shell--Hybrid Assembly Power and signal 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). 8 Electrical Interconnect Products MTC connector housings are offered with quickdisconnect or jack-screw mating hardware. Each connector shell is polarized and has 64 user-defined keying combinations. Lightweight, low-profile EME backshells are also available for increased shielding effectiveness of the connector. 8-109 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts MTC Shells Ordering Information MT C 1 0 0 X - X H X - X X 2 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) *Some combinations of shells, mating hardware and EME shielding accessories are not available. Contact Tyco Electronics for product information. 8-110 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts Accessories Low-Profile EME Backshells EME Backshell Adapters Lightweight rectangular EME backshells connect the overall bundle shield to the MTC connector housing. Individual cable shields can also be terminated to the backshell braid by using Raychem SolderSleeve devices. CHA-0275 2-inch adapter (plug or receptacle) CHA-0276 1-inch adapter (plug or receptacle) 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. MTC Shield-Grounding BusBars Raychem MTC shieldgrounding busbars allow for simple, cost-effective termination 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 terminated to "fingers" on the busbar with Raychem SolderSleeve devices. Shield-Grounding Busbars CTA-0022 1-inch busbar (with 5 SolderSleeve terminators) CTA-0023 2-inch busbar (with 10 SolderSleeve terminators) 8 The busbar is mounted on the MTC housing via cable clamp screws. EME Shielding Accessories for MTC Connectors Grounding Block Allows for cable shield termination grounding on the MTC shell housing via crimp-removable contacts. This grounding scheme allows individual cables to be removed from the connector without cutting a ganged ground connection. Sufficient ground contacts are available to handle shielded twisted-pair cables. Electrical Interconnect Products MTC busbar features include a simple termination, cost effectiveness, light weight, and Level I EME performance. Grounding Block CHA-0301 1-inch grounding block receptacle shell CHA-0302 2-inch grounding block receptacle shell CHA-0303 1-inch grounding block plug shell CHA-0304 2-inch grounding block plug shell 8-111 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnect Products Engineering Notes 8-112 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire and Cable Table of Contents 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 Electroloss FilterLine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 Multicore Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-76 Cable Jacket Materials 9 Properties and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-77, 9-78 FDR 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-79, 9-80 Wire and Cable 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. 9-1 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire and Cable Introduction Tyco Electronics provides wire and cable solutions for challenging environments and demanding applications. The Raychem product range includes highperformance insulated wires, coaxial and data bus cables, power cables, electronics wire, and multicore cables. n n n SPEC 44 wire is an economical yet rugged dual-wall insulation system rated at 150C [221F], with consistently low cost and reliable performance. SPEC 55 wire insulation provides high reliability in harsh environments from -65C to +200C [-85F to +392F]. Resistant to electrical arc tracking, it combines the easy handling of a flexible wire with excellent resistance to scrapes, abrasion, and cutthrough. RCW is a small size, ultra light weight insulated wire with a temperature rating of -65C to +260C [-85F to +500F]. It is resistant to electrical arc tracking in wet or dry conditions and has excellent cut-through resistance. n n n n Type 99T dual-wall insulation system is a 105C [221F] rated wire that combines excellent chemical and mechanical resistance with limited fire hazard performance. ElectroLoss Filterline wire reduces the vulnerability of critical circuits to high-frequency electromagnetic interference. Cheminax coaxial and data bus cables allow system designers to optimize minimum size and weight with impedance and attenuation characteristics. Multiconductor (multicore) cables organize a variety of Raychem wire and cable products in controlled 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: n n n n n n n Limited-fire-hazard wire and cable for mass transit and marine applications. High-performance, high temperature automotive wiring. Small, light hookup wires for high-temperature applications in commercial appliances, tools, and devices. Very flexible, rugged, thin-wall insulated power cables. Low-outgassing spacevehicle wiring. Lightweight, shielded wire and cable constructions for aerospace applications. Thermocouple extension cables with a range of our high-performance insulations materials. Contact Tyco Electronics to find out more about wire and cable and our associated interconnection products. 9-2 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 44 Product Facts n Dual wall construction 600, 1000 and 2500 voltage rating n Small size, light weight n Low smoke and low corrosive gas generation n Resistant to most chemicals and electrical arc tracking n Applications SPEC 44 wire has 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 insulation system that offers a 150C [302F] temperature rating, small size, light weight, solder iron resistance, and resistance to most solvents, fuels and lubricants. SPEC 44 wire and cable is highly flame retardant, nonmelting, does not cold flow, and though mechanically very tough, is easy to handle and install using conventional tools. replacement for PVC/Nylon/ Glass braid type wire and cables. SPEC 44 wire is offered in a wide range of sizes in stranded conductors, 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 where further size and weight savings are achieved. Originally developed for aerospace and military requirements in applications of high density and complex circuitry, SPEC 44 wire and cable now finds Conductor wide use throughout industry, in commercial and military electronics, avionics, on satellites, aircraft, helicopters, ships, trains, and offshore platforms where environmental conditions demand consistently reliable performance. In airPrimary frame applications SPEC 44Insulation Radiation Crosslinked, constructions can offerExtruded a Polyalkene modern dimensional Jacket Radiation Crosslinked, Modified PVDF 9 Wire and Cable Conductor Primary Insulation Radiation Crosslinked, Extruded Polyalkene Available in: Jacket Radiation Crosslinked, Modified PVDF Americas Europe Asia Pacific n n n 9-3 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 44 (Continued) Physical Characteristics Small Size General Handling Lengths SPEC 44 equipment wire, 600 volt rated has a 0.19 [.008] nominal wall thickness compared to 0.25 [.010] and 0.38 [.015] for equivalent PTFE and PVC wires in MIL-W-16878, MILW-22759 or BS G210. 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. SPEC 44 is available in long continuous lengths and can be supplied for use on automatic cut and strip wire preparation machines. Light Weight For details of appropriate tools see separate wire handling 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. 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 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 NATO Stock Numbers (NSN's) exist for most standard constructions Civil Aviation Authority Accessory Approval E11623 Lloyds Register of Shipping NASA Preferred Product List Raychem Specification 44 Typical Properties Temperature rating Voltage rating (thin wall) Voltage rating (thick wall) Tensile strength and elongation of insulation Notch propagation, 0.05mm notch Solder iron resistance (370C, 1 minute) Shrinkage, 200C Low temperature bend Voltage withstand (thin wall) Resistance: fuels, oils, solvents -65C to +150C [-85F to +302F] 600 V 2500 V 28 N/mm2 , 230%, 4000 PSI Pass Pass <1% -65C [-85F] 2500 V Pass 9-4 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 44 (Continued) Environmental Performance Temperature Rating SPEC 44 wire and cable is rated for continuous operation from -65C to +150C [-85F to +302F] and for short periods at temperatures as high as 300C [572F]. Heat ageing tests are routinely performed at temperatures of 200C [392F] (168 h) and 300C [572F] (6 h). In addition SPEC 44 insulation will not shrink back under repeated cycling. Mechanical Performance SPEC 44 wire provides better cut through resistance than some wires with much thicker walls. 600 volt equipment wire 44A0111 (0.19 mm wall) has 40% greater cut through resistance than 600 volt PTFE insulated wire (0.25 mm wall). Fire Hazard Performance Flammability The radiation crosslinking of the materials used in SPEC 44 makes them nonmelting at high temperature. As a result SPEC 44 wire is resistant to prolonged contact with solder irons and is resistant to current overloads which would melt most thermoplastic insulations. Chemical Resistance The irradiated dual wall construction of SPEC 44 wire is highly resistant to many acids, alkalis, hydrocarbon solvents, fuels, lubricants, water, and many missile fuels and oxidizers. Cold Flow 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 demonstrates a total resistance to arc tracking under both wet and dry conditions at aircraft system voltages. Low Outgassing For use in space applications, special constructions of SPEC 44 wire are available with low outgassing characteristics, for use in an environment of high vacuum and high temperature. Radiation cross-linking of SPEC 44 prevents cold flow of the insulation -- a recognized problem of some uncrosslinked materials. Federal Aviation Reg FAR-25 BS4066 vertical flammability S424 14751 (Swedish chimney) NFC 32070 (2) (French chimney) IEC 332 part 3 (Cable ladder) Smoke Index, Def Stan 61-12 (18) Toxicity Index, Def Stan 61-12 (18) Oxygen Index, NES 714 Temperature Index, NES 715 Pass Pass Pass Pass Pass 6 per meter of wire 0.8 per meter of wire 30% Oxygen >300C [572F] 9 Wire and Cable Smoke/Toxicity Index Solder Iron/Overload Resistance 9-5 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 44 (Continued) Part Numbering System 44 X X X X X- AWG- X/X- X Basic Product Number Temperature Rating: / - 135C (XL-PVF2 cable jacket) A - 150C (XL-PVF2 cable jacket) AC - 150C (same as 44AM with 90% min. shield coverage) AM - 150C (M27500, shielded and/or XL-PVF2 jacketed cable) B - 150C (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 2 - 1000 V, general purpose 3 - 2500 V, general purpose 4 - 600 V, outerspace* 5 - 1000 V, outerspace* 6 - 2500 V, outerspace* 7 - 600 V, airframe 8 - 600 V, medium weight Number of Conductors 1 through 10 (designator for 10 conductor = 0) 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 A - Silver-coated CS95 C - Silver-coated high strength copper alloy (cadmium-free) D - Nickel-coated high strength copper alloy (cadmium-free) Conductor Size (AWG) 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) * 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 Ordering information 3 conductors, brown, yellow with green stripe, blue, white jacket. If 600 volt, round braid, 20 AWG tinned conductor, 44A1131-20-1/45/6-9. Other constructions and custom designed wire and cable are available on request. 9-6 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 44 (Continued) NEMA WC-27500 Cable Part Numbering System M27500 X AWG XX X X XX Basic Specification Number Component Wire ID/Shield Coverage Code Shield Coverage 85% 90% - C A B F D E H G K L P S J M N R T Component Wire Identification Colored Stripes on White Wire (9/96/93/95/92/90/94/97/98/91... etc.) Solid Color Wires (9/6/3/5/2/0/4/7/8/1...etc.) Band Marks on Solid Colors (by AWG) Alternate Colored Stripes (92/96/94/95/9/90/91/93/97/98...etc) Alternate Solid Colors (2/6/4/5/9/0/1/3/7/8...etc.) Number Marking on Solid Colors (by AWG) Number Marking on White Wires Band Marks on Colored Stripes (by AWG) 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 9 Wire and Cable Jacket Material and Style Code 00 - No jacket 08 - Crosslinked, white PVDF 23 - Crosslinked, white Modified ETFE Example: M27500-22ML3T08 = 44AM1131-22-9/96/93-9 Raychem Part No. Military Part No. 9-7 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 44 (Continued) Primary Wires/Twisted Pair 44A011X (600 V) Primary Wire Stranding Wire Size (AWG) 30 28 26* 24 22 20 18 16 14 12 10 8 #/AWG (mm) 7/0.10 7/0.13 19/0.10 19/0.13 19/0.16 19/0.20 19/0.25 19/0.29 19/0.36 37/0.32 37/0.40 133/0.29 7/38 7/36 19/38 19/36 19/34 19/32 19/30 19/29 19/27 37/28 37/26 133/29 CSA (mm2) 0.06 0.09 0.15 0.25 0.40 0.60 1.00 1.25 2.00 3.00 5.00 -- 44A011X (600 V) Max. Weight (g/m) lb/kft 0.68 [0.027] 1.06 [0.71] 0.76 [0.030] 1.43 [0.96] 0.86 [0.034] 2.08 [1.4] 1.02 [0.040] 2.98 [2.0] 1.19 [0.047] 4.46 [3.0] 1.40 [0.055] 6.70 [4.5] 1.65 [0.065] 10.12 [6.8] 1.83 [0.072] 12.80 [8.6] 2.26 [0.089] 19.64 [13.2] 2.74 [0.108] 30.06 [20.0] 3.28 [0.129] 46.28 [31.1] -- -- Nom. OD 44A021X (1000 V) Primary Wire 44A021X (1000 V) Max. Weight (g/m) lb/kft -- -- -- -- 1.02 [0.040] 2.38 [1.6] 1.17 [0.046] 3.57 [2.4] 1.37 [0.054] 5.20 [3.5] 1.57 [0.062] 7.59 [5.1] 1.85 [0.073] 11.46 [7.7] 2.06 [0.081] 14.58 [9.8] 2.49 [0.098] 21.88 [14.7] 2.97 [0.117] 32.89 [22.1] 3.71 [0.146] 52.98 [35.6] 5.23 [0.206] 91.97 [61.8] Nom. OD *For 44A0211-26 the stranding is 7/0.16mm 7/34 AWG 44A031X (2500 V) Primary Wire 44A081X (600 V) Airframe Wire 44A031X (2500 V) Max. Weight (g/m) lb/kft -- -- -- -- 1.35 [0.053] 3.13 [2.1] 1.44 [0.057] 4.46 [3.0] 1.75 [0.069] 6.40 [4.3] 1.98 [0.078] 9.08 [6.1] 12.95 [8.7] 2.23 [0.088] 2.46 [0.097] 16.22 [10.9] 2.92 [0.115] 24.10 [16.2] 3.32 [0.131] 36.01 [24.2] 4.09 [0.161] 54.32 [36.5] 96.20 [0.219] 96.73 [65.0] 44A081X (600 V) Max Weight (g/m) lb/kft -- -- -- -- 1.22 [0.048] 2.98 [2.0] 3.87 [2.6] 1.37 [0.054] 1.57 [0.062] 5.65 [3.8] 1.78 [0.070] 8.04 [5.4] 2.03 [0.080] 11.91 [8.0] 2.26 [0.089] 14.73 [9.9] 2.74 [0.108] 22.17 [14.9] 3.20 [0.126] 32.59 [21.9] 3.94 [0.155] 52.08 [35.0] 92.94 [0.214] 93.46 [62.8] Nom. OD Nom. OD 44A012X (600 V) Twisted Pair 44A012X (1000 V) Max. Weight (g/m) lb/kft 1.37 [0.054] 2.38 [1.6] 1.52 [0.060] 3.13 [2.1] 1.73 [0.068] 4.47 [3.0] 2.03 [0.080] 6.69 [4.5] 2.38 [0.094] 9.82 [6.6] 2.79 [0.110] 14.73 [9.9] 22.32 [15.0] 3.30 [0.130] 3.65 [0.144] 28.42 [19.1] 4.52 [0.178] 44.35 [29.8] 5.48 [0.216] 69.00 [46.5] -- -- -- -- Nom. OD 9-8 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 44 (Continued) Shielded and Jacketed Cable 44A121X (600 V) 1 Conductor 44A111X (600 V) 1 Conductor Wire Size (AWG) 30 28 26 24 22 20 18 16 14 12 Stranding (mm) #/AWG 7/0.10 7/0.13 19/0.10 19/0.13 19/0.16 19/0.20 19/0.25 19/0.29 19/0.36 37/0.32 7/38 7/36 19/38 19/36 19/34 19/32 19/30 19/29 19/27 37/28 44A111X (600 V) Max. Weight (g/m) lb/kft 1.47 [0.058] 5.20 [3.5] 1.55 [0.061] 5.80 [3.9] 1.57 [0.065] 6.84 [4.6] 1.83 [0.072] 8.63 [5.8] 2.01 [0.079] 10.71 [7.2] 2.26 [0.089] 14.73 [9.9] 2.62 [0.103] 20.68[13.9] 2.79 [0.110] 24.55 [16.5] 3.22 [0.127] 34.08 [22.9] 3.70 [0.146] 47.77 [32.1] 44A121X (600 V) Nom. OD Nom. OD -- 1.60 [0.063] 1.73 [0.068] 1.98 [0.078] 2.24 [0.088] 2.54 [0.100] 2.82 [0.111] 3.02 [0.119] 3.45 [0.136] 4.14 [0.155] Max. Weight (g/m) lb/kft -- 5.65 [3.8] 6.85 [4.6] 9.67 [6.5] 12.35 [8.3] 17.41 [11.7] 22.62 [15.2] 26.64 [17.9] 36.16 [24.3] 49.56 [33.3] Other sizes are also available in some constructions depending on conductor type and construction required. 44A112X (600 V) 2 Conductor 44A181X (600 V) 1 Conductor 44A181X (600 V) Max. Weight (g/m) lb/kft -- -- -- -- -- -- 2.26 [0.089] 11.76 [07.9] 2.57 [0.101] 15.48 [10.4] 2.77 [0.109] 19.19 [12.9] 3.02 [0.119] 24.11 [16.2] 3.25 [0.128] 28.13 [18.9] 3.73 [0.147] 38.69 [26.0] 4.19 [0.165] 52.38 [35.2] Nom. OD 44A112X (600 V) Nom. OD 2.23 [0.088] 2.38 [0.094] 2.59 [0.102] 2.99 [0.118] 3.35 [0.132] 3.76 [0.148] 4.32 [0.170] 4.67 [0.184] 5.53 [0.218] 6.50 [0.256] Max. Weight (g/m) lb/kft 8.63 [5.8] 9.82 [6.6] 12.05 [8.1] 16.82 [11.3] 21.57 [14.5] 27.97 [18.8] 38.24 [25.7] 44.94 [30.2] 64.28 [43.2] 91.51 [61.5] 9 Wire and Cable Wire Size (AWG) 30 28 26 24 22 20 18 16 14 12 Other sizes are also available in some constructions depending on conductor type and construction required. 9-9 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 55 by hot stamp, ink jet or laser, and can be potted without pre-etching. Product Facts n Resistant to electrical arc tracking in wet or dry conditions n Single or dual wall constructions n Small size, ultra light weight n Exceptional chemical resistance n -65C to 200C [-85F to 392F] SPEC 55PC Wire and Cable Insulation System Applications SPEC 55 wire is insulated with modified radiation cross-linked ETFE polymer. It has a temperature rating of -65C to 200C [-85F to 392F] continuous using a silver plated copper conductor, and combines the easy handling of a flexible wire with excellent scrape abrasion and cut-through characteristics. Available in: Americas Europe Asia Pacific n n n The dual wall airframe construction of SPEC 55 wire is 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 damage indicator. Chosen for its balance of properties, SPEC 55 wire has outstanding resistance to chemicals and solvents, excellent electrical arc track resistance, and is not susceptible to UV and moisture degradation. Single wall equipment 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 solderiron resistance make it a wire which is very easy to install reliably. Both single and dual wall insulated wires are available in twisted pairs, triples, etc., and as shielded and jacketed 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 insulation wall thickness of either 0.2 [.008] or 0.25 [.010] for robustness in unprotected harnesses and has excellent wire to wire abrasion properties. The single wall equipment wire has 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 wire has a nominal 0.1 [.004] wall and provides considerable weight and size savings over other comparable wires. This product was originally developed to meet Boeing's material standard BMS1348 for the 777 airliner. SPEC 55PC provides lightweight, 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-controlled manufacturing has produced Raychem wiring that is rugged and versatile enough for a wide range of commercial and defense aerospace applications, including electronic hookups in harsh, open airframe environments. SPEC 55PC wire and cable systems feature an 8-mil airframe wire that is lighter and smaller than typical 10-mil wire, with little reduction in key mechanical performance features. SPEC 55PC wire offers flame resistance superior to FAA standards and also resists scrape abrasion, notch, propagation, cut-through, and electrical arc tracking. n n Meets Boeing material standard BMS 13-48. Exceeds FAR 25 test requirements for flame resistance and smoke density. 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 9-10 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 55 (Continued) Specifications Conductor Conductor Insulation Radiation Crosslinked, Modified ETFE SPEC 55 insulation system - single wall Insulations Radiation Crosslinked, Modified ETFE Inner layer colored blue 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 E11749 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 -65C to +150C [-85F to +302F] -65C to +200C [-85F to +392F] 200 C [392F], 10000 h >100 cycles at 150C [302F] >1000 cycles 600 V, 450V (Dual wall wire) 35 N/mm2, 125% min. (Dual wall wire) 35 N/mm2, 75% min. Pass Pass <0.8 secs to wet 9 Wire and Cable Temperature rating (Tin plated conductor) (Silver or nickel plated conductor) Thermal endurance Scrape abrasion (BS 3G233) Flexing endurance (Boeing BSS 7324) Voltage rating Tensile strength + elongation (core only) Tensile strength + total elongation (core & primary jacket) Notch propagation BS 3G230 0.05 mm notch Solder iron resistance (370 C, 1 minute) Solderability Tin plated copper conductor BS 3G233 conditions Shrinkage Long term water resistance Permitivity 1 KHz (ASTM D150) Dissipation factor (ASTM D150) FAR 25 Afterburn (sec) Burn length <1% Will not hydrolyze 2.7 0.001 O 30 sec. max. 75 mm [3 in.] max. 9-11 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 55 (Continued) Environmental Performance Temperature Rating Chemical Resistance SPEC 55 wire and cable is rated for continuous operation from -65C to +200C [-85F to +392F] and for short periods at temperatures as high as 400C [752F]. 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). Mechanical Performance Radiation crosslinking of the SPEC 55 insulation significantly improves the following mechanical characteristics; scrape (sharp edges), cross wire abrasion, cut-through resistance and creep resistance. Solder Iron/Overload Resistance Conductor SPEC 55 insulation demonstrates resistance to arc tracking under both wet and dry conditions at aircraft system voltages. Space Wire SPEC 55 is available in special versions suitable for use in outer space meeting both ESA and NASA requirements for outgassing. Flammability Radiation crosslinking ensures that the insulation resists melting at high temperatures. As a result SPEC 55 wire is resistant to hot solder irons and current overloads which would melt most thermoplastic insulations. SPEC 55 Wire & Cable: Standard Constructions, Nominal Sizes, Strandings, Diameters and Weights Electrical Arc Tracking Resistance Special additives increase the flame retardance of SPEC 55 compared to unirradiated ETFE so that it meets the latest high performance tests, eg. BS 3G230 vertical test FAR 25. 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. 9-12 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 55 (Continued) 55A - AWG Conductor: Equipment/Interconnect Wires & Cables Wire Size (AWG) 30 28 26 24 22 20 18 16 14 12 10 8 55A011X Stranding (mm) 7/0.102 7/127 19/102 19/127 19/0.16 19/0.203 19/0.25 19/287 19/0.36 37/0.32 37/0.403 133/0.287 Max. Weight (g per m/lbs per kft) 0.98 [0.66] 1.35 [0.91] 2.08 [1.4] 2.98 [2.0] 4.17 [2.8] 6.40 [4.3] 9.67 [6.5] 12.35 [8.3] 19.34 [13.0] 29.32 [19.7] 47.32 [31.8] 87.50 [58.8] Nom. OD 0.61 [0.024] 0.68 [0.027] 0.81 [0.032] 0.94 [0.037] 1.09 [0.043] 1.27 [0.050] 1.52 [0.060] 1.73 [0.068] 2.20 [0.085] 2.62 [0.103] 3.25 [0.128] 4.77 [0.188] 55A012X Nom. Max. Weight OD (g per m/lbs per kft) 1.27 [0.048] 1.94 [1.3] 1.42 [0.054] 2.68 [1.8] 1.67 [0.064] 4.16 [2.8] 1.93 [0.074] 5.96 [4.0] 2.23 [0.086] 8.63 [5.8] 2.66 [0.102] 13.24 [8.9] 3.20 [0.122] 20.09 [13.5] 3.58 [0.138] 25.75 [17.3] 4.47 [0.172] 39.58 [26.6] 5.38 [0.208] 59.97 [40.3] 6.65 [0.256] 96.58 [64.9] 9.80 [0.376] 178.58 [120.0] 55A112X 55A111X Wire Size (AWG) 30 28 26 24 22 20 18 16 14 12 10 8 55A - AWG Conductor: Airframe Wires & Cables Max. Weight (g per m/lbs per kft) 1.51 [0.057] 1.59 [0.060] 1.71 [0.065] 1.84 [0.070] 1.99 [0.076] 2.20 [0.084] 2.45 [0.094] 2.67 [0.102] 3.10 [0.119] 3.55 [0.137] 4.20 [0.161] 5.80 [0.223] 5.06 [3.4] 5.80 [3.9] 6.85 [4.6] 8.19 [5.5] 10.27 [6.9] 13.40 [9.0] 17.86 [12.0] 21.73 [14.6] 30.36 [20.4] 42.41 [28.5] 62.65 [42.1] 110.42 [74.2] 55A081X Stranding (mm) 19/102 19/127 19/0.16 19/0.203 19/0.25 19/287 19/0.36 37/0.32 37/0.403 Nom. OD 1.01 [0.040] 1.14 [0.045] 1.27 [0.050] 1.47 [0.058] 1.78 [0.070] 1.96 [0.077] 2.40 [0.094] 2.82 [0.111] 3.40 [0.134] Max. Weight (g per m/lbs per kft) 2.5 [1.7] 3.4 [2.3] 4.8 [3.2] 7.0 [4.7] 10.7 [7.2] 13.4 [9.0] 20.5 [13.8] 30.5 [20.5] 48.3 [32.4] Nom. OD Max. Weight (g per m/lbs per kft) 2.12 [0.081] 2.27 [0.087] 2.53 [0.097] 2.80 [0.107] 3.07 [0.119] 3.50 [0.135] 4.10 [0.155] 4.43 [0.171] 5.30 [0.205] 6.30 [0.243] -- -- 7.74 [5.2] 8.90 [6.0] 11.32 [7.6] 13.84 [9.3] 17.86 [12.0] 23.81 [16.0] 32.60 [21.9] 39.73 [26.7] 57.00 [38.3] 81.10 [54.5] -- -- 55A082X Nom. Max. Weight OD (g per m/lbs per kft) 2.10 [0.080] 5.06 [3.4] 2.33 [0.090] 6.84 [4.6] 2.64 [0.102] 9.98 [6.7] 3.07 [0.118] 14.73 [9.9] 3.63 [0.140] 21.88 [14.7] 4.06 [0.156] 27.53 [18.5] 4.90 [0.190] 42.26 [28.4] 5.80 [0.224] 63.00 [42.3] 98.96 [66.5] 7.10 [0.272] 55A181X Wire Size (AWG) 26 24 22 20 18 16 14 12 10 Nom. OD 9 Wire and Cable Wire Size (AWG) 26 24 22 20 18 16 14 12 10 Nom. OD 55A182X Max. Weight (g per m/lbs per kft) 1.71 [0.073] 1.84 [0.078] 1.99 [0.084] 2.20 [0.092] 2.45 [0.103] 2.67 [0.111] 3.10 [0.128] 3.55 [0.145] 4.20 [0.168] 7.89 [5.3] 9.37 [6.3] 11.76 [7.9] 14.88 [10.0] 19.79[13.3] 23.81[16.0] 33.03 [22.2] 45.09 [30.3] 66.97[45.0] Nom. OD Max. Weight (g per m/lbs per kft) 2.63 [0.113] 2.80 [0.123] 3.07 [0.135] 3.50 [0.151] 4.10 [0.173] 4.43 [0.189] 6.30 [0.225] 6.30 [0.259] -- [0.308] 14.29 [9.6] 16.37 [11.0] 20.68 [13.9] 27.08[18.2] 36.46 [24.5] 42.86 [28.8] 61.61 [41.4] 85.42 [57.4] 127.54 [85.7] 9-13 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 55 (Continued) 55PC - AWG Conductor: Statistical Process Controlled Airframe Wires & Cables Wire Size (AWG) 26 24 22 20 18 16 14 12 10 Stranding (mm) 19/102 19/127 19/0.16 19/0.203 19/0.25 19/287 19/.036 37/0.32 37/0.403 55PC021X Max. Weight Nom. OD (g per m/lbs per kft) 0.087 [0.045] 2.05 [1.38] 1.00 [0.0395] 2.95 [1.98] 1.15 [0.0455] 4.31 [2.90] 1.37 [0.0540] 6.51 [4.38] 1.61 [0.0635] 9.81 [6.59] 1.80 [0.0710] 12.46 [8.37] 2.18 [0.0860] 19.17 [12.88] 2.66 [0.1047] 29.36 [19.73] 3.27 [0.1290] 46.31 [31.12] 55PC022X Nom. Max. Weight OD (g per m/lbs per kft) -- -- 2.00 [0.079] 5.95 [4.00] 2.31 [0.091] 8.74 [5.87] 2.74 [0.108] 13.2 [8.87] 3.22 [0.127] 19.84 [13.33] 3.60 [0.142] 25.21 [16.94] 4.36 [0.172] 38.80 [26.07] 5.30 [0.209] 59.42 [39.93] 6.55 [0.258] 93.92 [63.11] 55PC122X 55PC121X Wire Size (AWG) 26 24 22 20 18 16 14 12 10 Nom. OD Max. Weight (g per m/lbs per kft) Nom. OD 6.54 [4.4] 7.86 [5.28] 9.81 [6.59] 12.83 [8.62] 17.01 [11.43] 20.36 [13.68] 28.69 [19.28] 40.73 [27.37] 59.90 [40.25] 2.33 [0.100] 2.89 [0.109] 2.89 [0.122] 3.30 [0.139] 3.78 [0.158] 4.16 [0.174] 4.92 [0.204] 5.92 [0.244] 7.39 [0.297] 1.52 [0.064] 1.65 [0.069] 1.80 [0.075] 2.00 [0.083] 2.23 [0.093] 2.44 [0.100] 2.79 [0.116] 3.30 [0.135] 3.98 [0.159] Max. Weight (g per m/lbs per kft) 11.34 [7.62] 13.90 [9.34] 17.89 [12.02] 23.84 [16.02] 32.10 [21.57] 39.00 [26.21] 55.21 [37.10] 80.23 [53.91] 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.) 9-14 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 55 (Continued) Part Numbering System 55 X X X X X- Size- X/X- X 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 9 Type A M / PC D - General purpose Metric conductor Space wire Process control Defense Standard 61-12 Part 33 Issue 4 Basic Specification Number 9-15 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire and Cable 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). High Performance Wire and Cable SPEC 55 (Continued) 3 conductors, 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. A list 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. Typical Ordering Example Ordering Information SPEC 55 Part Numbering System Temperature Rating Conductor Material 600-V Lightweight Single-wall Hookup Wire, .152 [.006] Nominal Wall AWG Range Available Raychem Part No. MIL-SPEC No. 150C [302F] Tin-coated copper 12-30 55A0111 M22759/32 200C [392F] Silver-coated copper 12-28 55A0112 M22759/44 200C [302F] Nickel-coated copper 12-28 55A0113 M22759/45 200C [392F] Silver-coated high-strength alloy 20-30 55A0114 M22759/33 200C [392F] Nickel-coated high-strength alloy 20-28 55A0116 M22759/46 -- 600-V Lightweight Dual-wall Airframe Wire, .203 [.008] Nominal Wall 150C [302F] Tin-coated copper 6-26 55A0211 200C [392F] Silver-coated copper 10-26 55A0212 -- 200C [392F] Nickel-coated copper 10-26 55A0213 -- 200C [392F] Silver-coated high-strength alloy 18-30 55A0214 -- 200C [392F] Nickel-coated high-strength alloy 16-26 55A0216 -- 600-V Dual-wall Airframe Wire, .254 [.010] Nominal Wall 150C [302F] Tin-coated copper 00-24 55A0811 M22759/34 200C [392F] Silver-coated copper 00-26 55A0812 M22759/43 200C [392F] Nickel-coated copper 00-26 55A0813 M22759/41 200C [392F] Silver-coated high-strength alloy 20-26 55A0814 M22759/35 200C [392F] Nickel-coated high-strength alloy 20-26 55A0816 M22759/42 -- 600-V Medium-Weight Dual-wall Airframe Wire, .381 [.015] Nominal Wall 150C [302F] Tin-coated copper 10-24 55A0711 200C [392F] Silver-coated copper 16-24 55A0712 -- 200C [392F] Nickel-coated copper 16-24 55A0713 -- 200C [392F] Silver-coated high-strength alloy 16-24 55A0714 -- 200C [392F] Nickel-coated high-strength alloy 16-26 55A0716 -- 9-16 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 55 (Continued) SPEC 55 Cable Constructions Construction Number of Components Component Conductor1 Shield Material1 2-10 1 2 3 4 6 1 2 3 4 6 1 2 3 4 6 1 2 3 4 6 -- -- -- -- -- -- -- -- -- -- 1 2 3 1 3 1 1 1 1 1 Unshielded, unjacketed 2-10 Unshielded, jacketed 1-10 Shielded (round braid), jacketed 1-10 Shielded (flat braid), jacketed Type of conductor or shield material: 1 = tin-coated copper 2 = silver-coated copper 3 = nickel-coated copper 4 = silver-coated high-strength copper alloy 6 = nickel-coated high-strength copper alloy * = A or PC 1 2 Part Number Light Wt.2 Medium Wt. 55*01X1-AWG-Y 55*08X1-AWG-Y 55*01X2-AWG-Y 55*08X2-AWG-Y 55*01X3-AWG-Y 55*08X3-AWG-Y 55*01X4-AWG-Y 55*08X4-AWG-Y 55*01X6-AWG-Y 55*48X6-AWG-Y 55*41X1-AWG-Y 55*48X1-AWG-Y 55*41X2-AWG-Y 55*48X2-AWG-Y 55*41X3-AWG-Y 55*48X3-AWG-Y 55*41X4-AWG-Y 55*48X4-AWG-Y 55*41X6-AWG-Y 55*18X6-AWG-Y 55*11X1-AWG-Y 55*18X1-AWG-Y 55*11X2-AWG-Y 55*18X2-AWG-Y 55*11X3-AWG-Y 55*18X3-AWG-Y 55*11X4-AWG-Y 55*18X4-AWG-Y 55*11X6-AWG-Y 55*18X6-AWG-Y 55*21X1-AWG-Y 55*28X1-AWG-Y 55*21X2-AWG-Y 55*28X2-AWG-Y 55*21X3-AWG-Y 55*28X3-AWG-Y 55*28X4-AWG-Y 55*21X4-AWG-Y 55*21X6-AWG-Y 55*28X6-AWG-Y X = no. of wire components Y = color code For complete part number, see Part Numbering System on page 9-15. 9 Wire and Cable 9-17 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 55 (Continued) NEMA WC-27500 Cable Part Numbering System M27500 X AWG XX X X XX Basic Specification Number Component Wire ID/Shield Coverage Code Shield Coverage 85% 90% - C A B F D E H G K L P S J M N R T Component Wire Identification Colored Stripes on White Wire (9/96/93/95/92/90/94/97/98/91... etc.) Solid Color Wires (9/6/3/5/2/0/4/7/8/1...etc.) Band Marks on Solid Colors (by AWG) Alternate Colored Stripes (92/96/94/95/9/90/91/93/97/98...etc) Alternate Solid Colors (2/6/4/5/9/0/1/3/7/8...etc.) Number Marking on Solid Colors (by AWG) Number Marking on White Wires Band Marks on Colored Stripes (by AWG) 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 Example: M27500-22SB3T23 = 55AM1131-22-9/96/93-9 Raychem Part No. Military Part No. 9-18 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable RCW Product Facts n -65C to +260C [-85F to +500F] n Small size, ultra light weight n Resistant to electrical arc tracking in wet or dry conditions n Excellent cut-through resistance n Exceptional chemical resistance Applications Physical Characteristics Raychem Composite Wire (RCW) is insulated with a combination of PTFE and Polyimide materials. It has a temperature rating of -65C to +260C [-85F to +500F] continuous using a nickelplated conductor, and combines the easy handling of a flexible wire with excellent cut-through characteristics. Size and Weight Chosen for its balance of properties, RCW has outstanding resistance to chemicals and solvents, excellent arc track resistance, and is not susceptible to UV and moisture degradation. RCW airframe wire has an insulation wall thickness of either .006" or 0.008" for robustness in unprotected harnesses and has excellent 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. 9 Wire and Cable RCW can be supplied in a thin wall, lightweight construction which provides considerable weight and size savings over comparable wires. RCW provides one of the most comprehensive wiring product ranges for aerospace users with a wide choice of conductor sizes and insulation wall thicknesses. RCW is easily stripped with conventional tooling, and readily marked by laser or ink jet. RCW is available in twisted pairs, triples, etc. and shielded and jacketed constructions. Available in: Americas Europe Asia Pacific n n n 9-19 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable RCW (Continued) Specifications Insulation - Tape Wraps Conductor Silver-Coated Copper / Nickel-Coated Copper RCW insulation system MIL-DTL-22759/81-92 Lockheed Martin Selected C-Specs Typical Properties Lightweight / Normal Weight Silver Copper / Nickel Copper -65C to +200C [-85F to +392F] / -65C to +260C [85F to +500F] 600V 4,000 volts/mil (avg. min.) MIL-STD-2223 Method 3006 * MIL-DTD-2223 Method 3007 * ASTM D 3032 Section 22 * MIL-STD-2223, Method 1006, Procedure A * Insulation Resistance 5000 megohms for 1000 ft. (min.) Life Cycle 500 hours @ 230C [446F] / 500 hrs @ 290C [554F] Low Temperature (Cold Bend) -65C [-85F] (4 hrs) Smoke 200C [392F] / 260C [500F] No visible smoke Thermal Index 200C [392F] min. / 260C min. [500F] 10,000 hrs. *as defined by the applicable MIL-Spec slash sheets Conductor Temperature Voltage Rating Dielectric Strength Wet Arc Propagation Resistance Dry Arc Propagation Resistance Dynamic Cut-Through Flammability Environmental Performance Temperature Rating Chemical Resistance RCW wire and cable is rated for continuous operation from -65C to +260C [-85F to +500F] and for short periods at temperatures as high as 320C [608F]. 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. 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. RCW Wire & Cable: Standard Constructions, Nominal Sizes, Strandings, Diameters and Weights Conductor Electrical Arc Tracking Resistance RCW insulation demonstrates resistance to arc tracking under both wet and dry conditions at aircraft system voltages. 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. Primary Wire Twisted Pair Shielded & Jacketed Single Pair 9-20 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable RCW (Continued) RCW - AWG Conductor: Equipment/Interconnect Wires & Cables (Lightweight) RCW - AWG Conductor: Airframe Wires & Cables (Normal Weight) RCW59XX Stranding (mm) Wire Size (AWG) 26 24 22 20 18 16 14 12 10 Shield Size (AWG) Wire Size (AWG) 26 24 22 20 18 16 14 12 10 8 6 4 Stranding (mm) Wire Size (AWG) 26 24 22 20 18 16 14 12 10 Shield Size (AWG) 19 x 38 19 x 36 19 x 34 19 x32 19 x 30 19 x29 19x 27 37 x 28 37 x 26 38 38 38 38 38 38 38 38 38 19 x 38 19 x 36 19 x 34 19 x 32 19 x 30 19 x 29 19 x 27 37 x 28 37 x 26 133 x 29 133 x 27 133 x 25 38 38 38 38 38 38 38 38 38 Max. Weight (g per m/lbs per kft) 2.13 [1.43] 2.87 [1.93] 4.24 [2.85] 6.52 [4.38] 9.82 [6.60] 12.35 [8.30] 18.75 [12.6] 29.17 [19.6] 45.54 [30.6] RCWxWx2U00-AWG Nom. Max. Weight OD (max.) (g per m/lbs per kft) 1.73 [0.068] 4.35 [2.92] 1.93 [0.076] 5.86 [3.94] 2.18 [0.086] 8.65 [5.81] 2.59 [0.102] 13.30 [8.94] 3.05 [0.120] 20.09 [13.5] 3.40 [0.134] 25.15 [16.9] 4.06 [0.160] 38.25 [25.7] 5.08 [0.200] 59.53 [40.0] 6.25 [0.246] 92.86 [62.4] RCWxWx1xxx-AWG-x Nom. Max. Weight@90% OD max. (g per m/lbs per kft) 1.83 [0.072] 8.27 [5.56] 1.93 [0.076] 9.52 [6.40] 2.06 [0.081] 11.55 [7.76] 2.26 [0.089] 14.88 [10.0] 2.49 [0.098] 19.35 [13.0] 2.67 [0.105] 22.77 [15.3] 30.95 [20.8] 2.99 [0.118] 3.50 [0.138] 44.05 [29.6] 4.09 [0.161] 63.69 [42.8] RCWxWx2xxx-AWG-x Nom. Max. Weight@90% OD max. (g per m/lbs per kft) 2.69 [0.106] 13.84 [9.30] 2.89 [0.114] 16.22 [10.9] 3.15 [0.124] 20.24 [13.6] 3.56 [0.140] 26.64 [17.9] 4.01 [0.158] 35.42 [23.8] 4.37 [0.172] 42.12 [28.3] 5.03 [0.198] 58.19 [39.1] 6.15 [0.242] 85.57 [57.5] 7.32[0.288] 124.41[83.6] RCW59xx Nom. Max. Weight OD max. (g per m/lbs per kft) 0.52 [0.0204] 2.31 [1.55] 0.62 [0.0244] 3.19 [2.15] 0.87 [0.0314] 4.46 [3.00] 1.00 [0.0394] 6.77 [4.55] 1.25 [0.0494] 9.97 [6.70] 1.41 [0.0554] 12.80 [8.60] 1.76 [0.0694] 19.27 [12.95] 2.27 [0.0894] 29.91 [20.10] 2.84 [0.112] 46.73 [31.40] 4.29 [0.169] 85.72 [57.60] 5.38 [0.212] 131.40 [88.30] 6.81 [0.268] 212.81 [143.0] RCWxWx2U00-AWG Nom. Max. Weight@90% OD max. (g per m/lbs per kft) 1.88 [0.074] 4.70 [3.16] 2.13 [0.084] 6.53 [4.39] 2.39 [0.094] 9.11 [6.12] 2.79 [0.110] 13.81 [9.28] 3.30 [0.130] 20.39 [13.70] 3.71 [0.146] 26.04 [17.50] 4.37 [0.172] 39.29 [26.40] 5.33 [0.210] 61.01 [41.00] 6.45 [0.254] 95.39 [64.10] 9.55 [0.376] 174.86[117.50] -- -- -- -- RCWxWx1xxx-AWG-x Max. Weight@90% Nom. OD max. (g per m/lbs per kft) 8.82 [5.93] 1.91 [0.075] 2.03 [0.080] 10.45 [7.02] 2.16 [0.085] 12.28 [8.25] 15.63 [10.50] 2.36 [0.093] 2.62 [0.103] 20.09 [13.50] 2.82 [0.111] 24.11 [16.20] 3.15 [0.124] 32.29 [21.70] 3.63 [0.143] 45.54 [30.60] 4.19 [0.165] 65.33 [43.90] RCWxWx2xxx-AWG-x Max. Weight@90% Nom. OD max. (g per m/lbs per kft) 2.84 [0.112] 14.88 [10.0] 3.10 [0.122] 18.01 [12.1] 3.35 [0.132] 21.58 [14.5] 27.98 [18.8] 3.76 [0.148] 4.27 [0.168] 36.76 [24.7] 4.67 [0.184] 44.35 [29.8] 5.33 [0.210] 60.57 [40.7] 6.40 [0.252] 88.25 [59.3] 7.52 [0.296] 127.83 [85.9] Nom. OD (max.) 0.48 [0.019] 0.61 [0.024] 0.76 [0.030] 0.97 [0.038] 1.22 [0.048] 1.37 [0.054] 1.73 [0.068] 2.21 [0.087] 2.79 [0.110] 9 Wire and Cable Wire Size (AWG) 26 24 22 20 18 16 14 12 10 9-21 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable RCW (Continued) Part Numbering System -- Cable (Per NEMA WC 27500) 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) Example: RCWAWJ2G24-22-9 = M27500A22WJ2G24 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 Military Part Number Raychem Part Number 9-22 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable RCW (Continued) Part Numbering System -- Primary Wire (Per MIL-W-22759) RCW59 XX - AWG - X Basic Product Number MIL-W-22759 Slash Sheet as follows: 81 82 86 87 89 90 91 92 - Lightweight, silver-coated, high-strength or ultra high-strength copper alloy, AWG 26-20 Lightweight, nickel-aoted, high-strength or ultra high-strength copper alloy, AWG 26-20 Normal weight, silver-coated copper, AWG 26-4 Normal weight, nickel-coated copper, AWG 26-4 Normal weight, silver-coated, high-strength or ultra high-strength copper alloy, AWG 26-20 Normal weight, nickel-coated, high-strength or ultra high-strength copper alloy, AWG 26-20 Lightweight, silver-coated copper, AWG 26-10 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 1 2 3 4 Example: RCW5991-22-9 = - Black Brown Red Orange Yellow 5 6 7 8 9 - Green Blue Violet Gray White M27559/91-22-9 9 Military Part Number Raychem Part Number Wire and Cable 9-23 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable RCW (Continued) Part Numbering System -- Cable (Per NEMA WC 27500) 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 Example: M27500A22WJ2G24 = RCWAWJ2G24-22-9 Raychem Part Number Military Part Number 9-24 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 FlexLine SPEC 80 Product Facts n Reduced weight Flexibility n Low outgassing n Function over a broad temperature range n Flammability n Arc track resistance n Resistance to atomic oxygen n Radiation resistance n High quality and reliability n Ease of fabrication (into Harnesses due to flexibility) n Agency approvals n -65C up to +150C [-85F up to +302F] n Small size n 600V rating n Optional high strand count for increased flexibility n Variety of insulation/jacket options n Dual wall and single wall options n Easy to install n Mechanically tough n Compliance with FAR 25 flammability requirements n Resistance to harsh fluids & solvents per MIL-W-22759 n Applications FlexLine wire (also known as SPEC 80) is insulated with a flexible modified radiation cross-linked ETFE polymer. It has a temperature rating of -65C to +150C [-85F to +302F] continuous using silver copper conductor, and combines the easy handling of our SPEC 55 wire and cable with additional flexibility. FlexLine wire is used in a broad range of applications, from Hook-up wire to Power Cables. FlexLine wire constructions provide maximum flexibility similar to the MIL-W-22759 products in Mechanical, Chemical and Thermal properties. 9 Wire and Cable Available in: Americas Europe Asia Pacific n n n 9-25 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 FlexLine SPEC 80 (Continued) FlexLine Insulation System Single Wall Single Wall 82 Wire High strand count conductors Light weight AWG sizes 28 to 00 (6-mil nominal insulation thickness) Dual Wall Dual Wall 81 Wire Standard M22759 conductor stranding Increased toughness AWG sizes 28 to 000 (10-mil nominal insulation thickness) Part Numbering System 8x X X X X X- Size- X/X- X Jacket Color Identification Code (in accordance with MIL-STD-681) Primary Wire Insulation Color (in accordance with MIL-STD-681) 0 - Black 4 - Yellow 1 - Brown 5 - Green 2 - Red 6 - Blue 3 - Orange 7 - Violet 8 - Gray 9 - White Conductor Size (AWG) Conductor Type 1 - Tin-coated copper 2 - Silver-coated copper 3 - Nickel-coated copper 4 - Silver-coated high strength copper alloy 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 9-26 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable FR-1000 Halogen-Free, Fire Resistant Cable Range Product Facts n Highly flame retardant Halogen-free n Low smoke generation n Low toxicity index n Low acid gas emission n Low water uptake n Compatible with Raychem System 100 heat-shrink components, heat-shrink tubing, molded parts and adhesives n Applications FR-1000 cable consists of Raychem Type 95 primary wire with a Zerohal jacket and can be used throughout the installation, simplifying the selection for designers and electrical engineers. By a combination of our proven expertise in polymer and radiation chemistry, low fire hazard technology and precision extrusion capability, Available in: 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 available. This results in lower installed costs by downsizing 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: n n n Tough and flexible constructions aiding installation through smaller bend radii and extending service life. Controlled dimensions simplifying connector and transit selection. Resistance to widely used fluids such as diesel fuels, oils, and greases. 9 Wire and Cable Tyco Electronics has developed a new halogen-free, lightweight, small size, fire resistant Raychem cable to exceed the exacting fire resistant requirements of IEC 60331 (ie withstands 950C [1742F] for 3 hours as opposed to the 750C [1382F] requirement) and meet the flame-retardant requirements of IEC 60332-3 (Cat A), while maintaining significant size and weight savings over conventional materials. Operating Temperature Range -30C to +90C [-22F to +194F] Americas Europe Asia Pacific n n n 9-27 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable FR-1000 (Continued) RAYCHEM FR-1000 4x1.5 Batch No. Generic Cable Construction Example: FR-1000 4x1.5 93497A Conductors Tin-plated copper to BS 6360. Insulation Mica based tape, halogen-free, low smoke material complying with Raychem spec WSD695. Core Identification Pairs - black and white and numbered. Triples - black, red and white and numbered. Multicore - white and numbered. Shielding Aluminized Mylar(R) 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 50C [122F], 3 hours). Sheath printed with Raychem number and size of conductors, IEC60331 (950C [1742F). Sheath color black. Oxygen index >30% (BS2782). Temperature index >260C [500F] (BS2782). Smoke index <13 (BS6883). Toxicity index <2 (NES713). Temperature Rating 90C [194F] maximum operating temperature. Voltage Rating 600/1000V. MYLAR is a trademark of Dupont Teijin Films U.S. 9-28 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable FR-1000 (Continued) Halogen-Free, Fire Resistant Cable Range Outer Sheath Armor Inner Sheath Mica Based Tape Conductor Insulation FR-1000 Multicore Control Cables, Unshielded, Armored, 600/1000V* Selection Table Part No. EPD 87486A 87488A 87490A 87492A 87494A 87496A 87498A 87487A 87489A 87491A 87493A 87495A 87497A 87499A Construction Conductor Stranding CSA Nominal mm2 Diameter Over Inner Sheath 2x1.5 3x1.5 4x1.5 7x1.5 12x1.5 19x1.5 27x1.5 2x2.5 3x2.5 4x2.5 7x2.5 12x2.5 19x2.5 27x2.5 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 7/0.67 7/0.67 7/0.67 7/0.67 7/0.67 7/0.67 7/0.67 1.5 1.5 1.5 1.5 1.5 1.5 1.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 6.6 [.260] 7.1 [.280] 7.7 [.303] 9.4 [.370] 12.5 [.492] 14.7 [.579] 17.9 [.705] 7.7 [.303] 8.2 [.323] 9.0 [.354] 10.9 [.429] 14.6 [.575] 17.5 [.689] 21.1 [.831] Cable Outer Nominal Diameter Weight kg/km (min.) (max.) 10.2 [.402] 11.2 [.441] 178 10.8 [.425] 11.6 [.457] 203 236 11.2 [.441] 12.4 [.488] 13.0 [.512] 14.4 [.567] 328 16.0 [.630] 17.6 [.693] 486 18.2 [.717] 20.2 [.795] 677 21.3 [.839] 23.5 [.925] 906 11.2 [.441] 12.4 [.488] 224 11.7 [.461] 12.9 [.508] 257 12.6 [.496] 14.0 [.551] 312 14.7 [.579] 15.7 [.618] 429 18.1 [.713] 20.1 [.791] 661 20.9 [.823] 23.1 [.909] 936 25.3 [.996] 27.3 [1.075] 1321 Jacket Color Black Black Black Black Black Black Black Black Black Black Black Black Black Black *Cables are armored with an overall galvanized steel wire braid armor. 9 Wire and Cable 9-29 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable FR-1000 (Continued) Outer Sheath Insulation Mica Based Tape Conductor FR-1000 Multicore Control Cables, Unshielded, Unarmored, 600/1000V Selection Table Cable Part No. EPD 87472A 87474A 87476A 87478A 87480A 87482A 87484A 87473A 87475A 87477A 87479A 87481A 87483A 87485A Construction 2x1.5 3x1.5 4x1.5 7x1.5 12x1.5 19x1.5 27x1.5 2x2.5 3x2.5 4x2.5 7x2.5 12x2.5 19x2.5 27x2.5 Conductors Insulation Core Identification Inner Sheath Armor Outer Sheath Temperature Rating Voltage Rating Conductor Stranding CSA Nominal mm2 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 7/0.67 7/0.67 7/0.67 7/0.67 7/0.67 7/0.67 7/0.67 1.5 1.5 1.5 1.5 1.5 1.5 1.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 Outer Diameter (min.) 7.5 [.295] 7.8 [.307] 8.4 [.331] 10.1 [.398] 13.3 [.524] 15.2 [.598] 18.5 [.728] 8.4 [.331] 8.8 [.346] 9.7 [.382] 11.5 [.453] 15.1 [.594] 17.9 [.705] 21.3 [.839] (max.) 7.9 [.311] 8.6 [.339] 9.2 [.362] 11.1 [.437] 14.3 [.563] 16.8 [.661] 19.9 [.783] 9.2 [.362] 9.8 [.386] 10.7 [.421] 12.7 [.500] 16.7 [.657] 19.7 [.776] 23.5 [.925] Nominal Weight kg/km 87 108 134 204 332 490 684 122 150 192 288 475 720 995 Jacket Color Black Black Black Black Black Black Black Black Black Black Black Black Black Black Tin plated copper to BS6360 Mica based tape, halogen-free, low smoke material complying with Raychem specification WSD695 White and numbered Halogen-free, low smoke material complying with Raychem specification WCD51/1663 and WSD696 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 +/- 50C [122F], 3 hours) Sheath printed with number and size of conductors, IEC331, Raychem, voltage rating and EPD number Sheath color black Oxygen index >30% (BS2782), Temperature index > 260C (BS2782), Smoke index <13 (BS6883) Toxicity Index <2 (NES713) 90C [194F] maximum conductor operating temperature 600/1000V 9-30 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable FR-1000 (Continued) Halogen-Free, Fire Resistant Cable Range Outer Sheath Armor Inner Sheath Aluminized Mylar(R) Screen Insulation Drainwire Conductor Mica Based Tape FR-1000 Multipair Control Cables, Collectively Shielded and Armored 600/1000V* Selection Table Part No. EPD 93491A 93492A 93493A 93494A 87500A 87501A 87502A 87503A 87504A 87505A 87506A 87507A 87508A Construction 3x2x0.75 7x2x0.75 12x2x0.75 20x2x0.75 2x1.5 2x2x1.5 3x2x1.5 5x2x1.5 7x2x1.5 10x2x1.5 12x2x1.5 20x2x1.5 24x2x1.5 Conductor Stranding 19/0.23 19/0.23 19/0.23 19/0.23 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 CSA Nominal mm2 0.75 0.75 0.75 0.75 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 Diameter (Nominal) Over Shield 9.7 [.382] 13.1 [.516] 16.4 [.646] 21.2 [.835] 5.4 [.213] 7.2 [.283] 11.2 [.441] 13.8 [.543] 15.2 [.598] 17.5 [.705] 19.0 [.748] 24.7 [.972] 26.6 [1.047] Over Inner Sheath 11.1 [.437] 14.6 [.575] 18.1 [.713] 23.0 [.906] 6.7 [.264] 8.6 [.339] 12.7 [.500] 15.3 [.602] 16.9 [.665] 19.2 [.756] 20.7 [.815] 26.5 [1.043] 28.6 [1.126] Cable Outer Diameter (min.) 14.6 [.575] 18.1 [.713] 21.5 [.846] 26.8 [1.055] 10.7 [.421] 12.3 [.484] 16.1 [.634] 18.8 [.740] 20.3 [.799] 22.5 [.886] 25.2 [.992] 30.5 [1.201] 33.6 [1.323] (max.) 16.2 [.638] 20.1 [.791] 23.7 [.933] 29.6 [1.165] 11.3 [.445] 13.5 [.531] 17.9 [.705] 20.8 [.819] 22.5 [.886] 24.9 [.980] 26.6 [1.047] 33.7 [1.327] 35.6 [1.402] Nominal Weight kg/km Jacket Color 319 484 685 1090 192 267 404 541 649 817 999 1541 1762 Grey Grey Grey Grey Black Black Black Black Black Black Black Black Black *Cables have an overall aluminized Mylar(R) shield with drainwire and an overall galvanized steel wire braid armor. 9 Wire and Cable MYLAR is a trademark of Dupont Teijin Films U.S. 9-31 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable FR-1000 (Continued) Outer Sheath Armor Inner Sheath Drainwire Insulation Mica Based Tape Conductor Aluminized Mylar(R) Screen FR-1000 Multitriple control cables, Collectively Shielded and Armored, 600/1000V* Selection Table Part No. EPD Construction 87509A 87510A 87511A 87512A 1x3x1.5 3x3x1.5 7x3x1.5 12x3x1.5 Conductor Stranding 19/0.32 19/0.32 19/0.32 19/0.32 CSA Nominal mm2 1.5 1.5 1.5 1.5 Diameter (Nominal) Over Shield 5.9 [.232] 12.0 [.472] 16.2 [.638] 22.2 [.874] Over Inner Sheath 7.2 [.283] 13.5 [.531] 17.9 [.705] 24.0 [.945] Cable Outer Diameter (min.) 10.7 [.421] 16.9 [.665] 21.3 [.839] 28.1 [1.106] (max.) 11.9 [.469] 18.7 [.736] 23.5 [.925] 31.1 [1.224] Nominal Weight kg/km Jacket Color 216 480 815 1357 Black Black Black Black *Cables have an overall aluminized Mylar(R) shield with drainwire and an overall galvanized steel wire braid armor. Conductors Insulation Core Identification Shielding Inner Sheath Armor Outer Sheath Temperature Rating Voltage Rating Tin plated copper to BS6360 Mica based tape, halogen-free, low smoke material complying with Raychem specification WSD695 Pairs - black and white and numbered. Triples - black, red and white and numbered Aluminized Mylar(R) tapewrap in contact with tinned copper drainwire Halogen-free, low smoke material complying with Raychem specification WCD51/1663 and WCD696 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 +/- 50C [122F]z, 3 hours) Sheath printed with number and size of conductors, IEC331, Raychem, voltage rating and EPD number Sheath color black Oxygen index >30% (BS2782), Temperature index > 260C [482F] (BS2782), Smoke index <13 (BS6883) Toxicity Index <2 (NES713) 90C maximum conductor operating temperature 600/1000V MYLAR is a trademark of Dupont Teijin Films U.S. 9-32 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable FR-1000 (Continued) Halogen-Free, Fire Resistant Cable Range Outer Sheath Armor Drainwire Inner Sheath Aluminized Mylar(R) Screen Mica Based Tape Conductor Insulation FR-1000 Multipair Control Cables, Collectively Shielded and Armored 600/1000V* Selection Table Part No. EPD 93491A 93492A 93493A 93494A 87500A 87501A 87502A 87503A 87504A 87505A 87506A 87507A 87508A Construction 3x2x0.75 7x2x0.75 12x2x0.75 20x2x0.75 2x1.5 2x2x1.5 3x2x1.5 5x2x1.5 7x2x1.5 10x2x1.5 12x2x1.5 20x2x1.5 24x2x1.5 Conductor Stranding 19/0.23 19/0.23 19/0.23 19/0.23 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 19/0.32 CSA Nominal mm2 0.75 0.75 0.75 0.75 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 Diameter (Nominal) Over Shield 9.7 [.382] 13.1 [.516] 16.4 [.646] 21.2 [.835] 5.4 [.213] 7.2 [.283] 11.2 [.441] 13.8 [.543] 15.2 [.598] 17.5 [.689] 19.0 [.748] 24.7 [.972] 26.6 [1.047] Over Inner Sheath 11.1 [.437] 14.6 [.575] 18.1 [.713] 23.0 [.906] 6.7 [.264] 8.6 [.339] 12.7 [.500] 15.3 [.602] 16.9 [.665] 19.2 [.756] 20.7 [.815] 26.5 [1.043] 28.6 [1.126] Cable Outer Diameter (min.) 14.6 [.575] 18.1 [.713] 21.5 [.846] 26.8 [1.055] 10.7 [.421] 12.3 [.484] 16.1 [.634] 18.8 [.740] 20.3 [.799] 22.5 [.886] 25.2 [.992] 30.5 [1.201] 33.6 [1.323] (max.) 16.2 [.638] 20.1 [.791] 23.7 [.933] 29.6 [1.165] 11.3 [.445] 13.5 [.531] 17.9 [.705] 20.8 [.819] 22.5 [.886] 24.9 [.980] 26.6 [1.047] 33.7 [1.327] 35.6 [1.402] Nominal Weight kg/km Jacket Color 319 484 685 1090 192 267 404 541 649 817 999 1541 1762 Grey Grey Grey Grey Black Black Black Black Black Black Black Black Black *Cables have an overall aluminized Mylar(R) shield with drainwire and an overall galvanized steel wire braid armor. 9 Wire and Cable MYLAR is a trademark of Dupont Teijin Films U.S. 9-33 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable FR-1000 (Continued) Outer Sheath Armor Drainwire Inner Sheath Mica Based Tape Conductor Insulation Aluminized Mylar(R) Screen FR-1000 Multitriple Control Cables, Individually Shielded, Armored, 600/1000V* Selection Table Part No. EPD 93500A 93501A 93502A 93503A Construction 3x3x0.75 7x3x0.75 12x3x0.75 3x1.00 Conductor Stranding 19/0.23 19/0.23 19/0.23 19/0.25 CSA Nominal mm2 0.75 0.75 0.75 1.0 Diameter (Nominal) Over Inner Sheath 12.4 [.488] 16.8 [.661] 22.6 [.890] 6.6 [.260] Cable Outer Diameter (min.) 15.9 [.626] 20.2 [.795] 26.4 [1.039] 10.6 [.417] (max.) 17.5 [.689] 22.4 [.881] 29.2 [1.150] 11.6 [.457] Nominal Weight kg/km Jacket Color 407 682 1111 198 Grey Grey Grey Grey *Cables have pairs individually shielded with aluminized Mylar(R) and drainwire and an overall galvanized steel wire braid armor. Conductors Insulation Core Identification Shielding Inner Sheath Armor Outer Sheath Temperature Rating Voltage Rating Tin plated copper to BS6360 Mica based tape, halogen-free, low smoke material complying with Raychem specification WSD695 Pairs - black and white and numbered. Triples - black, red and white and numbered Aluminized Mylar(R) tapewrap in contact with tinned copper drainwire Halogen-free, low smoke material complying with Raychem specification WCD51/1663 and WSD696 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 +/- 50C [122F], 3 hours) Sheath printed with number and size of conductors, IEC331, Raychem, voltage rating and EPD number Sheath color black Oxygen index >30% (BS2782), Temperature index > 260C [500F] (BS2782), Smoke index <13 (BS6883) Toxicity Index <2 (NES713) 90C [194F] maximum conductor operating temperature 600/1000V MYLAR is a trademark of Dupont Teijin Films U.S. 9-34 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable Type 99M Product Facts n Low flammability Low smoke generation n Low toxicity index n Low generation of corrosive gases n Small size, lightweight n Applications During the 1980's there were major changes in the demands of many wire and cable specifications to reduce the risks associated with all aspects of fire Available in: This has led to a tightening of the requirements for flammability, smoke generation, corrosive gas generation and hazardous fume emission. Type 99M wire achieves these improvements 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 wire with virtually no springback once set. It is easily stripped with tools such as conventional die-blade strippers. 9 Small Size Type 99M equipment wire has a nominal 0.2 mm insulation wall thickness which is comparable to other established thin wall wires such as SPEC 44 wire. Wire and Cable Type 99M wire has a dual wall construction of radiation cross-linked modified polyester. This combines excellent mechanical performance and chemical resistance with a range of enhanced fire hazard properties. Type 99M wire is designed to meet the stringent low fire hazard performance now being specified by many authorities, in particular for naval, mass transit and industrial control panel wiring. hazards. Specifications such as Def Stan 61-12 Part 18, have been developed over the last decade demanding improved performance of wires and cables under fire conditions. Light Weight Type 99M wire is designed to have the same weights as SPEC 44 wire. Americas Europe Asia Pacific n n n 9-35 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable Type 99M (Continued) Approvals Raychem WCD 281 Def Stan 61-12 Part 18 Issue 4 Type 1 Italian Navy STN-SR-01 Lloyds Register 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 99M011X (600 V) Size Stranding (mm) OD 26 24 22 20 18 16 14 12 19x0.10 19x0.12 19x0.15 19x0.20 19x0.25 19x0.30 37x0.25 37x0.32 0.88 [.035] 0.98 [.039] 1.13 [.044] 1.40 [.055] 1.65 [.065] 1.90 [.075] 2.25 [.089] 2.60 [.102] Weight (g/m) 2.00 3.00 4.40 6.50 9.90 14.15 18.62 25.70 99M021X (1000 V) OD 1.01 [.040] 1.17 [.046] 1.37 [.054] 1.57 [.062] 1.85 [.073] 2.10 [.083] 2.50 [.098] 2.97 [.117] Weight (g/m) 2.2 3.4 4.9 7.3 10.9 14.5 21.8 31.3 99M1111 OD 1.80 [.071] 1.90 [.075] 2.05 [.081] 2.30 [.091] 2.55 [.100] 2.95 [.116] 3.13 [.123] 3.48 [.137] 99M1121 Weight (g/m) 7.5 9.2 11.1 14.6 19.3 24.9 30.9 43.4 OD 2.91 [.115] 3.20 [.126] 3.52 [.139] 4.02 [.158] 4.57 [.180] 5.13 [.202] 5.72 [.225] 6.42 [.253] Weight (g/m) 13.3 16.6 20.5 27.7 37.1 48.5 60.5 86.0 Typical Properties Test Temperature rating Voltage rating Tensile strength/elongation of insulation Notch propagation (0.05 mm notch) Shrinkage 200C [392F] Low temperature bend Voltage withstand Insulation resistance (20C [68F]) Pliability rating Fluid resistance Fuels - aircraft Oils - (ASTM No 3) Solvents Method BS G230 Raychem -- BS G230 BS G230 BS G230 BS G230 BS G230 Def Stan 61-12 (18) Def Stan 61-12 (18) Typical value 125C [257F] 600 V thin wall 30 MPa/250% Pass <1% -55C [-67F] 2.5 kV 1000 M ohms km (min) 82 - Pliable Pass Pass Pass 9-36 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable Type 99M (Continued) Environmental Properties Fire Hazard Characteristics Corrosivity Mechanical Performance Low Toxicity Index The scrape abrasion and cut through resistance of Type 99M wire out performs the well-established performance of SPEC 44 wire throughout its operating temperature range. Type 99M wire is designed to meet the low hazardous fume emission levels required in modern specifications. For example, the change in the Toxicity Index requirement from 1.5 to 0.2 between Issue 2 and Issue 3 of Def Stan 61-12 (Part 18), is met by Type 99M wire. 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 specifications. Fluid Resistance Type 99M wire demonstrates outstanding resistance to most acids, alkalis, hydrocarbon solvents, fuels, lubricants and water. Flammability Type 99M wire is resistant to electrical arc tracking under both wet and dry conditions. 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) Voltage Ratings Smoke Generation Standard available voltage ratings for Type 99M wire are 600 V (0.2 mm wall thickness) and 1000 V (0.3 mm wall thickness). 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. Electrical Arc Tracking Fire Hazard Properties Method IEC 332 Pt 3 Def Stan 61-12 (18) Def Stan 61-12 (18) TDE 76/P/76 Typical value Pass 0.1 per meter of wire 8 per meter of wire <1.5% 9 Wire and Cable Test Flammability Toxicity index Smoke index Acid gas equivalent 9-37 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable Type 99M (Continued) Part Numbering System 99 X X X X X- Size- X/X- X 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 * The cable jackets are Raychem Zerohal and the preferred color is black. 9-38 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable Zerohal 100A Product Facts n Halogen free, low smoke Highly flame retardant n Flexible, easy to install n Small size, lightweight (thin wall construction) n 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 applications where space and weight are at a premium; fire safety is important; reliability is imperative; rugged properties to withstand service in an RMT environment are required. Physical Characteristics Handleability Zerohal 100A 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. 9 Wire and Cable 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, lightweight, flexibility, non-wrinkling, ease of stripping, compatibility with standard stripping equipment, lack of recoil and mechanical robustness. Insulation - dual wall modified polymer blend Conductor - tin plated copper Available in: Americas Europe Asia Pacific n n n 9-39 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable Zerohal 100A (Continued) Typical Properties Test Physical Properties Insulation Tensile Strength and Ultimate Elongation Scrape Abrasion Resistance Method Typical Values ASTM D3032 Tensile Strength 3500 psi minimum Ultimate Elongation 250% minimum 1000 cycles minimum (90, 0.01 inch radial edge blade, 6N load, 20C [68F]) 20 lbs. minimum (90, 0.01 inch radial edge blade, 0.2 inch per min, 20C [68F]) No contact with the conductor (90, 0.01 inch radial edge blade, 10 min, 9N load, 125C [257F]) AAR S 501 Dynamic Cut Through ASTM D3032 Static Cut-through Penetration AAR S 501 Thermal Properties Temperature Index Accelerated ageing Shrinkage ASTM D3032 ASTM D3032 IEC 811-1-3 Insulation Blocking MIL-W-22759E 10,000 hours minimum at 125C [257F] No cracks, flow or dielectric breakdown. (168hr at 170C [338F]) 0.5% maximum at each end. (6hr at 160C [320F) Cores must be easily separated without damage (24hr at 125C [257F], 6X mandrel.) Electrical Properties IR Constant ASTM D3032 >10000 Mkft at 20C [68F] >100 Mkft at 60C [140F] >10 Mkft at 90C [194F] ASTM D3032 Fluid NATO code Temp (C) -- 100 ASTM No.1 Oil -- 100 IRM 902 Oil IRM 903 Oil -- 100 -- 23 70/30 iso-octane/toluene Engine lubricating oil O-236 70 Grease G-354 70 Hydraulic fluid, petroleum base H-515 50 Silicone damping fluid S-1724 70 Automotive brake fluid H-542 23 Fire resistant hydraulic fluid H-544 50 De-icing fluid S-745 23 Methyl Ethyl Ketone -- 23 5% max swell. No dielectric breakdown. (30mm diameter mandrel) Environmental Properties Fluid Immersion Time (hr) 70 70 70 24 24 24 24 24 24 24 24 1 Fire Hazard Properties Flammability - small scale IEC 332-1 Flammability - large scale IEC 332-3 Smoke - small scale ISO 5659-2 Smoke - large scale IEC 1034 Toxicity Halogen Content Copper Mirror Corrosion IMO FTPC IEC 684-2 ASTM D2671 Acid Gas Detection IEC 754-2 Charring confined between 50mm and 540mm from lower edge of top support. (Single vertical wire, 60 s flame) 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., 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. (3m cube smoke box. Eight 1m long 7-wire bundles, horizontal. Fire source: 1 litre burning alcohol.) Toxicity index < 1 (Test conditions as in smoke - small scale) Less than 0.2% Cl + Br + I. Less than 0.1% F (Wet chemical analysis) 5% maximum etched area. (0.4g sample, 200C [392F], 16hr.) pH greater than 4.3 10 S/mm maximum (1g sample, tube furnace, T > 935C [1715F], gases dissolved in water) Ordering Information Conductor Wire Size AWG Stranding No x AWG Dia (mm) 24 22 20 18 16 14 12 10 19x36 19x34 19x32 19x30 19x29 19x27 37x28 37x26 Diameter Min. 0.550 [0.022] 0.735 [0.029] 0.940 [0.037] 1.170 [0.046] 1.321 [0.052] 1.650 [0.065] 2.080 [0.082] 2.690 [0.106] Max. 0.63 [0.025] 0.79 [0.031] 1.01 [0.040] 1.26 [0.050] 1.37 [0.054] 1.79 [0.070] 2.24 [0.088] 2.83 [0.111] Finished Wire Maximum Resistance at 20C /kft/km 25.7 [84.32] 15.9 [52.2] 9.9 [32.4] 6.2 [20.4] 4.8 [15.8] 3.1 [10.0] 2.0 [6.63] 1.3 [4.13] Diameter Min. Max. Maximum Weight lbs/kft kg/km 1.09 [0.043] 1.26 [0.050] 1.46 [0.057] 1.69 [0.067] 1.84 [0.072] 2.27 [0.089] 2.71 [0.107] 3.33 [0.131] 1.19 [0.047] 1.33 [0.052] 1.54 [0.061] 1.79 [0.071] 1.94 [0.076] 2.39 [0.094] 2.86 [0.113] 3.51 [0.138] 2.41 [3.59] 3.34 [4.98] 4.98 [7.42] 7.31 [10.89] 9.19 [13.70] 14.45 [21.53] 21.03 [31.33] 33.27 [49.58] Part No. 100A0111-24-* 100A0111-22* 100A0111-20* 100A0111-18* 100A0111-16* 100A0111-14* 100A0111-12* 100A0111-10* 9-40 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable Zerohal 100A (Continued) Environmental Properties Fire Hazard Characteristics Flammability Fluid Resistance Zerohal 100A is a halogen free insulation system and does not contain phosphorus or sulphur. It meets the toxicity, smoke density, halogen content, corrosivity and flammability requirements of major recognized agencies. Zerohal 100A meets the flammability/burning behavior requirements of major recognized agencies. Zerohal 100A wire demonstrates 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 Properties Test Method Flammability - small scale IEC 332-1 Flammability - large scale IEC 332-3 Flammability IEEE 383 Smoke - small scale ISO 5659-2 Smoke - small scale ASTM E662 Toxicity Halogen Content Copper Mirror Corrosion IMO FTPC IEC 684-2 ASTM D2671 Acid Gas Detection IEC 754-2 Typical Value Charring confined between 50mm and 540mm from lower edge of top support. (Single vertical wire, 60 s flame) 2.5m maximum burn length. (Five 3.5m long 37-wire bundles, vertical, 20.5 kW flame) Pass Ds1.5 of 100 max., Ds4 of 150 max., 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) Smoke density - Ds4 (Max.) Flaming - 200 Non-Flaming - 75 Toxicity index < 1 (Test conditions as in smoke - small scale) Less than 0.2% Cl + Br + I. Less than 0.1% F (Wet chemical analysis) 5% maximum etched area. (0.4g sample, 200C [392F], 16hr.) pH greater than 4.3 10 S/mm maximum (1g sample, tube furnace, T > 935C [715F], gases dissolved in water) Part Numbering System 100 A X X X X- Size- X Primary Wire Insulation Color 0 - Black 4 - Yellow 1 - Brown 5 - Green 2 - Red 6 - Blue 3 - Orange 7 - Violet 8 - Gray 9 - White 9 Wire and Cable 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 9-41 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable Zerohal 100G Product Facts n Qualified to VG 95218-20, Type E n Halogen free, low smoke n Highly flame retardant n Flexible, easy to install n Small size, lightweight (thin wall construction) Applications System Zerohal 100G wire has been developed to meet the requirements of German Specification VG 95218-20, Type E primary wire. 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, lightweight, flexibility, nonwrinkling, ease of stripping, compatibility with standard stripping equipment, lack of recoil and mechanical robustness. n System 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. Insulation - dual wall modified polymer blend Conductor - tin plated copper Available in: Americas Europe Asia Pacific n n n 9-42 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable Zerohal 100G (Continued) Approvals VG 95218-20, Type E (Electrical cables and insulated wires for low frequency - Part 20: Single core insulated wires.) Typical Properties Test Max. operating temperature Insulation shrinkage (160C) Low temperature bend Pressure test at high temperature Heat aging (150C, 6 h) (140C, 120 h) Voltage rating Abrasion resistance Insulation blocking (125C) Voltage withstand (23C, 2.5 kV rms) Insulation resistance Chemical resistance Grease (G-354)* Hydraulic fluid (H-515, H-544)* Brake fluid (H-542)* De-icing fluid (S-745)* Method VG 95218-20, ASTM D 3032 DIN VDE 0472 Pt 628, IEC 811-1-3 VG 95218 - Pt 2 DIN VDE 0472 Pt 609, IEC 811-3-1 DIN VDE 0472 Pt 303, IEC 811-1-2 VG 95218-20 VG 95218 - Pt 2 VG 95218 - Pt 2 DIN VDE 0472 pt 509 < 5% diameter change, no dielectric breakdown < 5% diameter change, no dielectric breakdown < 5% diameter change, no dielectric breakdown < 5% diameter change, no dielectric breakdown < 5% diameter change, no dielectric breakdown < 5% diameter change, no dielectric breakdown VG 95218 - Pt 2, 23C 1h Elongation at break No cracking, no dielectric breakdown 750/1300 V AC Pass Pass Pass VG 95218 - Pt 2, 70C 24h VG 95218 - Pt 2, 23C 24h Tensile strength -55C [-67 F] 125C [257F] < 30% indentation > 500 M ohms. km (20C [68F]) > 0.5 M ohms. km (90C [194F]) VG 95218 - Pt 2, 23C 24h 70/30 ISO-Octane/ Toluene Insulation < 0.5% DIN VDE 0472 pt 502, IEC 885-1 VG 95218 - Pt 2, 50C 24h MEK Typical Value 125C [257F] (20,000 h) VG 95218 - Pt 2, 23C 24h DIN VDE 0472 pt 602, IEC 811-1-1 DIN VDE 0472 pt 602, IEC 811-1-1 > 20 MPa > 200% *NATO code. For further details please consult the German Standard VG 95218-20, Type E. Part Numbering System 100 G X X X X- Size- X 7 8 9 - 9 Violet Gray White Wire and Cable Primary Wire Insulation Color 0 - Black 3 - Orange 1 - Brown 4 - Yellow 2 - Red 5 - Green 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 9-43 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable Zerohal 100G (Continued) Environmental Properties Fire Hazard Characteristics Flammability Fluid Resistance Zerohal 100G is a halogen free insulation system and does not contain phosphorus or sulphur. It meets the toxicity, smoke density, halogen content, corrosivity and flammability requirements of VG 95218-20, Type E. Zerohal 100G meets the flammability/burning behavior requirements of VG 95218-20, Type E. Method NES 713 IEC 1034 Pt 1 and 2 DIN VDE 0472 pt 815 DIN VDE 0472 pt 813, IEC 754-2 Typical value 3.5 95% light transmittance Non-detected 5.0 pH, <4 S/mm conductivity < 15 sec afterburn < 150 mm burn length Zerohal 100G wire demonstrates an outstanding balance of resistance to a wide range of commonly used solvents, fluids and lubricants. Voltage Rating Zerohal 100G wire is a 750/1300 V AC rated wire. Fire Hazard Properties Test Toxicity Smoke density Halogen content Corrosivity of combustion gases Flammability VG 95218 Pt 2 Ordering Information Conductor Nominal Cross Sectional Area mm2 Stranding No x nom Dia (mm) 0.40 0.50 0.60 0.75 1.00 1.20 1.50 2.00 2.50 3.00 4.00 19x0.16 19x0.18 19x0.20 19x0.23 19x0.25 19x0.29 37x0.23 37x0.25 37x0.29 37x0.32 56x0.30 min. max. Insulated Wire Maximum Resistance at 20C ohms/km 0.74 [.029] 0.82 [.032] 0.95 [.037] 1.04 [.041] 1.17 [.046] 1.32 [.052] 1.46 [.057] 1.68 [.066] 1.85 [.073] 2.12 [.083] 2.41 [.095] 0.79 [.031] 0.90 [.035] 1.01 [.040] 1.15 [.045] 1.26 [.050] 1.42 [.056] 1.58 [.062] 1.82 [.072] 2.01 [.079] 2.24 [.088] 2.56 [.101] 50.50 40.10 31.10 26.70 20.00 15.30 13.70 10.50 8.21 6.58 4.86 Diameter Diameter min. max. 1.28 [.050] 1.37 [.054] 1.47 [.058] 1.59 [.063] 1.69 [.067] 1.88 [.074] 2.03 [.080] 2.31 [.091] 2.48 [.098] 2.70 [.106] 3.01 [.119] 1.39 [.055] 1.47 [.058] 1.57 [.062] 1.70 [.067] 1.80 [.071] 1.98 [.078] 2.13 [.084] 2.41 [.095] 2.63 [.104] 2.86 [.113] 3.16 [.124] Maximum Weight g/m VG 95218 Part No. Part No. 5.17 6.60 7.54 8.90 10.73 13.59 15.96 20.29 25.65 31.00 43.48 VG 95218 T020-E02* VG 95218 T020-E03* VG 95218 T020-E04* VG 95218 T020-E05* VG 95218 T020-E06* VG 95218 T020-E07* VG 95218 T020-E08* VG 95218 T020-E09* VG 95218 T020-E10* VG 95218 T020-E11* -- 100G0111-0.40-* 100G0111-0.50-* 100G0111-0.60-* 100G0111-0.75-* 100G0111-1.00-* 100G0111-1.20-* 100G0111-1.50-* 100G0111-2.00-* 100G0111-2.50-* 100G0111-3.00-* 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. 9-44 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Commercial Wire Family FlexLite Available in: Americas Europe Asia Pacific n n n Selection Guide Application Temperature Rating (C/F) Features and Benefits Insulation that does not melt and flow at high temperatures n Excellent chemical resistance n VW-1 n Small size, light weight n No plasticizers or corrosive outgassing n Good mechanical and shop handling characteristics n VW-1 n Excellent chemical resistance n Insulation does not melt and flow at high temperature n VW-1 n Excellent shop handling n No cold-flow problems n Very high temperature n VW-1 n Superb chemical resistance n Excellent shop handling Product Name n -45C to 125C -49F to 257F Electronics, appliance, and motor applications -55C to 135C -67F to 275F General purpose appliance wire -55C to 150C -67F to 302F Lighting, motor applications -55C to 200C -67F to 392F Lighting, appliances, motors -65C to 250C -85F to 482F FlexLite DW FlexLite TW FlexLite MT 9 FlexLite HT Wire and Cable Intermittent-duty motors and heating elements FlexLite TX Primary Wire FlexLite/UL Style Cross-Reference 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. Product UL Style Temperature Rating Voltage Rating AWG Range Part Description FlexLite DW FlexLite TW FlexLite MT FlexLite HT FlexLite TX 3584 10208 10916 3557 10297 125C [257F] 135C [275F] 150C [302F] 200C [392F] 250C [482F] 600 volts 600 volts 600 volts 600 volts 600 volts 4-28 10-32 6-26 6-26 4-28 FLDWX031X FLTWX031X FLMTX031X FLHTX031X FLTXX031X Note: Additional UL-recognized cable constructions are available. Please contact Tyco Electronics for details. 9-45 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Commercial Wire Family FlexLite (Continued) Part Numbering System FL XX X X X X X - Size - X/X - X Basic Product Number Product Type (UL Style - Temperature Rating) DW - UL Style 3584 - 125C TW - UL Style 10208 - 135C MT - UL Style 10916 - 150C HT - UL Style 3557 - 200C TX - UL Style 10297 - 250C Conductor Stranding A - Solid B - 7 strand C - 19 strand D - 37 strand E - Rope Lay 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 Number of Conductors 1 through 10 (designator for 10 conductor = 0) Conductor Type 1 - Tin-coated copper 2 - Silver-coated copper 3 - Nickel coated copper 9 - Bare copper Conductor Size (AWG) or (Metric) 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 Jacket Color (code per MIL-STD-681) (codes same as for Primary Wire Insulation Color) *Shield coating same as conductor coating Typical ordering example Ordering information 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. 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. 9-46 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Commercial Wire Family FlexLite DW Dual-Wall Primary Wire Product Facts n UL rated operating temperature to 125C [257F] n Non melting insulation material n Thin-wall product for size and weight savings n Excellent chemical resistance n Dual-wall construction for increased mechanical performance n Compatibility with automated stripping equipment n Variety of colors and constructions Applications FlexLite DW (FLDW) offers a high-performance non melting insulation suitable for a variety of applications, especially those with occasional hightemperature excursions, such as high-power batteryoperated devices or intermittent-duty motors or heating elements. Conductor Tin-coated copper Primary insulation Radiation-crosslinked, extruded polyalkene Jacket Radiation-crosslinked, modified PVDF 9 Wire and Cable Specifications/Approvals Series DW Available in: UL CUR Style 3584 Flammability VW-1 Recognized Temperature rating 125C [257F] CSA Raychem Certified AWMIA WCD-3106 Americas Europe Asia Pacific n n n 9-47 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Commercial Wire Family FlexLite DW (Continued) Construction Details Part No. Wire Size (AWG) Conductor Stranding (No. x AWG) Nominal Diameter mm [inch] Finished Wire Maximum Resistance at 20C (68F) /km [ /1000 ft] 26 24 22 20 18 16 14 12 19 x 38 19 x 36 19 x 34 19 x 32 19 x 30 19 x 29 19 x 27 37 x 28 .470 [.0185] .597 [.0235] .749 [.0295] .953 [.0375] 1.18 [.0465] 1.33 [.0525] 1.68 [.0660] 2.16 [.0850] 132 [40.1] 83.3 [25.4] 52.2 [15.9] 32.0 [9.76] 20.4 [6.22] 15.8 [4.82] 10.0 [3.05] 6.59 [2.01] FLDWC0311-26-* FLDWC0311-24-* FLDWC0311-22-* FLDWC0311-20-* FLDWC0311-18-* FLDWC0311-16-* FLDWC0311-14-* FLDWD0311-12-* Minimum mm [inch] Diameter Nominal mm [inch] Maximum mm [inch] .965 [.038] 1.12 [.044] 1.32 [.052] 1.52 [.060] 1.78 [.070] 1.98 [.078] 2.39 [.094] 2.87 [.113] 1.02 [.040] 1.17 [.046] 1.37 [.054] 1.57 [.062] 1.85 [.073] 2.06 [.081] 2.49 [.098] 2.97 [.117] 1.07 [.042] 1.22 [.048] 1.42 [.056] 1.63 [.064] 1.93 [.076] 2.13 [.084] 2.59 [.102] 3.07 [.121] Nominal Weight in kg/km [lb/1000 ft] 2.38 [1.6] 3.57 [2.4] 5.21 [3.5] 7.59 [5.1] 11.46 [7.7] 14.58 [9.8] 21.88 [14.7] 32.89 [22.1] * Replace asterisk with color code designator: 0 = Black 3 = Orange 7 = Violet 1 = Brown 4 = Yellow 8 = Gray 5 = Green 9 = White 2 = Red For example: FLDWC0311-20-9 = AWG 20, white. Construction Details Nominal CSA Part No. Wire Size (mm2) Conductor Stranding (No. x Dia.) FLDWC0311-0.25* FLDWC0311-0.35* FLDWC0311-0.50* FLDWC0311-0.75* FLDWC0311-1.00* FLDWC0311-1.50* 0.25 0.35 0.50 0.75 1.00 1.50 19 x 0.127 19 x 0.15 19 x 0.19 19 x 0.23 19 x 0.25 19 x 0.32 Diameter (min.) mm [inch] (max.) mm [inch] 0.55 [.022] 0.72 [.028] 0.86 [.034] 1.05 [.041] 1.17 [.046] 1.46 [.057] 0.63 [.025] 0.77 [.030] 0.88 [.035] 1.08 [.043] 1.26 [.050] 1.51 [.059] Finished Wire Maximum Resistance at 20C (68F) /km [ /1000 ft] 83.6 [25.5] 56.1 [17.1] 40.1 [12.2] 24.7 [7.53] 20.0 [6.1] 13.7 [4.2] Lower Spec. Limit mm [inch] 1.12 [.044] 1.31 [.052] 1.46 [.057] 1.65 [.065] 1.78 [.070] 2.21 [.095] Diameter Target Value mm [inch] 1.17 [.046] 1.37 [.054] 1.51 [.059] 1.70 [.067] 1.85 [.073] 2.28 [.090] Upper Spec. Limit mm [inch] 1.22 [.048] 1.42 [.056] 1.56 [.061] 1.75 [.069] 1.93 [.076] 2.36 [.093] Nominal Weight in kg/km [lb/1000 ft] 3.77 [2.53] 5.17 [3.46] 6.92 [4.64] 9.53 [6.39] 11.88 [7.96] 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. 9-48 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Commercial Wire Family FlexLite TW Thin-Wall Hookup Wire and Cable Product Facts n UL rated operating temperature to 135C [275F] n Thin-wall product for size and weight savings n Tough insulation material n Excellent chemical resistance n Gauge sizes from 10-32 AWG n No plasticizers or corrosive outgassing, which can be detrimental to sensitive electrical and electronic components 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 9 Wire and Cable Available in: Americas Europe Asia Pacific n n n 9-49 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Commercial Wire Family FlexLite TW (Continued) Specifications/Approvals Series TW UL Style 10208 Temperature rating 135C [275F] CUR CSA Raychem Recognized Certified AWMIA WCD-3106 Construction Details Part No. Wire Size (AWG) Conductor Stranding (No. x AWG) Nominal Diameter mm [inch] Finished Wire Maximum Resistance at 20C (68F) /km [ /1000 ft] 26 24 22 20 18 16 14 12 19 x 38 19 x 36 19 x 34 19 x 32 19 x 30 19 x 29 19 x 27 37 x 28 .470 [.0185] .597 [.0235] .749 [.0295] .953 [.0375] 1.18 [.0465] 1.33 [.0525] 1.68 [.0660] 2.16 [.0850] 132 [40.1] 83.3 [25.4] 52.2 [15.9] 32.0 [9.76] 20.4 [6.22] 15.8 [4.82] 10.0 [3.05] 6.59 [2.01] FLTWC0311-26-* FLTWC0311-24-* FLTWC0311-22-* FLTWC0311-20-* FLTWC0311-18-* FLTWC0311-16-* FLTWC0311-14-* FLTWD0311-12-* Minimum mm [inch] Diameter Nominal mm [inch] Maximum mm [inch] .813 [.032] .965 [.038] 1.14 [.045] 1.35 [.053] 1.60 [.063] 1.75 [.069] 2.16 [.085] 2.64 [.104] .864 [.034] 1.02 [.040] 1.19 [.047] 1.40 [.055] 1.65 [.065] 1.83 [.072] 2.26 [.089] 2.74 [.108] .914 [.036] 1.07 [.042] 1.24 [.049] 1.45 [.057] 1.70 [.067] 1.91 [.075] 2.36 [.093] 2.84 [.112] Nominal Weight in kg/km [lb/1000 ft] 1.93 [1.3] 2.83 [1.9] 4.17 [2.8] 6.25 [4.2] 9.52 [6.4] 12.20 [8.2] 18.90 [12.7] 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. 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. 9-50 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Commercial Wire Family FlexLite MT Medium Temperature Hookup Wire Product Facts n UL rated operating temperature to 150C [302F] n Thin-wall, for size and weight savings n Tough fluoropolymer insulation material n Excellent stripping and handling n Variety of constructions and colors n VW-1 flammability rating n 600 V rating Applications FlexLite MT is a general purpose wire for appliance, electronics, and electrical equipment that require 150C [302F] and 600 V ratings. Conductor Tin-coated copper Insulation Modified ETFE 9 Wire and Cable Available in: Americas Europe Asia Pacific n n n 9-51 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Commercial Wire Family FlexLite MT (Continued) Specifications/Approvals Series MT UL Style 10916 Flammability VW-1 Temperature rating 150C [302F] CUR Raychem Recognized WCD-3106 Construction Details Part No. Wire Size (AWG) Conductor Stranding (No. x AWG) 26 24 22 20 18 19 x 38 19 x 36 19 x 34 19 x 32 19 x 30 FLMTC0311-26-* FLMTC0311-24-* FLMTC0311-22-* FLMTC0311-20-* FLMTC0311-18-* Nominal Diameter mm [inch] .470 [.0185] .597 [.0235] .749 [.0295] .953 [.0375] 1.18 [.0465] Finished wire Maximum Resistance at 20C (68F) /km [ /1000 ft] 150 [45.8] 94.2 [28.7] 59.4 [18.1] 37.4 [11.4] 23.5 [7.15] Diameter Minimum mm [inch] Nominal mm [inch] Maximum mm [inch] .765 [.030] .892 [.035] 1.04 [.041] 1.25 [.049] 1.52 [.060] .800 [.032] .927 [.037] 1.08 [.043] 1.28 [.051] 1.56 [.062] .836 [.034] .963 [.039] 1.12 [.045] 1.32 [.053] 1.61 [.064] Nominal Weight in kg/km [lb/1000 ft] 1.89 [1.29] 2.75 [1.88] 4.08 [2.75] 6.21 [4.17] 9.66 [6.49] * Replace asterisk with color code designator: 3 = Orange 6 = Blue 9 = White 0 = Black 1 = Brown 4 = Yellow 7 = Violet 2 = Red 5 = Green 8 = Gray For example: FLMTC0311-18-9 = AWG 18, 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. 9-52 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Commercial Wire Family FlexLite HT High-Temperature Hookup Wire Product Facts n UL rated operating temperature to 200C [392F] n Exceptional chemical resistance n Thin-wall, for size and weight savings n Tough fluoropolymer insulation material n Excellent stripping and handling n Variety of constructions and colors n Crosslinked to minimize cold flow n VW-1 flammability rating n 600 V rating 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 where space and temperature are issues. Conductor Tin-coated copper Insulation Radiation-crosslinked, modified ETFE 9 Wire and Cable Available in: Americas Europe Asia Pacific n n n 9-53 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Commercial Wire Family FlexLite HT (Continued) Specifications/Approvals Series HT UL Style 3557 Flammability VW-1 Temperature rating 200C [392F] CUR CSA Raychem Recognized Certified AWMIA/B WCD-3106 Construction Details Part No. Wire Size (AWG) Conductor Stranding (No. x AWG) Nominal Diameter mm [inch] 26 24 22 20 18 16 14 12 19 x 38 19 x 36 19 x 34 19 x 32 19 x 30 19 x 29 19 x 27 37 x 28 .470 [.0185] .597 [.0235] .749 [.0295] .953 [.0375] 1.18 [.0465] 1.33 [.0525] 1.68 [.0660] 2.16 [.0850] FLHTC0311-26-* FLHTC0311-24-* FLHTC0311-22-* FLHTC0311-20-* FLHTC0311-18-* FLHTC0311-16-* FLHTC0311-14-* FLHTD0311-12-* Finished Wire Maximum Resistance at 20C (68F) /km [ /1000 ft] Minimum mm [inch] Nominal mm [inch] Maximum mm [inch] Nominal Weight in kg/km [lb/1000 ft] 132 [40.1] 83.3 [25.4] 52.2 [15.9] 32.0 [9.76] 20.4 [6.22] 15.8 [4.82] 10.0 [3.05] 6.59 [2.01] .765 [.0301] .892 [.0351] 1.04 [.0411] 1.25 [.0491] 1.48 [.0583] 1.67 [.0656] 2.03 [.0799] 2.50 [.0984] .800 [.0315] .927 [.0365] 1.08 [.0425] 1.28 [.0505] 1.52 [.0600] 1.71 [.0675] 2.08 [.0820] 2.57 [.1010] .836 [.0329] .963 [.0379] 1.12 [.0439] 1.32 [.0519] 1.57 [.0617] 1.76 [.0694] 2.14 [.0841] 2.63 [.1036] 1.89 [1.27] 2.75 [1.85] 4.08 [2.74] 6.21 [4.17] 9.43 [6.34] 12.0 [8.09] 18.6 [12.5] 28.7 [19.3] Diameter Construction Details Part No. FLHTC0311-0.25-* FLHTC0311-0.35-* FLHTC0311-0.50-* FLHTC0311-0.75-* FLHTC0311-1.00-* FLHTC0311-1.50-* FLHTC0311-2.00-* FLHTC0311-2.50- Nominal CSA (mm2) 0.25 0.35 0.50 0.75 1.00 1.50 2.00 2.50 Conductor Stranding No/Dia. (mm) 19/0.127 19/0.15 19/0.19 19/0.23 19/0.25 19/0.32 19/0.36 19/0.41 Diameter (min.) mm [inch] (max.) mm [inch] 0.55 [.022] 0.74 [.029] 0.86 [.034] 1.05 [.041] 1.17 [.046] 1.35 [.053] 1.66 [.065] 1.85 [.073] 0.63 [.025] 0.76 [.030] 0.88 [.035] 1.08 [.043] 1.26 [.050] 1.58 [.062] 1.79 [.070] 2.01 [.080] Finished Wire Maximum Resistance at 20C (68F) (ohms/km) 84.3 56.1 40.1 24.7 20.0 13.7 9.7 8.2 Diameter Lower Spec. Limit mm [inch] 0.96 [.038] 1.12 [.044] 1.24 [.049] 1.43 [.056] 1.58 [.062] 1.82 [.072] 2.05 [.081] 2.24 [.088] Target Value mm [inch] 1.00 [.039] 1.16 [.046] 1.27 [.050] 1.47 [.058] 1.62 [.064] 1.87 [.074] 2.10 [.083] 2.31 [.091] Upper Spec. Limit mm [inch] 1.03 [.041] 1.19 [.047] 1.31 [.052] 1.51 [.059] 1.66 [.065] 1.92 [.076] 2.16 [.085] 2.38 [.094] Nominal Weight (kg/km) 2.95 4.22 5.59 7.95 9.85 15.69 18.67 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. 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. 9-54 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Commercial Wire Family FlexLite TX Ultrahigh-Temperature Hookup Wire Product Facts n UL rated operating temperature -65C to 250C [-85F to 482F] n UL Style 10297 n 600 V rating n Clear legible wire marking n Excellent fluid resistance n Excellent handling characteristics Applications Conductor Nickel-coated copper FlexLite TX wire is a UL recognized hookup wire for lighting fixtures, appliance, wiring and industrial applications requiring a 250C [482F] rated wire. Insulation Modified fluoropolymer 9 Wire and Cable Available in: Americas Europe Asia Pacific n n n 9-55 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Commercial Wire Family FlexLite TX (Continued) Specifications/Approvals Series TX UL Style 10297 Flammability VW-1 Temperature Rating 250C [482F] CUR CSA Raychem Recognized AWMIA/B WCD-3106 Construction Details Part No. Wire Size (AWG) Conductor Stranding (No. x AWG) Nominal Diameter mm [inch] Finished Wire Maximum Resistance at 20C (68F) /km [ /1000 ft] 28 26 24 22 20 18 16 14 12 10 7 x 36 19 x 38 19 x 36 19 x 34 19 x 32 19 x 30 19 x 29 19 x 27 37 x 28 37 x 26 .368 [.0145] .470 [.0185] .597 [.0235] .749 [.0295] .953 [.0375] 1.18 [.0465] 1.33 [.0525] 1.68 [.0660] 2.16 [.0850] 2.72 [.1070] 224 [68.2] 132 [40.1] 83.3 [25.4] 52.2 [15.9] 32.0 [9.76] 20.4 [6.22] 15.8 [4.82] 10.0 [3.05] 6.59 [2.01] 4.13 [1.26] FLTXB0313-28-* FLTXC0313-26-* FLTXC0313-24-* FLTXC0313-22-* FLTXC0313-20-* FLTXC0313-18-* FLTXC0313-16-* FLTXC0313-14-* FLTXD0313-12-* FLTXD0313-10-* Minimum mm [inch] .940 [.037) 1.04 [.041] 1.17 [.046] 1.30 [.051] 1.50 [.059] 1.73 [.068] 1.88 [.074] 2.18 [.086] 2.67 [.105] 3.23 [.127] Diameter Nominal mm [inch] .991 1.09 1.22 1.37 1.57 1.80 1.96 2.29 2.77 3.33 [.039) [.043] [.048] [.054] [.062] [.071] [.077] [.090] [.109] [.131] Maximum mm [inch] 1.04 [.041) 1.14 [.045] 1.27 [.050] 1.45 [.057] 1.65 [.065] 1.88 [.074] 2.03 [.080] 2.39 [.094] 2.87 [.113] 3.43 [.135] Nominal Weight in kg/km [lb/1000 ft] 2.20 [1.48] 2.96 [1.99] 3.97 [2.67] 5.46 [3.67] 7.84 [5.27] 11.3 [7.60] 13.9 [9.32] 20.5 [13.8] 30.8 [20.7] 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. 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. 9-56 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Commercial Wire Family FLT Flexible, Double Insulated, High Performance Wire for a Wide Range of Industrial Applications Product Facts n Highly flame retardant/non melting n Limited fire hazard n 600V rated n Excellent fluid resistance n Flexible n Double insulation (for Class 2 equipment) n Tough, thin wall n Small size, light weight 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. 9 Wire and Cable Available in: Americas Europe Asia Pacific n 9-57 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Commercial Wire Family FLT (Continued) Approvals UL Styles 1385 CSA Class 5851 IEC 332-1 Standard Colors Color Code Color Code Physical Characteristics Black 0 Green 5 Brown 1 Blue 6 Orange 3 Grey 8 Yellow 4 White 9 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 are made over similarly rated PTFE wires. Typical Properties Red 2 Violet 7 22 AWG PTFE equipment wire MIL-W-22759 5.54 grams/meter max. strippers. For details of appropriate tools see separate wire handling guide. The tin-plated copper conductor usually specified is easily soldered or crimped. General Handling Lengths The flexibility of FLT 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 FLT is available in long continuous lengths and can be supplied for use on automatic cut and strip preparation machines. For Example: FLT0111 0.35 equipment wire 4.38 grams/meter max. Temperature rated Rated at 125C [257F] Voltage rating No Voltage rating specified Tensile strength + elongation of insulation Notch propagation BS 3G230 0.05 mm notch Meets BS4066/IEC332-1 Flammability test Solder iron resistance (370C [698F], 1 minute) Shrinkage @ +150C [+302F] Low temperature bend (Tin-plated conductor) -65C to +150C [-85F to +302F] In UL style sheet 1385 600V In UL style sheet 1385 30 N/mm 2 , 230% Pass Pass Pass < 1% -65C [-85F] 9-58 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Commercial Wire Family FLT (Continued) Flexible, Double Insulated, High Performance Wire for a Wide Range of Industrial Applications Environmental Performance Temperature Rating FLT wire is rated for continuous operation from -65C to +125C [-85F to +257F] 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. Ordering Information 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. Primary Insulation Radiation Crosslinked Modified Polyolefin Conductor Tin plated Copper or Bare Copper Conductor Stranding No/Dia mm 0.25 0.35 0.50 0.75 1.00 1.50 2.00 2.50 19/0.127 19/0.15 19/0.19 19/0.23 19/0.25 19/0.32 19/0.36 19/0.41 Conductor Diameter min. mm [inch] max. mm [inch] 0.55 [.022] 0.70 [.028] 0.82 [.032] 1.05 [.041] 1.17 [.046] 1.35 [.053] 1.66 [.065] 1.85 [.073] 0.63 [.025] 0.80 [.031] 0.90 [.035] 1.15 [.045] 1.26 [.050] 1.60 [.063] 1.85 [.073] 2.05 [.081] Finished Wire Maximum Resistance @20C (68F) ohms/km 83.6 56.1 40.1 24.7 20.0 13.7 9.9 8.2 Diameter min. mm [inch] max. mm [inch] 0.91 [.036] 1.06 [.042] 1.18 [.046] 1.41 [.056] 1.55 [.061] 1.73 [.068] 2.12 [.083] 2.31 [.091] 1.04 [.041] 1.21 [.048] 1.31 [.052] 1.56 [.061] 1.70 [.067] 2.06 [.081] 2.38 [.093] 2.61 [.103] Nominal Weight kg/km Ordering Description 2.96 4.14 6.63 8.20 10.86 16.47 20.32 26.56 FLT011X-0.25-Y FLT011X-0.35-Y FLT011X-0.50-Y FLT011X-0.75-Y FLT011X-1.00-Y FLT011X-1.50-Y FLT011X-2.00-Y FLT011X-2.50-Y 9 Wire and Cable Nominal CSA mm 2 Jacket Radiation Crosslinked Modified (PVDF) Note: X = Conductor Type 1 = Tin Plated Copper 9 = Bare Copper Y = Color (see color code on page 9-58) 9-59 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Thermocouple Extension Cables Thermocouple Extension Cable Product Facts n 19-strand conductor for flexibility Applications Tyco Electronics manufactures a broad range of Raychem Thermocouple extension cables in four thermoelement combinations. Each provides accurate transmission of electromotive force (EMF) from a Thermocouple element lead wire of the same conductor material to a thermometer, also known as a pyrometer. All four types of Thermocouple extension cables use 19-strand conductors and are available in twisted pair, jacketed twisted pair, and shielded Available in: and jacketed twisted pair configurations. A range of cables is available from 16 AWG to 24 AWG. Operating Temperature Range -65C to 200C [-85F to 392F] Wires and cables are insulated and jacketed with radiation-crosslinked ETFE, which has a continuous operating temperature of -65C to +200C [-85F to +392F]. This material, which is fully specified in Raychem SPEC 55, has excellent physical properties and is highly resistant to a wide range of chemicals. Americas Europe Asia Pacific n n n 9-60 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Thermocouple Extension Cables Thermocouple Extension Cable (Continued) Properties Initial Calibration Tolerances for Thermocouple Extension Wires Extension Cable Type Thermoelement Combination Temperature Range Limit of Range EX JX KX TX Chromel-Constantan Iron-Constantan Chromel-Alumel Copper-Constantan 0C to 200C [0F to 392F] 0C to 200C [0F to 392F] 0C to 200C [0F to 392F] 0C to 100C [0F to 212F] 1.7C [35.1F] 2.2C [36.0F] 2.2C [36.0F] 1.0C [32.0F] EMF (mv)* (min.-max.) 6.18-6.45 5.15-5.39 4.00-4.19 4.24-4.32 Note: The above is in accordance with ANSI-MC-96.1-1982. *EMF is measured in millivolts (mv) at 100C [212F] with reference junction at 0C [0F]. Product Dimensions** (Nominal) Twisted Pair AWG Size 24 22 20 18 16 Outside Diameter 2.29 [.090] 2.60 [.102] 2.99 [.118] 3.56 [.140] 3.96 [.156] Twisted, Jacketed Pair Weight in kg/km (lb/1000 ft) 7.3 [4.9] 9.9 [6.7] 14.4 [9.7] 20.9 [14.1] 26.3 [17.7] Outside Diameter Weight in kg/km (lb/1000 ft) 2.67 [.106] 2.99 [.118] 3.40 [.134] 3.96 [.156] 4.37 [.172] 9.9 [6.7] 13.0 [8.8] 18.0 [12.1] 25.1 [16.9] 30.9 [20.8] Twisted, Shielded, 38 AWG Braid Strand, Jacketed Pair Weight Outside in kg/km Diameter (lb/1000 ft) 3.12 [.123] 16.5 [11.1] 3.43 [.135] 21.4 [14.4] 3.83 [.151] 27.8 [18.7] 4.34 [.173] 37.5 [25.2] 4.80 [.189] 44.9 [30.2] **Dimensions for 19-strand-conductor thermocouple. Extension Types EX, JX, KX, and TX. Extension Cable Color-Coding Special Cables Thermocouple extension cables are available with the wires color-coded in accordance with four standards: MIL-STD-687, ANSI-MC96.1, British Standard Code BS 1843, and Japanese JIS-C-1602. Thermocouple extension cables are also available in solid-conductor and sevenstrand-conductor configurations. They come in a variety of thermoelement combinations, gauges, insulations, and multiplepair designs, and they are available for outer space applications. Contact Tyco Electronics for details. 9 Extension Cable Red Blue Red Jacket (if present) Violet Brown Violet Color code Wire 7/2 1/6 7/2 Iron + Black White Yellow Red Constantan Yellow Red Blue White Jacket White Black Black Yellow Wire 0/4 9/2 4/6 2/9 Jacket 9 0 0 4 Type KX MIL-STD-687 ANSI-MC-96.1 British Std.-BS 1843 JIS-C-1602 Chromel + White Yellow Brown Red Alumel Green Red Blue White Jacket White Yellow Red Blue Wire 9/5 4/2 1/6 2/9 Jacket 9 4 2 6 Type TX MIL-STD-687 ANSI-MC-96.1 British Std.-BS 1843 JIS-C-1602 Copper + Red Blue White Red Constantan Yellow Red Blue White Jacket White Blue Blue Brown Wire 2/4 6/2 9/6 2/9 Jacket 9 6 6 1 Chromel + Constantan - ANSI-MC-96.1 British Std.-BS 1843 JIS-C-1602 Violet Brown Violet Type JX MIL-STD-687 ANSI-MC-96.1 British Std.-BS 1843 JIS-C-1602 Jacket Wire and Cable Type EX 7 1 7 9-61 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Thermocouple Extension Cables Thermocouple Extension Cable (Continued) Part Number Selection Table The Thermocouple cable options outlined in the table on the previous page can be ordered from the table below. Tyco Electronics will assign a new part number on request for cables falling outside the range shown in the table. Type Twisted Pair Twisted, Jacketed Pair Shield Plating* EX CTC-0077 CTC-0079 T N Twisted, Shielded, Jacketed Pair CTC-0074 55A6169 JX 55A8131 CTC-0080 T CTC-0044 KX 55A8002 CTC-0012 T N S CTC-0018 CTC-0015 CTC-0057 TX CTC-0078 CTC-0081 T CTC-0073 *T = Tin-coated copper. N = Nickel-coated copper. S = Silver-coated copper. 9-62 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Controlled Electrical Cables ElectroLoss Filterline Lightweight, Ruggedized Filterline Wire and Cable Product Facts n Suppresses EMI above 100 MHz n Light weight, small size n SPEC 55 insulation n 600 volt n -65C to 150C [-85F to 302F] -65C to 200C [-85F to 392F] also available Applications Available in: Americas Europe Asia Pacific n n n 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 more sensitive, 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 conventional electrical wiring. Application-driven alternative ElectroLoss FilterLine constructions built to the The absorptive layer in same rigorous standards ElectroLoss FilterLine cable Radiation-crosslinked, Radiation-crosslinked demanded of the ETFE MIL SPEC is constructed of a ferritemodified PVDF products are also available. loaded high-temperature These alternatives offer polymer, which provides significant weight savings high-frequency EMI through the use of flat absorptive characteristics. braids, improved laser mark Achieving maximum attenuation requires concentrating contrast, and a broader Conductorfields Absorptive choice oflayer conductors. the electromagnetic 55FA0511 Radiation-crosslinked PVDF Conductor Radiation-crosslinked, modified conductive EFTE jackets are used over shielded filter line cables to eliminate pathways between adjacent cable shields. The Raychem ElectroLoss FilterLine wire and cable meets the performance requirements of MIL-C85485, a military specification developed to provide EMI protection for military electrical interconnects. 9 Wire and Cable ElectroLoss FilterLine products include highperformance wire and cable, which when used as specified, suppress conducted and radiated EMI above 100 MHz. in the absorptive layer -- either with a metallic shield on each wire or by an overall metallic shield protecting a bundle of individual component wires. A reliable alternative to conventional discrete filters and filter-pin connectors, ElectroLoss FilterLine cables are flexible, lightweight, and compatible with high-density connectors. 55FB1511 Radiation-crosslinked, modified ETFE Absorptive layer Radiation-crosslinked Radiation-crosslinked, modified ETFE PVDF Conductor Absorptive layer Radiation-crosslinked, modified, conductive ETFE Shield -65C to 200C [-85F to 392F] also available. 9-63 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters Dimensions are shown for Radiation-crosslinked, Radiation-crosslinked, Radiation-crosslinked modified ETFE reference modified, conductive andPVDF inches unless otherwise purposes only. ETFE Specifications subject specified. Values in brackets are U.S. equivalents. to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Controlled Electrical Cables ElectroLoss Filterline (Continued) Performance Effective against conducted EMI ElectroLoss FilterLine wire and cable systems attenuate high-frequency EMI and allow low frequency signals to pass with minimum loss. When properly installed and used, filter line wire and cables function as low-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. Graph 1 - Typical insertion loss 200 1.2m 180 160 140 120 Attenuation 100 0.6m 80 4 ft 60 2 ft 0.3m 40 1 ft 20 0 10 100 55FB1511-22 Temperature rating Voltage rating 1000 Frequency (MHz) -65C to +150C [-85F to302F] 600V r.m.s -65C to 200C [-85F to 392F] also available 9-64 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Controlled Electrical Cables ElectroLoss Filterline (Continued) Lightweight, Ruggedized Filterline Wire and Cable Single Conductor Wire Specifications AWG Size 24 22 20 18 16 14 12 10 Conductor Stranding (Number x AWG) 19 x 36 silver coated high strength copper alloy 19 x 34 tin coated copper 19 x 32 tin coated copper 19 x 30 tin coated copper 19 x 29 tin coated copper 19 x 27 tin coated copper 37 x 28 tin coated copper 37 x 26 tin coated copper Maximum Outside Diameter mm (in) Maximum Weight Kg/Km (Ib/1000 ft) MIL-SPEC Part Number Raychem Part Number 1.19 [.047] 4.46 [3.0] M85485/10-24A 55FA0514-24-* 1.37 [.054] 5.95 [4.0] M85485/9-22A 55FA0511-22-* 1.57 [.062] 8.63 [5.8] M85485/9-20A 55FA0511-20-* 1.85 [.073] 12.95 [8.7] M85485/9-18A 55FA0511-18-* 2.08 [.082] 16.67 [11.2] M85485/9-16A 55FA0511-16-* 2.51 [.099] 23.96 [16.1] M85485/9-14A 55FA0511-14-* 2.95 [.116] 35.71 [24.0] M85485/9-12A 55FA0511-12-* 3.58 [.141] 55.06 [37.0] M85485/9-10A 55FA0511-10-* * 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 9 Wire and Cable 9-65 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Controlled Electrical Cables ElectroLoss Filterline (Continued) Unshielded, Unjacketed 2-5 Conductor Cable Specifications 2 2 2 2 2 2 Maximum Outside Diameter 2.39 [.094] 2.74 [.108] 3.15 [.124] 3.71 [.146] 4.17 [.164] 5.03 [.198] Maximum Weight Kg/Km (Ib/1000 ft) 9.08 [6.1] 12.20 [8.2] 17.56 [11.8] 26.34 [17.7] 33.93 [22.8] 48.81 [32.8] MIL-SPEC Part Number M85485/11-24M2A M85485/11-22T2A M85485/11-20T2A M85485/11-18T2A M85485/11-16T2A M85485/11-14T2A Raychem Part Number. 55FA0524-24-* 55FA0521-22-* 55FA0521-20-* 55FA0521-18-* 55FA0521-16-* 55FA0521-14-* 24 22 20 18 16 14 3 3 3 3 3 3 2.59 [.102] 2.97 [.117] 3.40 [.134] 4.01 [.158] 4.50 [.177] 5.44 [.214] 13.69 [9.2] 18.15 [12.2] 26.34 [17.7] 39.58 [26.6] 51.03 [34.3] 73.36 [49.3] M85485/11-24M3A M85485/11-22T3A M85485/11-20T3A M85485/11-18T3A M85485/11-16T3A M85485/11-14T3A 55FA0534-24-* 55FA0531-22-* 55FA0531-20-* 55FA0531-18-* 55FA0531-16-* 55FA0531-14-* 24 22 20 18 16 14 4 4 4 4 4 4 3.28 [.129] 3.78 [.149] 4.34[.171] 5.11 [.201] 5.74 [.226] 6.91 [.272] 18.15 [12.2] 24.25 [16.3] 35.27 [23.7] 52.82 [35.5] 68.00 [45.7] 97.76 [65.7] M85485/11-24M4A M85485/11-22T4A M85485/11-20T4A M85485/11-18T4A M85485/11-16T4A M85485/11-14T4A 55FA0544-24-* 55FA0541-22-* 55FA0541-20-* 55FA0541-18-* 55FA0541-16-* 55FA0541-14-* 24 22 20 18 16 14 5 5 5 5 5 5 3.58 [.141] 4.11 [.162] 4.72 [.186] 5.56 [.219] 6.25 [.246] 7.54 [.297] 22.77 [15.3] 30.36 [20.4] 44.04 [29.6] 66.07 [44.4] 84.96 [57.1] 122.16 [82.1] M85485/11-24M5A M85485/11-22T5A M85485/11-20T5A M85485/11-18T5A M85485/11-16T5A M85485/11-14T5A 55FA0554-24-* 55FA0551-22-* 55FA0551-20-* 55FA0551-18-* 55FA0551-16-* 55FA0551-14-* AWG Size Number of Conductor 24 22 20 18 16 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 7L 7L6 7L3 7L5 7L2 Color designator 9-66 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Controlled Electrical Cables ElectroLoss Filterline (Continued) Lightweight, Ruggedized Filterline Wire and Cable Shielded, Jacketed 1-5 Conductor Cable Specifications Electroloss Filterline Wire and Cable Light Weight Ruggedized Constructions AWG Size Number of Conductors 24 22 20 18 16 14 12 10 1 1 1 1 1 1 1 1 Shield Size AWG Tin Coated Copper 38 38 38 38 38 38 38 38 24 22 20 18 16 14 2 2 2 2 2 2 24 22 20 18 16 14 Maximum Weight Kg/Km (Ib/1000 ft) MIL-SPEC Part Number Raychem Part Number 2.13 [.084] 2.31 [.091] 2.51 [.099] 2.79 [.110] 3.02 [.119] 3.45 [.136] 3.89 [.153] 4.55 [.179] 10.86 [7.3] 13.09 [8.8] 16.67 [11.2] 22.17 [14.9] 26.78 [18.0] 35.86 [24.1] 49.40 [33.2] 71.57 [48.1] M85485/12-24U1A M85485/12-22T1A M85485/12-20T1A M85485/12-18T1A M85485/12-16T1A M85485/12-14T1A M85485/12-12T1A M85485/12-10T1A 55FB1514-24-* 55FB1511-22-* 55FB1511-20-* 55FB1511-18-* 55FB1511-16-* 55FB1511-14-* 55FB1511-12-* 55FB1511-10-* 38 38 38 38 38 38 3.33 [.131] 3.68 [.145] 4.09 [.161] 4.65 [.183] 5.11 [.201] 6.02 [.237] 19.34 [13.0] 23.81 [16.0] 30.50 [20.5] 41.37 [27.8] 50.59 [34.0] 69.49 [46.7] M85485/12-24U2A M85485/12-22T2A M85485/12-20T2A M85485/12-18T2A M85485/12-16T2A M85485/12-14T2A 55FB1524-24-* 55FB1521-22-* 55FB1521-20-* 55FB1521-18-* 55FB1521-16-* 55FB1521-14-* 3 3 3 3 3 3 38 38 38 38 38 38 3.53 [.139] 3.91 [.154] 4.34 [.171] 4.95 [.195] 5.44 [.214] 6.43 [.253] 25.30 [17.0] 31.10 [20.9] 41.07 [27.6] 56.54 [38.0] 69.94 [47.0] 96.87 [65.1] M85485/12-24U3A M85485/12-22T3A M85485/12-20T3A M85485/12-18T3A M85485/12-16T3A M85485/12-14T3A 55FB1534-24-* 55FB1531-22-* 55FB1531-20-* 55FB1531-18-* 55FB1531-16-* 55FB1531-14-* 24 22 20 18 16 14 4 4 4 4 4 4 38 38 38 38 38 38 4.19 [.165] 4.67 [.184] 5.23 [.206] 5.99 [.236] 6.68 [.263] 7.85 [.309] 31.69 [21.3] 39.58 [26.6] 52.68 [35.4] 72.91 [49.0] 91.36 [61.4] 125.59 [84.4] M85485/12-24U4A M85485/12-22T4A M85485/12-20T4A M85485/12-18T4A M85485/12-16T4A M85485/12-14T4A 55FB1544-24-* 55FB1541-22-* 55FB1541-20-* 55FB1541-18-* 55FB1541-16-* 55FB1541-14-* 24 22 20 18 16 14 5 5 5 5 5 5 38 38 38 38 38 38 4.52 [.178] 5.05 [.199] 5.66 [.223] 6.55 [.258] 7.24 [.285] 8.53 [.336] 37.80 [25.4] 47.32 [31.8] 63.39 [42.6] 89.43 [60.1] 111.00 [74.6] 153.26 [103.0] M85485/12-24U5A M85485/12-22T5A M85485/12-20T5A M85485/12-18T5A M85485/12-16T5A M85485/12-14T5A 55FB1554-24-* 55FB1551-22-* 55FB1551-20-* 55FB1551-18-* 55FB1551-16-* 55FB1551-14-* * 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 9 Wire and Cable Maximum Outside Diameter mm (in) Fluid Resistance Fluids Hydrocarbons Fuels and lubricants Alcohols Cleaning fluids Glycols Synthetic fuels and lubricants Ketones 9-67 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Controlled Electrical Cables Cheminax Coaxial Cables Small, Lightweight Coaxial Cables Product Facts n Light weight, small size Temperature range of -65C to 200C [-85F to 392F] n Low capacitance and attenuation n High velocity of propagation n High flexibility n Applications electronic systems, such as computers, military equipment, and other areas of high-density packing, where cables are required to perform to more exacting specifications than standard radio-grade (RG) or UL recognized (UR) constructions. Cheminax controlled electrical cables are used in the aircraft and aerospace industries. They have a wide range of applications in missiles, avionics, radiofrequency and microwave systems, computers, security and surveillance systems, and communications. Tyco Electronics' advanced materials technology has allowed the design and development of Raychem Cheminax coaxial cables were designed to solve interconnect problems in A B C 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 standard RG and UR cables or provide significantly lower attenuation and capacitance with no significant increase in size. D A B C D Available in: Conductor Dielectric Shield Jacket Americas Europe Asia Pacific n n n 9-68 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Controlled Electrical Cables Cheminax Coaxial Cables (Continued) Part Numbering System 95 27 XX XX A X 1 3 X X 1 X 7 X - 0 - X Example: 9527A1317-0 Jacket Color Identification Code 0 - Black 4 - Yellow 1 - Brown 5 - Green 2 - Red 6 - Blue 3 - Orange 7 - Violet 8 - Gray 9 - White 9X - Translucent White 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) 2 - Rayfoam H (Foamed FEP) 3 - Rayolin F (Solid) 4 - Modified FEP (Solid) 6 - Modified XL-ETFE (SPEC 55) 7 - Flex XL-ETFE 8 - Rayfoam M (Foamed MFA) 0 - Other Outer Jacket Material 1 - General purpose PVF 2 - Outerspace PVF 3 - Thermorad F & S 4 - Modified FEP 5 - ETFE (Uncrosslinked) 6 - Modified XL-ETFE (SPEC 55) 7 - Flex XL-ETFE (SPEC 80) 8 - Zerohal & Thermorad Low Smoke 9 - None 0 - Other Construction 1 - Round braid 2 - Flat braid 3 - 2 round braids 4 - 2 shields (other) 5 - Triax-round braids 6 - Triax - other 7 - Other 8 - Composite shield 9 - Core only 0 - Other 9 Wire and Cable 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 9-69 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Controlled Electrical Cables Cheminax Coaxial Cables (Continued) Specifications/Approvals Series Raychem Cheminax cables 1200 Product Dimensions (Nominal) Typical Product Part No. Impedance (ohms) 5012E1339 5012M1612 5024A1311 5026D1027 5030A1317 5030A1424 7520A1311 7524A1311 7528H1424 7530A1317 7530H1424 9522A1311 9527J1528 9530H1014 50 50 50 50 50 50 75 75 75 75 75 95 95 95 Capacitance pF/m (pF/ft) 98.4 [30.0] 82.0 [25.0] 83.7 [25.5] 88.9 [27.1] 90.2 [27.5] 100.4 [30.6] 56.1 [17.1] 56.4 [17.2] 54.5 [16.6] 60.4 [18.3] 57.4 [17.5] 44.3 [13.5] 44.3 [13.5] 44.3 [13.5] Attenuation at 400 MHz dB/100m (dB/100 ft) 14.8 [4.5] 16.1 [4.9] 50.3 [15.3] 63.7 [19.4] 97.5 [29.7] 94.5 [28.8] 20.0 [6.1] 31.8 [9.7] 44.0 [13.4] 58.8 [17.9] 58.1 [17.7] 19.7 [6.0] 31.8 [9.7] 44.3 [13.5] A Conductor Diameter B Dielectric Diameter 2.26 [.089] 2.26 [.089] 0.62 [.025] 0.48 [.019] 0.30 [.012] 0.30 [.012] 1.02 [.040] 0.62 [.025] 0.32 [.013] 0.30 [.012] 0.30 [.012] 0.79 [.031] 0.43 [.017] 0.30 [.012] 7.24 [.285] 6.07 [.239] 1.70 [.067] 1.27 [.050] 0.79 [.031] 0.86 [.034] 4.57 [.180] 2.82 [.111] 1.37 [.054] 1.35 [.053] 1.30 [.051] 5.51 [.217] 2.84 [.112] 1.83 [.072] C Shield Diameter 7.98 [.314] 6.60 [.260] 2.18 [.085] 1.70 [.067] 1.12 [.044] 1.19 [.047] 5.11 [.201] 3.25 [.128] 1.73 [.068] 1.78 [.07] 1.73 [.068] 6.05 [.238] 3.18 [.125] 2.26 [.089] D Jacket Diameter Weight in kg/km (lb/1000ft) 10.24 [.403] 7.06 [.278] 2.67 [.104] 2.21 [.087] 1.57 [.062] 1.60 [.063] 6.12 [.241] 3.86 [.152] 2.13 [.084] 2.29 [.09] 2.03 [.08] 7.32 [.288] 3.58 [.141] 2.62 [.103] 162.2 [109.0] 74.5 [50.1] 11.8 [7.9] 11.8 [7.9] 4.5 [3.0] 5.7 [3.8] 43.2 [29.0] 19.2 [12.9] 8.9 [6.0] 8.3 [5.6] 8.5 [5.7] 55.1 [37.0] 19.2 [12.9] 13.1 [8.8] Note: All values are nominal. Product Characteristics Conductor Range Operating Temperature Range* Impedance range Dielectric constant Velocity of propagation General Electrical 12 AWG to 30 AWG -65C to 200C [-85Fto 392F] 50 ohms to 125 ohms 1.65-2.3 67%-80% *Temperature rating varies depending on materials used in specific construction. Small, Lightweight Coaxial Cables Properties (per SCD) Physical Rayfoam L 6.8 MPa (1000 psi) 50% Tensile (min.) Elongation (min.) Electrical Dielectric withstand (min.) Velocity of propagation (nom.) Dielectric constant Physical Tensile (min.) Elongation (min.) Temperature (max.) Flammability* Fluid category* Typical Value of Dielectric Material Rayolin F Rayfoam H 4.1 MPa 12.2 MPa (600 psi) (1800 psi) 50% 200% 1000 V 78% 1.65 1000 V 78% 1.65 1000 V 67% 2.2 Thermorad 13.6 MPa (2000 psi) 250% 125C [257F] Method C C SPEC 55 34 MPa (5000 psi) 50% 200C [392F] Method B A Type Value of Jacket Material FlexLine 20.4 MPa (3000 psi) 100% 200C [392F] Method B A FEP 13.6 MPa (2000 psi) 200% 200C [392F] Method B A Zerohal 8.2 MPa (1200 psi) 150% 125C [257F] Method B C SPEC 44 27.2 MPa (2500 psi) 150% 150C [302F] Method B *See Raychem specification WCD-1200 for details. 9-70 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Controlled Electrical Cables Cheminax -- High Performance Alternatives to Standard Cables Raychem Alternatives to RG Cables RG/U 4 5 8 11 29 31 55 58 59 62 63 87 89 115 122 124 133 140 141 142 144 149 Raychem Alternative 5020A3311-0 5018D3311-0 5018D3311-0 5012E1339-0 7518A1311-0 5020A1311-0 5012E1339-0 5020A3311-0 5018D3311-0 5021D1331-0 5020A1311-0 5018A1311-0 7523D1331-0 7524A1311-0 7520A1311-0 9524A1311-0 2524A1311-0 5012A3311-0 5012A3311-0 5012A3311-0 5020A1311-0 7524A1311-0 9524A1311-0 7524A1311-0 5020A1311-0 5019D3318-0 5018D3311-0 7518A1311-0 7518A1311-0 Comments RG/U Small/light Improved electricals Small/light Dimensionally similar Small/light Small/light Dimensionally similar Small/light Improved electricals Dimensionally similar Small/light Improved electricals Dimensionally similar Small/light Improved electricals Small/light Small/light Small/light Small/light Small/light Improved electricals Small/light Small/light Small/light 159 Small/light Small/light Improved electricals Small/light Small/light 174 178 179 180 188 210 213 214 223 225 235 279 282 302 303 304 316 393 400 403 Raychem Alternative 5020A1311-0 5026A1311-0 5024A1311-0 5030A1317-0 5028A1317-0 7530A1317-0 7528A1317-0 9530E1014-0 9527A1318-9 5026A1311-0 5024A1311-0 9524A1311-0 5012E1339-0 5012A3311-0 5019D3318-0 5018D3311-0 5012A3311-0 5012A3311-0 7524A1311-0 5024A1311-0 7524A1311-0 5020A1311-0 5018A1311-0 5026A1311-0 5024A1311-0 5012A3311-0 5020A3311-0 5018D3311-0 5030A5314-0 Comments Small/light Small/light Improved electricals Small/light Improved electricals Small/light Improved electricals Small/light Improved electricals Small/light Improved electricals Small/light Dimensionally similar Small/light Small/light Improved electricals Small/light Small/light Dimensionally similar Small/light Small/light Small/light Small/light Small/light Improved electricals Small/light Small/light Improved electricals 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. 9 Wire and Cable 9-71 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Controlled Electrical Cables Cheminax -- High Performance Alternatives to Standard Cables (Continued) Raychem Alternatives to UR Cables UR 43 57 65 67 70 72 76 84 90 95 96 102 104 105 106 107 108 109 110 111 112 113 116 117 200 201 202 203 204 205 207 208 210 301 306 Raychem Alternative 5020A1311-0 7518A1311-0 7518A1311-0 5012E1339-0 7524A1311-0 5020A1311-0 5020A1311-0 7524A1311-0 7522A1311-0 5026A1311-0 9524A1311-0 5012E1339-0 7522A1311-0 7518A1311-0 7222A1311-0 5012E1339-0 5020A1311-0 5026A1311-0 5030A1317-0 7530A1317-0 5012A3311-0 7518A1311-0 5026A1311-0 7524A1311-0 7524A1311-0 7522A1311-0 7522A1311-0 7520A1311-0 7518A1311-0 7518A1311-0 7524A1311-0 7524A1311-0 7524A1311-0 5020A1311-0 7524A1311-0 Comments Small/light Small/light Small/light Dimensionally similar Small/light Small/light Small/light Small/light Small/light Small/light Dimensionally similar Dimensionally similar Small/light Small/light Small/light Small/light Small/light Small/light Small/light Small/light Small/light Small/light Small/light Small/light Dimensionally similar Dimensionally similar Dimensionally similar Small/light Dimensionally similar Dimensionally similar Small/light Small/light Small/light Small/light 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. 9-72 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Controlled Electrical Cables Cheminax Twin Axial Cable Small, Lightweight Twin Axial Cables Product Facts n Light weight, small size Temperature range of -65C to 200C [-85F to 392F] n Low capacitance n High data rates n Excellent shop handling n Applications These small, lightweight cables are specially 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. B 9 C D A B C D Available in: Wire and Cable A Cheminax twin axial cables provide elegant solutions to an increasing range of data bus and multiplex signal transmission applications. Conductor Dielectric Shield Jacket Americas Europe Asia Pacific n n n 9-73 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Controlled Electrical Cables Cheminax Twin Axial Cable (Continued) Specifications/Approvals Series Raychem Cheminax cables 1200 Product Dimensions* Typical Product Part No. 5024A1661 5026A1664 7520A1662 7526J1660 7820D0331 7824E0422 0022E0311 0024A0024 0026A0024 2524H0524 2526E1114 2530A0314 10595-24 10606-26 10612-24 10613-24 10614-24 Impedance (ohms) Capacitance pF/m(pF/ft) 50 50 75 75 78 78 100 100 100 125 125 125 70 75 77 77 77 104.7 [31.9] 136.2 [41.5] 74.2 [22.6] 88.6 [27.0] 67.3 [20.5] 55.1 [16.8] 49.2 [15.0] 44.3 [13.5] 44.0 [13.4] 39.4 [12.0] 36.1 [11.0] 39.4 [12.0] 91.9 [28.0] 91.9 [28.0] 91.9 [28.0] 91.9 [28.0] 91.9 [28.0] A Conductor Diameter .64 [.025] .48 [.019] 1.02 [.040] .48 [.019] 1.02 [.040] .64 [.025] .79 [.031] .64 [.025] .48 [.019] .64 [.025] .48 [.019] .30 [.012] .64 [.025] .53 [.021] .64 [.025] .64 [.025] .64 [.025] B Dielectric Diameter 0.89 [.035] 0.66 [.026] 2.03 [.080] 0.99 [.039] 2.11 [.083] 1.19 [.047] 1.98 [.078] 1.30 [.051] 1.14 [.045] 1.83 [.072] 1.40 [.055] 0.86 [.034] 1.19 [.047] 0.99 [.039] 1.22 [.048] 1.22 [.048] 1.22 [.048] C Shield Diameter 2.21 [.087] 1.75 [.069] 4.60 [.181] 2.41 [.095] 4.75 [.187] 2.82 [.111] 4.39 [.173] 3.02 [.119] 2.72 [.107] 4.09 [.161] 3.33 [.131] 2.16 [.085] 2.82 [.111] 2.41 [.095] 2.90 [.114] 3.33 [.131] 3.73 [.147] D Jacket Diameter 2.62 [.103] 2.16 [.085] 5.05 [.199] 2.82 [.111] 5.72 [.225] 3.33 [.131] 5.16 [.203] 3.63 [.143] 3.23 [.127] 4.50 [.177] 3.73 [.147] 2.67 [.105] 3.23 [.127] 2.82 [.111] 3.30 [.130] 3.73 [.147] 4.09 [.161] Weight in kg/km (lb/1000ft) 14.4 [9.7] 10.0 [6.7] 42.9 [28.8] 14.9 [10.0] 46.9 [31.5] 19.6 [13.2] 30.5 [20.5] 25.1 [16.9] 18.7 [12.6] 25.3 [17.7] 21.7 [14.6] 10.6 [7.1] 17.9 [12.0] 13.4 [9.0] 23.7 [15.9] 39.0 [26.2] 40.3 [27.1] *All dimensions are nominal. Small, Lightweight Twin Axial Cables Product Characteristics Conductor range Operating temperature range* Impedance range Capacitance range General Electrical 20 AWG to 30 AWG -65C to 200C [-85F to 392F] 50 ohms to 125 ohms 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 Tensile (min.) Elongation (min.) Rayfoam L Rayfoam H Rayolin F FEP (solid) Radiation-Crosslinked XL ETFE 6.8 MPa (1000 psi) 50% 9.1 MPa (600 psi) 50% 12.2 MPa (1800 psi) 200% 6.8 MPa (1000 psi) 150% 34 MPa (5000 psi) 50% 1000 V 78% 1.65 1000 V 67% 2.2 1000 V 69% 2.1 1000 V 61% 2.7 Electrical 1000 V Dielectric withstand (min.) Velocity of propagation (nom.) 78% 1.65 Permittivity (nom.) Physical Tensile (min.) Elongation (min.) Temperature (max.) Flammability** Fluid category** Thermorad 13.6 MPa (2000 psi) 250% 125C [257F] Method C C SPEC 55 34 MPa (5000 psi) 50% 200C [392F] Method B A Typical Value of Jacket Material FlexLine FEP 20.4 MPa 13.6 MPa (3000 psi) (2000 psi) 100% 200% 200C 200C [392F] [392F] Method B Method B A A Zerohal 8.2 MPa (1200 psi) 150% 125C [257F] Method B C SPEC 44 27.2 MPa (2500 psi) 150% 150C [302F] Method B B *See Raychem specification WCD-1200 for details. 9-74 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Multiconductor (Multicore) Cables Custom-designed and standard Multiconductor (Multicore) Cables Product Facts n Temperature capability: -55C to +260C [-67F to +500F] n Small size, lightweight n System compatibility with other Raychem products n Complete range of components n Specially formulated jacket materials n Special shielding to address EMI/EMC problems n Custom designed and purpose built n Fast response--design, pricing, and delivery n Prototype length facility n Raychem Dynalink extended flex-life and increased flexibility n Fire-resistant: circuit integrity (IEC331, enhanced 950C [1742F], 3 hours) n Small-size, lightweight, low-fire-hazard for modern high-speed vessels n n n Specifications/Approvals Tyco Electronics is the leading manufacturer of Raychem custom-designed, small-size, lightweight, high-performance multiconductor (multicore) cables. Applications are found in the aerospace, commercial marine, naval, mass transportation, automotive, offshore, military ground vehicle, ground support, high-performance instrumentation, industrial, and commercial markets. Raychem multiconductor (multicore) cables have been approved to many standards demanding high performance criteria in service use. Agency Underwriters' Laboratories BSENISO9001 MSV 34410-34413, 34435,34436 Multiconductor (Multicore) Cables Purpose Built and Designed Using Raychem Components and Technology Multiconductor cables are used in widely varying applications and environments. Careful consideration 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 polymer blending and subsequent radiation crosslinking has led to the development of a particularly broad range of Raychem cables. Highperformance component wires and miniature coaxial cables are combined with unique cable jacket materi- Industry Lloyd's Register of Shipping Det Norske Veritas -- 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 manufacturing expertise. Development of a sophisticated CAD system has allowed increasingly rapid response to any design request, followed by manufacturing to the highest quality standards. 9 Wire and Cable Available in: Americas Europe Asia Pacific Applications Planar Film-Bonded Cables Tyco Electronics can customdesign and build a variety of Raychem component wires and cables onto highperformance carrier films. Components and carriers are matched to ensure temperature and environmental stability. Military Def. Stan. 61-12 Pt 25 VG 95218 Pts 27 and 28 -- Raychem WCD series -- -- 9-75 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Multiconductor (Multicore) Cables Multicore Cables Design Flexibility Components n SPEC 44 wire and cable n ElectroLoss FilterLine cables n SPEC 55 wire and cable n Flexible power cables n Type 99 wire and cable n Optical fibers n 100 wire n Special components n Coaxial cables Wraps and Braids n Fabric and film tapes n Kevlar(R) or steel strength members n Full range of electrical screens (including SuperScreens) Jacket Materials n FDR 25 - Fluid resistant, flexible, high temperature n Thermorad - General purpose n KEVLAR is a trademark of E. I. du Pont de Nemours and Company Thermorad HTF/ - Very high temperature, Fluoroelastomer fluid resistant n Raythane C - Tough and flexible n Raythane FR - Tough, flexible, flameretardant n Rayolin - Low moisture transmission n Neoprene - Low-temperature flexibility n Zerohal - LFH 9-76 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable Jacket Materials Properties and Specifications Properties and Specifications Specifications and Approvals (Components and Jacket Materials) Specifications UK Designation FDR 25 US Designation Zerohal Zerohal Def Stan 61-12 Part 31 (NES 518) Def Stan 61-12 Part 25 Fluoroelastomer Thermorad HTF Thermorad Rayolin Thermorad F Raythane C AFR Neoprene Thermorad NTFR Raythane FR X X 55 Wire 55 Wire 100 Wire 100 Wire 99 Wire Hytrel X Def Stan 61-12 Part 18 type 1 (issue 4) (Maintenance range) X Def Stan 61-12 Part 18 type 1 (issue 4) Def Stan 61-12 Part 25 Def Stan 61-12 Part 26 34435, 34436 VG 95218 Part 20, 21, 22 and 23 X VG 95218 Part 24, 25 and 26 X VG 95218 Part 27 and 28 VG 95218 Part 1000 VG 95218 Part 1001 and 1002 MIL-C-24640 (PMS 400) MIL-W-81044/MIL-C-27500 MIL-W-22759/MIL-C-27500 A014000 O2-517 Approvals Lloyds Register of Shipping/DNV Bureau Veritas UL CAA BWB VDE Det Norskeveritas Germanischer Lloyds American Bureau of Shipping Lloyds Bureau Veritas 44 Wire 44 Wire X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X (FR) X X X X X X X X X X X X X X X X X X X X X X X X X 9 Wire and Cable 9-77 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable Jacket Materials Properties and Specifications (Continued) Major Cable Specifications Country Cable Specification UK Def Stan 61-12 Part 25 Germany VG 95218 (parts 27 and 28) USA MIL-C-24640 (PMS 400) Specification Description Royal Navy specification covering limited fire hazard thin-wall insulated electric cables using Def-Stan 61-12 Part 18 approved wire. Signal, control and light power circuits. Military ground systems specification for signal, control and power cables. Wire to VG 95218 Parts 20-23 and 1000. Navy specification covering limited fire hazard thin-wall insulated electric cables for signal, control and light power circuits. Wire to MIL-W-81044. Approved Jacket Zerohal FDR-25 Zerohal Summary of Typical Cable Jacket Properties UK Designation FDR25 Zerohal Fluoroelastomer Thermorad Raythane C -- Neoprene Rayolin AFR -- -- -- Polyvinylidene Fluoride Modified ETFE Modified Flexible ETFE US Designation -- Zerohal UK & US Thermorad HTF Thermorad F -- Raythane FR Thermorad NTFR -- -- Thermorad LS Thermorad O Thermorad 300 Thermorad K Thermorad HT Thermorad FL Temperature Range C* -40 to 150 -30 to 105 -20 to 200 -55 to 125 -25 to 80 -65 to 90 -55 to 110 -55 to 95 -40 to 105 -30 to 105 -55 to 125 -65 to 200 -65 to 150 -65 to 200 -55 to 200 Property Abrasion Flexibility Resistance Fair Very good Good Good Good Good Good Good Excellent Excellent Excellent Excellent Very Good Excellent Very Good Fair Excellent Good Good Good Good Good Very Good Fair Very Good Fair Very Good Fair Very Good Good Chemical Resistance Flame Resistance Self-ext;ing Self-ext;ing Nonburning Self-ext;ing Self-ext;ing Self-ext;ing Self-ext;ing -- Self-ext;ing Self-ext;ing Self-ext;ing Self-ext;ing Self-ext;ing Self-ext;ing Self-ext;ing Acid Alkaline Hydrocarbon Good Good Excellent Good Fair Fair Good Good Good Good Good Excellent Excellent Excellent Excellent Good Good Excellent Good Fair Fair Good Good Good Good Good Excellent Good Excellent Excellent Very Good Good Excellent Good Excellent Excellent Good Good Good Good Good Excellent 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. 9-78 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable Jacket Materials FDR25 Flexible, Diesel Resistant Wire and Cable Jacket Material Product Facts n Highly flame retardant Compatible with Raychem System 25 tubing, molded parts and adhesives n Qualified to VG standards n Available in: Americas Europe Asia Pacific n n n Applications Operating Temperature Range FDR 25 cable jacket was originally developed for the Leopard II main battle tank to provide an exceptional range of properties. Used in compartments exposed to hot diesel fuels and vibration, 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 applications such as test and communications equipment. FDR 25 is fully compatible with Raychem's high performance harnessing system -- System 25. -40C to 150C [-40F to 302F] 9 Wire and Cable FDR 25 9-79 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable Jacket Materials FDR25 (Continued) Typical Characteristics when Tested in Accordance with Raychem Specification WCD 2002 (UK) and WCD 3304 (US) Mechanical Thermal aging Tensile strength (MPa) Elongation (%) Tear strength (N/mm) Abrasion resistance (1.6 kg load) Cold bend Endurance IEC 216 Heat aging 120h, 175C [347F] Heat shock 4 h at 225C [437F] 24 h immersion Fluid resistance Electrical Diesel fuels 70C [158F] Hydraulic fluids 50C [122F] Lubricating oils 100C [212F] Cleaning fluids 23C [73F] Deicing fluids 23C [73F] Insulation resistance 20C [68F] M ohm.km min. 45 flammability Other Vertical flammability Acid gas 20 500 5 40 scrapes min. -40C [-40F] 2500 h 150C [302F] TS 8 MPa (min). Eb 150% (min) No cracks, drips or flowing, 6 mm total shrinkage in 300 mm % Retention of properties Elongation Tensile strength 70 70 70 70 70 80 90 95 90 95 2 30 s (max) afterburn 100 mm (max) burn length Self extinguishing 4% HCl equivalent (max.) 9-80 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable Jacket Materials Zerohal Low Fire Hazard Performance Wire and Cable Jacket Material Product Facts n Halogen free Low smoke generation n Highly flame retarded n Low toxicity index n Low corrosive gas emission n Temperature rating -30C to +105C [-22F to +221F] n Applications Available in: Americas Europe Asia Pacific n n n Raychem Zerohal is a halogen-free cable jacket material developed by Tyco Electronics and approved to the most exacting requirements for low fire hazard cables 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 wire or Type 99 and 100 wire, this jacket material provides small size, light weight cables (approximately 40% weight saving over conventional materials). Zerohal combines the good mechanical and electrical features of some conventional 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. 9 System n Wire and Cable Cables rarely initiate fires, but they could be involved in them and can significantly increase the damage caused should they propagate 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. System 100 Zerohal 9-81 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable Jacket Materials Zerohal (Continued) Product Characteristics when Tested in Accordance with Raychem Specification WCD 2015 and WC 2001 (Zerohal with Fungicide) Tensile strength (MPa) Elongation (%) Tear strength (N/mm) Abrasion resistance (1.6 kg load ) Cold bend Heat aging 120 h 130C [266F] Mechanical Thermal aging Heat shock 4 h at 225C [437F] Fluid resistance Diesel fuels 100C [212F] /24 h IRM 902 24h, 100C [212F] Lubricating oils 50C [122F]/24 h Water uptake (ASTM D570) 70C [158F]/28 days Insulation resistance 20C [68F] M ohms km (min) 45 flammability Vertical flammability (Swedish Chimney) Acid gas Limiting oxygen index Temperature index Toxicity index Smoke index Halogen content Electrical Other Low Fire Hazard Performance Flammability Current thinking on fire hazard defines the term `Fire Risk'. 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 conditions, the results are, at best, only weakly correlated to actual fire situations. Critical Temperature Index (CTI), is a related test and assesses performance at elevated temperature but nevertheless it is still conducted on a single specimen. More recent evidence and thinking places significantly greater importance on large scale flammability tests, such as IEC 60332-3, in which the sample consists of several bundles of wires. These tests predict more accurately the likely behavior of cables in actual fire scenarios. 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, polymers 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 reinforcement bars embedded in concrete. 8 200 5 30 scrapes min. -30C [-22F] 60% min retention of TS and Eb No cracks, drips or flowing, 6 mm total shrinkage in 300 mm Retention of properties Elongation Tensile strength 85 75 90 75 80 75 2% weight uptake (max) 40 Self extinguishing Self extinguishing 1.2% HCl equivalent (max) 32% 275C [527F] 2.5 per 100 g 18 None detected Test methods to evaluate corrosivity involve direct measurement of the amount of acid gas produced during pyrolysis, eg to British Rail Specification TDE 76/P/16 or measurement of pH and electrical conductivities of solutions. Toxicity Index The various gases given off by combustion of polymeric materials are toxic to differing degrees. The Def Stan 02-713, assesses the concentration of each of the possible byproducts and, by measuring the amounts of these materials, a Toxicity Index is assigned. Zerohal jacket material has a typical 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 authorities involves the use of the NBS smoke chamber where optical density of the chamber's atmosphere is constantly measured during pyrolysis. The 10% visibility line indicates the density of smoke which would cause human disorientation and confusion. 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. 9-82 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable Jacket Materials Zerohal (Continued) Navy Applications 37 Component Cable Comparison Raychem Cable to Cable DGS to Def Stan 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 For the vessel to achieve maximum speed, maneuverability and range, it is vital to The diagram shows a lightweight cable compared with a traditional Navy cable having the same crosssectional 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. 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 designers, particularly where cable glanding is involved. Weight savings within "maxima allowed" by existing specifications are also 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 fire would present a significant threat to people or equipment. 9 Wire and Cable Ships are becoming smaller and more sophisticated, 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 electronic hardware requires more and more communication 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 severe space problem within ducts and hangers. 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. 9-83 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable Jacket Materials Thermorad HTF/ Fluoroelastomer High Temperature Performance Wire and Cable Jacket Material Product Facts n High temperature capability -20C to +200C [-4F to 392F] n Excellent chemical resistance n Flame retardant n Continuous aircraft fuel immersion Available in: Americas Europe Asia Pacific n n n Applications Thermorad HTF/ Fluoroelastomer Thermorad HTF/ Fluoroelastomer is a material specially formulated for use in applications where exceptional performance is required. It displays excellent stability during continuous high temperature exposure to adverse chemical environments. ture of up to 200C [392F], and finds applications in aircraft fuel tanks and on high performance engine cables. Thermorad HTF/ Fluoroelastomer cable jackets are compatible with the Raychem high temperature harnessing systems -- System 200. System n System 200 Thermorad HTF/ Fluoroelastomer has a continuous operating tempera- Typical Characteristics when Tested in Accordance with Raychem Specification WCD 51/367 Mechanical Thermal aging Tensile strength Elongation Abrasion resistance (1.6 kg load) Cold bend -0C 3C [37F] Heat age Heat shock 4 h at 300C 3C [572F 37F] 72 h immersion Fluid resistance Electrical Other Diesel oil 100C [212F] ASTM No 2 oil 100C [212F] Insulation resistance 20C [68F] M ohms. km (min) 45 flammability Vertical flammability 12 MPa 400% 40 scrapes min. No cracking 168 h 250C [482F] No cracks, drips or flowing, 6 mm total shrinkage in 300 mm % Retention Tensile strength Elongation 60 60 60 60 10 30 s (max) afterburn 100 mm (max) burn length Self extinguishing 9-84 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable Jacket Materials Thermorad/Thermorad F General Purpose Wire and Cable Jacket Material Product Facts n Temperature rating -55C to +125C [-67F to 257F] n Highly flame retardant n Resistant to fuels, oils and greases n Resistant to NBC decontaminant n UL approved Applications Available in: Americas Europe Asia Pacific Thermorad is a general purpose jacket material which is unaffected by most common chemicals and solvents and is suitable for use during N.B.C. decontamination. Thermorad is highly flame retardant and has an overall balance of physical and chemical properties. n n n Thermorad Mechanical Thermal aging Tensile strength Elongation Abrasion resistance (1.6 kg load) Cold bend Heat aging 120 h, 170C [338F] Heat shock 4 hours at 225C [437F] 72 hour immersion, 50C [122F] Fluid resistance Electrical Other IRM 902 Skydrol(R) Insulation resistance 20C [68F] M ohms km (min) 45 flammability Acid gas 9 Wire and Cable Typical Characteristics when Tested in Accordance with Raychem Specification WCD 51/1602 (UK) and WCD 3310 (US) Thermorad cables find widespread use in industrial, commercial and military applications. This includes railways, commercial vehicles, medical equipment, communication equipment and commercial electronics. Thermorad cable jackets are compatible with Raychem polyolefin tubings, molded parts and adhesives. 22 MPa 550% 300 scrapes min. -55C [-67F] 60% min. retention of TS and Eb No cracks, drips or flowing, 6 mm total shrinkage in 300 mm % Retention of properties Tensile strength Elongation 60 60 60 60 100 30 s (max.) afterburn 75 mm (max.) burn length 4% HCl equivalent (max.) 9-85 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable Jacket Materials Raythane, Neoprene, Rayolin and AFR Specialized Wire and Cable Jacket Material Product Facts Raythane C n -25C to +80C [-13F to +176F] and Raythane FR n -65C to +90C [-85F to +194F] n Mechanically tough n Can be overmolded Rayolin -55C to +95C [-67F to +203F] n Excellent long term water immersion n Can be overmolded n Compatible with Raychem's underwater cable splices n Neoprene (US designation Thermorad NTFR) n -55C to +90C [-67F to +194F] n Extreme flexibility n Highly flexible at low temperatures AFR -40C to +105C [-40F to +221F] n Abrasion resistant n Fuel resistant n Flame retardant n Applications Available in: Americas Europe Asia Pacific 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 temperature flexibility or for enhanced abrasion resistance, or non-cross-linked materials for cable splicing or overmolding. n n n Jacket material Typical Characteristics when Tested in Accordance with Raychem Specification WCD Mechanical Thermal aging Fluid resistance Electrical Other Tensile strength (MPa) Elongation (%) Abrasion resistance (1.6 kg load) Cold bend Endurance (10000 h) 24 h immersion Diesel fuels 50C [122F] Skydrol(R) 50C [122F] IRM 902 100C [212F] Insulation resistance 20C [68F] M ohms. km (min) 45 flammability WCD51/1625 Raythane C 45 400 WCD3310 Raythane FR 45 400 WCD51/147 Neoprene* 12 400 WCD51/1601 Rayolin 14 12 250 WCD51/1619 AFR 500 scrapes 500 scrapes 30 scrapes 300 scrapes 200 scrapes -25C [-13F] 80C [176F] -15C [5F] 90C [194F] -55C [-67F] 90C [194F] -55C [-67F] 95C 203F] -40C [-40F] 105C [221F] Excellent Excellent Good -- Good -- Excellent -- Excellent Excellent Good Excellent Good Excellent Good 1 1 5 100 100 Pass Pass Pass -- Pass 150 * In the US use Thermorad NTFR to WCD 3314. 9-86 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Miscellaneous Electrical Shielding Interference -- Designing for the Threat 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. Available in: Americas Europe Asia Pacific n n n 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(R) film that provides electrostatic shielding, progressively more complex shielding can be designed incorporating plated copper braids and Mu metal wraps. Optimization Performance of conventional braiding can be significantly improved by computer optimization. This tightly controlled process can give many times the shielding performance 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 Shields Shield type Construction Typical Application 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 9 Wire and Cable Aluminized Mylar(R) MYLAR is a trademark of Dupont Teijin Films U.S. 9-87 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Miscellaneous Electrical Shielding (Continued) Surface Transfer Impedance (Zt) Design and Manufacturing Expertise The problems of shielding cables are complex. However, with the introduction of optimized braids and supershielded cables, Tyco Electronics has the capability 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 manufactures Raychem cable terminations and connector back fittings to give total interconnection system shielding performance. Shielded Cables Controlling the Threat Screening performance of various types of screen constructions Aluminized Mylar Single Stranded Braid 10 Single Optimized 75 85 Double Optimized 95 105 115 125 1 0.1 Single Superscreen 0.01 135 145 155 0.001 Double Superscreen Solid Copper screen 0.0001 Supershielding 10 3 10 4 10 5 10 6 10 7 165 175 10 8 Frequency (Hz) EMP Hardened Cables The requirements for nuclear hardened cables present the engineer with a range 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 conventionally shielded cables. Tyco Electronics has solved this problem with a range of 55 65 100 EM Shielding effectiveness (dB/meter) To assess the effectiveness of a shield, Tyco Electronics has adopted the line injection method as described in IEC 1196-1 to measure the surface transfer impedance (Zt) of a cable shield. This relates the open circuit voltage generated on a component 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 surface transfer impedance across a range of frequencies, a drive signal is generated 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 leakage mechanisms has enabled Tyco Electronics to design Raychem cables with guaranteed minimum Zt values for the desired operating environment. supershielded cables which give shielding performance at these frequencies by incorporating materials which change the inductance of the shield and lower the transfer impedance. Raychem supershielded cables have a sandwich construction of Mu metal tapes between optimized braids. Mu metal is a ferro-magnetic material which has a high permeability over a wide range of field strengths. It is applied to the cable in a way which maintains cable flexibility and minimizes work hardening and any consequent reduction in permeability. Supershielded cables not only give protection against EMP but also other major interference modes. Surface transfer impedance (m.ohms/meter) Measuring Shielding Efficiency 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. 9-88 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Miscellaneous Computer Aided Design Custom Design Capability Applications Every year, Tyco Electronics designs and builds several thousand custom, highperformance, multiconductor cables that meet unique product needs. Available in: Americas Europe Asia Pacific Quality Assurance Raychem WCD and WSD cable specifications ensure that performance and quality standards are maintained to the highest level. Tyco Electronics manufacturing 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. 9 Wire and Cable Design staff can draw on an extensive range of highperformance cable components and jacket materials, while incorporating both color-coding and alphanumeric marking techniques for component identification. These options, combined 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 factory engineers 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. n n n 9-89 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Miscellaneous Power Cables Product Facts n Choice of jacket materials -55C to +125C [-67F to +257F] n Size and weight savings n Excellent flexibility n Resistance to solvents and chemicals n 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, 125C [257F] construction normally specified for use inside cabinets in protected areas. Type ZHI is a halogen-free 105C [221F] 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. Available in: Americas Europe Asia Pacific Type FTR is a dual-wall, 125C [257F], diesel-oilresistant cable originally developed for tank engine compartment applications. It meets the German BWB VG 95218 specification. Refer to Raychem specification WCD 2002. Type AFR is a 105C [221F], single-extrusion, abrasionresistant, flame- and fuelresistant,radiation-crosslink ed polyolefin. Each offers particular advantages for specific applications and each is also available in multiconductor 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. Type ZHPCG is a halogenfree, 115C [239F] 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. n n n 9-90 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Miscellaneous Power Cables (Continued) Specifications/Approvals* Series TR ZHI FTR AFR ZHPCG Agency -- -- -- UL style 3496 -- Military Def. Stan. 61-12 Part 31 (jacket material) -- BWB VG 95218 Types G, H, and K -- -- Raychem WCD 2003, WCD 51/160 WCD 2015 WCD 2002 WCD 2011, WCD 51/160 WSD 1265 *See specifications listed for details of performance. Conductors (Tinned Soft Copper) Stranding Conductor Size mm2 1.5 2.5 4.0 6.0 10.0 16.0 25.0 35.0 50.0 70.0 95.0 120.0 150.0 185.0 240.0 300.0 400.0 IEC Class 5 No. x mm 30 x 0.25 50 x 0.25 56 x 0.30 84 x 0.30 80 x 0.40 126 x 0.40 196 x 0.40 276 x 0.40 396 x 0.40 360 x 0.50 475 x 0.50 608 x 0.50 777 x 0.50 925 x 0.50 1221 x 0.50 1554 x 0.50 2035 x 0.50 IEC Class 6 Nom. Dia. 1.49 [.05] 1.90 [.07] 2.49 [.10] 3.00 [.12] 4.60 [.18] 5.70 [.22] 7.10 [.28] 8.50 [.33] 10.30 [.41] 12.40 [.49] 14.50 [.57] 16.00 [.63] 18.00 [.71] 20.00 [.79] 23.00 [.91] 26.00 [1.0] 30.00 [1.2] No. x mm 85 x 0.15 140 x 0.15 228 x 0.15 189 x 0.20 324 x 0.20 513 x 0.20 783 x 0.20 1107 x 0.20 702 x 0.30 999 x 0.30 1332 x 0.30 1702 x 0.30 2109 x 0.30 2590 x 0.30 -- -- -- Nom. Dia. 1.53 [.06] 2.40 [.09] 2.90 [.11] 3.60 [.14] 4.55 [.18] 5.50 [.22] 7.30 [.29] 8.55 [.34] 10.15 [.40] 12.00 [.47] 14.05 [.55] 16.30 [.64] 17.40 [.68] 20.00 [.79] -- -- -- Max. Resistance at 20C in /km (/1000 ft) Class 5/6 13.20 [4.02] 7.82 [2.38] 4.85 [1.48] 3.23 [0.98] 1.88 [0.57] 1.19 [0.36] 0.78 [0.24] 0.55 [0.17] 0.39 [0.12] 0.27 [0.08] 0.20 [0.06] 0.15 [0.05] 0.13 [0.04] 0.10 [0.030] 0.08 [0.024] 0.06 [0.018] 0.05 [0.015] Note: Types TR and FTR use IEC Class 6 conductors. Types ZHI and AFR use IEC Class 5 conductors. 9 Materials Performance Summary TR ZHI FTR AFR ZHPCG Tensile Strength N/mm2 typical 20 9 18 18 8 Abrasion Resistance Cut Through Excellent Good Good Excellent Good Good Very Good Good Very Good Good Temperature Rating C 10000 h 125 105 125 105 115 Preferred Color Wire and Cable Material Black Black Black Grey Black Note: Where a higher operating temperature is required, Raychem SPEC 55 provides outstanding performance up to 200C continuous operating temperature. For these or other special applications, please contact Tyco Electronics. 9-91 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Miscellaneous Power Cables (Continued) Table 1. Nominal Diameters and Maximum Weights Conductor Size (mm2) Part No. 1.5 2.5 4.0 6.0 10.0 16.0 25.0 35.0 50.0 70.0 95.0 120.0 -- TR 16-2.5 -4 -6 -10 -16 -25 -35 -50 -70 -95 -- TR 16 Nom. OD in mm (in) -- 3.9 [.15] 4.5 [.17] 5.2 [.20] 6.2 [.24] 7.4 [.29] 9.3 [.37] 10.6 [.42] 12.5 [.49] 14.6 [.57] 17.0 [.67] -- Max. weight in kg/km (lb/1000 ft) -- 34.0 [22.8] 51.0 [34.2] 73.0 [48.9] 117.0 [78.4] 182.0 [121.9] 274.0 [183.6] 383.0 [256.6] 542.0 [363.1] 765.0 [512.6] 1020.0 [683.4] -- Part No. -- -- FTR 16-4 -6 -10 -16 -25 -35 -50 -70 -95 -120 FTR 16 Nom. OD in mm (in) -- -- 5.6 [.22] 6.3 [.25] 7.5 [.29] 8.8 [.35] 10.7 [.42] 12.1 [.48] 14.0 [.55] 16.2 [.64] 18.8 [.74] 21.3 [.84] Max. weight in kg/km (lb/1000 ft) -- -- 69.0 [46.2] 94.0 [63.0] 147.0 [98.5] 220.0 [147.4] 323.0 [216.4] 444.0 [297.5] 619.0 [414.7] 861.0 [576.9] 1148.0 [769.2] 1484.0 [994.3] Table 2. Nominal Diameters and Maximum Weights Conductor Size (mm2) Part No. 1.5 2.5 4.0 6.0 10.0 16.0 25.0 35.0 50.0 70.0 95.0 120.0 150.0 185.0 240.0 300.0 400.0 ZHI 15 -1.5 -2.5 -4 -6 -10 -16 -25 -35 -50 -70 -95 -120 -150 -185 -240 -300 -400 ZHI 15 Nom. OD in mm (in) 4.09 [.16] 4.69 [.18] 5.49 [.22] 6.16 [.24] 8.20 [.32] 9.30 [.37] 10.90 [.43] 12.30 [.48] 14.70 [.58] 16.80 [.66] 19.10 [.75] 21.00 [.83] 23.00 [.91] 25.60 [1.01] 28.60 [1.13] 32.00 [1.26] 36.40 [1.43] Max. Weight in kg/km (lb/1000 ft) 33.5 [22.4] 48.8 [32.7] 72.1 [48.3] 99.8 [66.9] 159.0 [106.5] 223.0 [149.4] 331.0 [221.8] 448.0 [300.2] 631.0 [422.8] 852.0 [570.8] 1108.0 [742.4] 1438.0 [963.5] 1748.0 [1171.2] 2088.0 [1399.0] 2705.0 [1812.4] 3363.0 [2253.2] 4396.0 [2945.3] Part No. AFR 35-1.5 -2.5 -4 -6 -10 -16 -25 -35 -50 -70 -95 -120 -150 -185 -240 -300 -400 AFR 35 Nom. OD in mm (in) 2.8 [.11] 3.9 [.15] 4.8 [.19] 6.2 [.24] 7.0 [.28] 8.1 [.32] 10.3 [.41] 11.7 [.46] 13.7 [.54] 16.0 [.63] 18.5 [.73] 20.4 [.80] 22.6 [.89] 24.8 [.98] 27.8 [1.1] 32.0 [1.2] 36.0 [1.4] Max. Weight in kg/km (lb/1000 ft) 31.0 [20.8] 42.0 [28.1] 61.0 [40.9] 92.0 [61.6] 143.0 [95.8] 211.0 [141.1] 333.0 [223.1] 452.0 [302.8] 634.0 [424.8] 885.0 [593.0] 1165.0 [780.6] 1480.0 [991.6] 1825.0 [1222.8] 2215.0 [1484.1] 2875.0 [1926.3] 3645.0 [2442.2] 4730.0 [3169.1] Table 3. Nominal Diameters and Maximum Weights Conductor Size (mm2) Part No. 1 1.5 2.5 4.0 6.0 10.0 16.0 25.0 35.0 50.0 70.0 95.0 120.0 150.0 185.0 240.0 300.0 400.0 ZHPCG-15-1 -1.5 -2.5 -4 -6 -10 -16 -25 -35 -50 -70 -95 -120 -150 -185 -240 -300 -400 ZHPCG-15 ZHPCG-35 Nom. OD Max. Weight in Nom. OD Part No. in mm [in] kg/km [lb/1000 ft] in mm [in] 3.77 [.14] 28.0 [18.1] ZHPCG-35 -1 -- 3.79 [.15] 36.0 [24.2] -1.5 4.55 [.18] 4.27 [.17] 45.0 [30.2] -2.5 5.07 [.20] 4.64 [.18] 60.0 [40.3] -4 5.66 [.22] 5.31 [.21] 85.0 [57.1] -6 6.15 [.24] 6.53 [.26] 135.0 [90.7] -10 7.33 [.29] 8.03 [.32] 195.0 [131.0] -16 8.83 [.35] 10.50 [.41] -25 300.0 [201.6] 9.70 [.38] 11.30 [.44] 443.0 [297.7] -35 11.70 [.46] 13.50 [.53] 623.0 [418.6] -50 13.48 [.53] 15.60 [.61] 847.0 [569.1] -70 15.33 [.60] 18.10 [.71] 1119.0 [751.9] -95 17.93 [.71] 19.80 [.78] 1445.0 [970.9] -120 19.80 [.78] 22.00 [.87] 1775.0 [1192.7] -150 21.44 [.84] 24.40 [.96] 2115.0 [1421.2] -184 23.28 [.92] 27.80 [1.09] 2762.0 [1856.0] -240 27.33 [1.08] 32.50 [1.28] -300 3452.0 [2320.0] 31.20 [1.23] Notes: Users should independently evaluate the suitability of the product for their application. 35.20 [1.39] 4474.0 [3006.4] -400 37.00 [1.46] Before ordering, contact Tyco Electronics check for most current data. Max. Weight in kg/km [lb/1000 ft] -- 60.0 [40.3] 82.0 [55.1] 100.0 [67.2] 130.0 [87.4] 185.0 [124.3] 250.0 [167.9] 350.0 [235.2] 430.0 [288.9] 590.0 [396.5] 790.0 [530.8] 1020.0 [685.4] 1320.0 [887.0] 1550.0 [1041.5] 1900.0 [1276.7] 2500.0 [1679.9] 3562.0 [2393.5] 5645.0 [3793.3] 9-92 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Miscellaneous Power Cables (Continued) Part Numbering System XXX XX - XX - X 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 9 Wire and Cable 9-93 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Miscellaneous Conductor Sizes, Strandings, and Resistance Values Applications The conductors used with Raychem wires are concentric in construction and are specifically designed for use with thin-wall insulations. The table on the next page gives nominal values for tin-plated copper, silverplated copper, and silverplated high-strength copper alloy (SPHSCA) constructions. Typically, tin-plated copper is suitable for use in applications up to 150C [302F] and silver-plated copper in applications up to 200C [392F] (SPEC 55 wire only). Available in: Americas Europe Asia Pacific The current-carrying capacities assume a maximum 60C [140F] increase in temperature of a single wire in free air at 40C [104F]. For details of performance in conditions other than 40C [104F], contact Tyco Electronics. n n n 9-94 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Miscellaneous Conductor Sizes, Strandings, and Resistance Values (Continued) Nominal Values of American Wire Gauge (AWG) and Metric Conductors Size AWG mm2 Stranding No./mm 30 28 26 24 22 20 18 16 14 12 10 8 0.06 0.09 0.15 0.25 0.40 0.60 1.00 1.20 2.00 3.00 4.50 9.00 7/0.10 7/0.13 19/0.10 19/0.13 19/0.15 19/0.20 19/0.25 19/0.30 37/0.25 37/0.32 37/0.40 133/0.29 6 13.5 133/0.36 4 21.0 133/0.45 2 33.0 665/0.25 0 51.0 1045/0.25 Note: Abbreviations: Cond. = SPHSCA = Tin-copper = Silver-copper = N/A = Stranding No./AWG 7/38 7/36 19/38 19/36 19/34 19/32 19/30 19/29 37/30 37/28 37/26 133/29 133/27 [5.30] 133/25 [6.62] 665/30 [8.54] 1045/30 [10.87] Max Resistance in /km (/1000 ft) Outside Diameter (min.-max.) SPHSCA CurrentCarrying Capacity (amps) Tin-copper Silver-copper 0.28-0.31 0.36-0.39 0.46-0.49 0.55-0.62 0.70-0.76 0.92-0.97 1.18-1.26 1.34-1.48 1.65-1.72 2.12-2.18 2.69-2.74 4.01-4.20 [0.011-0.012] [0.014-0.015] [0.018-0.019] [0.022-0.024] [0.028-0.030] [0.036-0.038] [0.046-0.050] [0.053-0.058] [0.065-0.068] [0.083-0.086] [0.106-0.108] [0.158-0.165] 347 [106] 220 [67] 133 [40] 84 [26] 51 [16] 31 [9] 20 [6] 15 [4] 10 [3] 7 [2] 4 [1] 2 [0.6] 324 [99] 205 [62] 123 [37] 78 [24] 49 [15] 30 [9] 20 [6] 15 [4] 10 [3] 7 [2] 4 [1] 2 [0.6] 377 [115] 239 [73] 144 [44] 91 [28] 56 [17] 34 [10] -- -- -- -- -- -- 3.0 4.0 5.5 7.5 10.0 13.0 17.5 20.0 28.0 3705.0 53.0 78.0 5.03-5.48 [0.198-0.216] 1.4 [0.4] 1.4 [0.4] -- 105.0 6.35-6.96 [0.250-0.274] 0.9 [0.3] 0.9 [0.3] -- 142.0 8.13-8.64 [0.320-0.340] 0.6 [0.2] 0.6 [0.2] -- 196.0 10.00-10.80 [0.394-0.425] 0.4 [0.1] 0.4 [0.1] -- 266.0 Conductor Silver-plated high-strength copper Tin-plated copper Silver-plated copper Not available For product details, please refer to relevant specification control drawing. Current Derating Factors for Wire Bundles in Free Air No. of wires Derating factor 2 .825 3 .73 4 .66 7 .54 9 .49 12 .43 15 .39 18 .36 21 .33 24 .31 27 .29 30 .28 37 .26 9 Wire and Cable 9-95 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Miscellaneous Fiber Optic Cables High Performance Interconnection Fiber Optic Link Product Facts n Low smoke Low corrosive gas emission n Limited fire hazard n Halogen free n Small size and lightweight n Custom design n Range of jacket materials n Inherent security of transmitted signals n Low loss, high performance cables n Water-blocking options n Meets the requirements of Def Stan 60-1 part 2 n Typical applications n Military communications Military control systems n Naval applications n Underwater and ROV's n Hazardous Environments n Standard Fiber Optic Cable Constructions The use of increasingly sensitive and more sophisticated equipment in marine and military applications means a corresponding requirement for high performance interconnection links. Fiber optic links offer high performance and have many advantages over copper systems such as: n n Available in: Americas Europe Asia Pacific Interference immunity (EMI & RFI). High bandwidth (for improved message capacity). n Small size, lightweight. n Low loss, durability. n Security and safety. However, to ensure the reliability of a fiber system the cable design, materials and interconnection accessories employed are all extremely important. Tyco Electronics provides a range of single and multicore Fiber Optic Cables offering innovative solutions to interconnect problems. Tyco Electronics leadership in the field of advanced material technology, coupled with more than 15 years experience of supplying ruggedized cables for marine and military applications, ensures superior performance levels in the harshest of environments. n n n 9-96 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Miscellaneous Fiber Optic Cables (Continued) Simplex Fiber Optic Cable 1 11 1 2 22 2 3 3 31 3 2 Component 1. Secondary Buffered Fiber 2. Strength Member 3. Zerohal Sheath Fiber Size (62.5/125) -- -- Qty/Diameter 1 1.5 mm 2.7 0.2 mm Component 1. Secondary Buffered Fiber 2. Strength Member 3. Zerohal Sheath 4. Strength Member 5. Zerohal Sheath Fiber size (62.5/125) -- -- -- -- Qty/Diameter 1 1.5 mm 2.7 mm 3.3 mm 5.3 0.2 mm Component 1. Strength Member 2. Simplex Cable 3. Strength Member 4. Zerohal Sheath Fiber size (62.5/125) Qty/Diameter 2 2 6.0 mm 8.2 0.3 mm Component 1. Strength Member 2. Simplex Cable 3. Strength Member 4. Zerohal Sheath Fiber size -- (62.5/125) -- -- Qty/Diameter 1 4 / 6.7 mm 7.3 mm 9.5 0.5 mm Component 1. Strength Member 2. Simplex Cable 3. Strength Member 4. Zerohal Sheath Fiber size -- (62.5/125) -- -- Qty/Diameter 1 8 / 9.8 mm 10.4 mm 12.5 0.5 mm 3 Ruggedized Simplex Fiber Optic Cable 1 11 1 2 22 2 3 3 31 3 4 4 42 4 5 5 53 5 4 2 Channel Ruggedized Fiber Optic Cable 5 1 11 1 2 22 2 3 3 31 3 4 4 42 4 3 4 4 Channel Ruggedized Fiber Optic Cable 1 11 1 2 22 2 3 3 31 3 4 4 42 4 3 4 8 Channel Ruggedized Fiber Optic Cable 1 11 1 2 22 2 3 3 31 3 4 4 42 4 3 9 4 Wire and Cable 9-97 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Miscellaneous Fiber Optic Cables (Continued) High Performance Interconnection Fiber Optic Link Fiber Optic Equipment Cable The diagram on the right shows a typical equipment cable, which can also be used as a sub-unit or simplex component for the larger multi-core cables, as shown in the diagrams on the previous page. The fiber used is a high performance tight buffer type comprising an all silica fiber, with multiple coatings designed to provide mechanical and environmental protection, microbend resistance, and ease of handling in the field. Most common fiber types are readily available (see table below) and more specialized fibers are available on request. The equipment cable has a layer of served aramid yarn providing high flexibility and tensile strength, while the outer sheath provides environmental and mechanical protection, along with low smoke emission and chemical resistance. Core and cladding Primary fiber unit Primary buffer Secondary (tight) buffer coating Aramid yarn Outer Zerohal sheath Simplex Fiber Optic Equipment 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 standard range of tight buffered multi and single mode fiber optic cables, Tyco Electronics also offers the option of custom design for specific applications. These cables capitalize on the small size of the fiber thereby enabling efficient, ergonomic and reliable interconnection. Typical 2-Channel Cable Fiber Types and Common Features Type -- 8/125 50/125 62.5/125 100/140 Attenuation dB/km@850/1300/1550nm --/0.4/0.25 3.5/1.2/-- 3.5/1.2/-- 4.5/2.0/-- Bandwidth MHz-km@850/1300nm n/a 400/600 160/500 200/200 Dispersion Slope ps/(nm2-km) 0.093 n/a n/a n/a Numerical Aperture -- 0.1 0.20 0.275 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. 9-98 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Miscellaneous Fiber Optic Cables (Continued) Table of Requirements and Results from Def Stan 60 - 1 Part 2 Definition Cable tensile strength Cable bend Cold bend Cyclic bend Cable impact Cable crush Cable snatch Dynamic cut through Tear resistance Shrinkage Scrape abrasion Fluids Accelerated ageing Arrhenius plot Stability Pressure Ozone UV light resistance Smoke Index Toxicity index Halogen index Oxygen index Temperature index Flammability Requirements <0.5% cable elongation no increase in attenuation at full load and after test compared to pre-test value. No cracking or deformation of cable sheath. <0.5dB change after test. No cracking or deformation of cable sheath. <0.5dB change after test. No cracking or deformation of cable sheath. <0.5dB change after test. No cracking or deformation of cable sheath. <0.5dB change after test. 100 impacts. No cracking or deformation of cable sheath. <0.5dB change after test <20% reduction from original diameter. No cracking or deformation of cable sheath. <0.5dB change after test <20% reduction from original diameter. 25N 5 N/mm <3mm total 500 cycles minimum 60 Eb ret 25 TS ret Volume swell 15 min % 60 min % max % 15 60 10 60 50 50 10 80 10 80 <20% change in TS/Eb/tear between 14 and 28 days. Eb 150% 40,000 hours at 85C 175% max. elongation, 25% max. permanent elongation. Indentation not to exceed 50%. No cracks with normal vision. 80% Eb change, 20% TS change. 20 maximum 5 maximum No detectable halogens. 29 minimum 250C minimum Not to reach within 50 mm of the lower clamp. Part 2 60 60 60 60 50 80 80 1000N applied at 100N/minute Pass 20N load, 10 cycles of wind and unwind. 6 wraps. Pass 20N load, 10 cycles of wind and unwind. 6 wraps, -30C. Pass 40N, 1000 cycles. Pass 12.5 mm radius, 1kg hammer, 100 mm height Pass 2000N/5 min Pass 1kg, 10 cycles Pass 85C, 60N/minute, 0.45mm diameter needle blade -- 16 hrs at -30C and 16 hrs at 85C 5N, 85C, 0.45 mm diameter needle blade Diesel F76 28 days @ 20C OX-30 28 days @ 50C OX-40 HS200X 28 days @ 50C OMD-113 28 days @ 50C OX-28 28 days @ 50C Deionized water 28 days @ 50C Deionized water + 3.5% NaCI 28 days @ 50C Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass 110C for 14 and 28 days. Pass End point measurement: 50% absolute elongation 105C, 0.2N/mm2 stress. 85C for 4 hrs. 80 - 100ppm for 120 hrs 8 hrs UV 55C, 4 hrs humidity 40C, (UV-B) 1000 hrs. NES 711 NES 713 Sodium fusion test (Lassaigne) BS 2782 Part 1 Method 141D Nes 715 BS 4066 Part 1 Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass 9 Wire and Cable 9-99 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire and Cable Engineering Notes 9-100 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment Table of Contents Raychem application equipment is designed and engineered specifically for installation of Raychem heat-shrinkable products. These tools provide the optimal heating temperatures, performance, and control features for maximum 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(R) 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 10 Application Equipment 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 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment AA-400 Super Heater Compressed-Air Heating Tool Product Facts n n n n n n Automatic power cut-off switch to protect heating element if air flow is interrupted Pressure regulator and gauge for adjusting air flow and temperature Indicator light that goes on when power is applied to heating element Very focused heat Wide variety of reflectors available Excellent tool for small items and confined areas Applications Used for installing heatshrinkable tubing in multiple applications. Excellent for installing SolderSleeve devices (wire-to-pin applications) and SolderTacts contacts. Specifications Utility Requirements 120-V model: 120 Vac, 4 A, 50-60 Hz 240-V model: 240 Vac, 2 A, 50-60 Hz 60 psig minimum, 5 cfm Electrical Air (oil free) Ordering Information Model AA-400 Super Heater with stand, needlepoint tip, Mini SolderSleeve reflector, and input air filter Voltage 120 Vac 240 Vac (CE version) Description AA-400-32-Mk3 (110V) AA-400-200-CE-SUPERHTR Part No. 582602-000 281917-000 Accessories and Replacement Parts* SolderSleeve reflector Needlepoint tip Boot and tubing tip Mini SolderSleeve reflector Low-flow tip Heating Element replacement kit, 120 V Heating Element replacement kit, 240 V (CE) Stand Input air filter Air hose replacement kit Gun and air hose replacement kit *Controller is not sold separately. Part No. 979646-000 979647-000 979691-000 979663-000 979672-000 013750-000 444179-000 979649-000 979673-000 156553-000 238231-000 Description AA-400-94-SLD-SLV-TIP-KIT AA-400-96 AA-400-101 AA-400-102 AA-400-103 AA-400-128 AA-400-228-EL-KT-240V-CE AA-400-09 AA-400-P-Y-92-Filter AA-400-136 AA-400-229-Gun-Hse-Kit NSN Stock No. 4940-00-609-4993 4940-00-148-9847 4940-00-148-9848 4940-01-043-7634 3439-01-173-8810 -- -- -- -- -- -- Available in: Americas Europe Asia Pacific n n n 10-2 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment Holding Fixture Tool AD-1319-9 Product Facts n n AD-1319-9 comes with two lateral wire clamps as standard Secures wire or cable, enabling easy installation of products Applications Simplifies and speeds installation of Raychem SolderSleeve terminators or splices and SolderTacts shielded contacts. Specifications and Dimensions Dimensions Weight 18 cm [7.07 in] W x 15 cm [5.91 in] L 300 g [.67 lb] Product Range Covered SolderSleeve splices Shield terminators SolderTacts contacts Ordering Information MiniSeal, CWT-9XXX, D-1744, D-110 D-100-XX D-602-XX Model Holding fixture 38999 size 8 SolderTacts adapter 38999 size 16 SolderTacts adapter Submin SolderTacts adapter 748 SolderTacts adapter 723 SolderTacts adapter 482 size 16 SolderTacts adapter Part No. 993850-000 395241-000 413186-000 993872-000 993877-000 993938-000 993917-000 Description AD-1319-9 AT-1319-22 AT-1319-78 AT-1319-12 AT-1319-14 AT-1319-19 AT-1319-17 Note: Additional tooling for SolderTacts can be found under SolderTacts contacts, see section 8. Americas Europe Asia Pacific n n n Application Equipment Available in: 10 10-3 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment Hand-Operated Crimp Tools AD-1377, AD-1522 AD-1377, AD-1522 AD-1377 Crimp Tool AD-1522 Crimp Tool The Raychem AD-1377 crimp tool fits all MiniSeal crimp barrels. It also meets MIL specification M22520/37-01. A calibration verification gauge, AD-1386, is also available for the AD-1377. The gauge meets MIL specification M22520/39-01 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. Ordering Information Model AD-1377 MiniSeal crimp tool AD-1386 Calibration gauge AD-1522 DuraSeal crimp tool Available in: Part No. 992008-000 992013-000 047011-000 Description AD-1377-CRIMP-TOOL AD-1386-CALIBRATION-GAUGE AD-1522-1-CRIMPING TOOL Americas Europe Asia Pacific n n n 10-4 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment AD-3050-SEAL-TEST-EQUIP Seal Test Equipment Splice Sealing and Connector Sealing Evaluation - Various Products Product Facts n n n Simple fixture design allows fast sealing test result assisting determination of installation conditions for splice sealing products Connector fixture adapter allows connector sealing verification Strong portable container allows use in various locations Applications The AD-3050-SEAL-TESTEQ-NC is a manually operated 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. Available in: 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 individual wire strands poke through the installed heatshrinkable sleeve by using the AD-3050-SEAL-POKEIND. Poke through is eliminated by ensuring correct welding and subsequent handling conditions. 10 Americas Europe Asia Pacific n n n Application Equipment 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 determined visually by looking for bubbles in the area of the sealing product. 10-5 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment AD-3050-SEAL-TEST-EQUIP (Continued) Seal Test Equipment Splice Sealing and Connector Sealing Evaluation - Various Products (Continued) Technical Specification Pneumatic Supply Machine Cycle Times for seal testing: Total System Noise: Dimensions: Weight: Ordering Information 6 bar maximum, filtered supply. 2 bar test pressure maximum. (Test pressure typically 0.5 bar) Typically 1 minute Negligible noise from air test 550 x 350 x 215 [22 x 14 x 8 in] (Excludes packing case) 4 Kg (8.80 lb) (Excludes packing case) 9.6 Kg (21.20 lb) (Includes packing case) Seal Test Equipment Description AD-3050-SEAL-TEST-EQ-NC Part No. C82893-000 Tool Case Splice Poke-through Indicator Description AD-3050-SEAL-TEST-CASE-ONLY AD-3050-SEAL-POKE-IND Part No. F66989-000 E63259-000 Description AD-3050-SEAL-8-KIT AD-3050-SEAL-CLAMP-ASSY EPDM foam, 6 mm x 9 mm, with acrylic adhesive backing. Part No. 299155-000 168927-000 -- Accessories Recommended Spares Set of 8 Seals** Clamp assembly including seals Sealing tape ** Full set of seals 10-6 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment AD-5000 and RH-396X Tinel-Lock Installation Tool Tinel-Lock Screened Termination Products Applications AD-5000 available in: RH-396X available in: 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. 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. Americas Europe Asia Pacific n n n Americas Europe Asia Pacific n 10 Application Equipment 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 accommodates Tinel Rings from size TR04 to TR24 inclusive. n 10-7 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment AD-5000 and RH-396X Tinel-Lock Installation Tool Tinel-Lock Screened Termination Products (Continued) Technical Specification Electrical Supply Machine Cycle Times for Tinel-Lock rings used on typical range of harnesses: Mains Fuse Total System Noise Dimensions Weight 220V-240V-50Hz 5 to 15 Seconds depending on ring size and braid type on the termination. 240 V 2 Amp (Type T anti - surge) Silent Operation 340 x 320 x 170 mm [13.4 x 13 x 6.7 in] 4.2 Kg STANDARD ELECTRODES FITTED : Conduit Electrodes Fitted Square Profile Electrodes Fitted Tinel-Lock Rings Sizes TRO4 to TR24 Conduit systems / TR rings on double braid TC02-TC03 RINGS Product Range Ordering Information 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 Recommended Spares -- AD-5000 Hand Tool Assembly Standard Electrodes (TR04 to TR24 RINGS) Conduit Electrodes (Conduit systems or TR rings on double braid) Square Profile Electrodes (TC02-TC03 RINGS) Recommended Spares -- RH-396X Hand Tool Assembly Foot Switch 120 VAC Transformer 220 VAC Transformer AD-5000-TINEL-HAND-TOOL AD-5000-TINEL-STD-ELECT 795257-000 180245-000 AD-5000-TINEL-COND-ELECT 747235-000 AD-5000-TINEL-SQ-EXT-ELEC 065583-000 915088-01-TINI-RING-HEATR IR-500-P-FOOT-SWITCH TRNSFMR-120V-105-A12-250W TRNSFMR-220V-105-A12-250W 170224-000 993702-000 570939-000 574557-000 N.B. Electrodes are two per P.C.N. 10-8 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment AD-5010-Tinel Bench-230V Tinel-Lock Installation Tool Tinel-Lock Screened Termination Products Applications The AD-5010-TINELBENCH-230V is a manually operated resistance heating tool designed specifically to install Raychem Tinel-Lock ring screened terminations in large batches, in continuous 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. Available in: ammeter on the front panel shows installation current used. A needle file is provided for periodic cleaning of the electrodes. 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 installation. 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 10 Americas Europe Asia Pacific n n n Application Equipment 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). 10-9 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment AD-5010-Tinel Bench-230V Tinel-Lock Installation Tool Tinel-Lock Screened Termination Products (Continued) Technical Specification Electrical Supply Machine Cycle Times for Tinel-Lock rings used on typical range of harnesses: Mains Fuses (2) Total System Noise Dimensions Weight Product Range Tinel-Lock rings Sizes TRO4 to TR24, conduit systems and TR rings on double braid TC02-TC03 RINGS STANDARD ELECTRODES FITTED : Square Profile Electrodes Fitted Accessories 230 V 50 Hz 3 to 12 Seconds depending on ring size and braid type on the termination. 240 V 2 Amp (Type T anti - surge) Silent Operation 245 x 305 x 290 mm [10 x 12 x 11 in] 24 Kg Part No. 072845-000 Description AD-5010-BENCH-FOOTSW-KIT Footswitch Kit Recommended Spares Standard Electrodes (TR04-TR24 RINGS) Square Profile Electrodes (TC02-TC03 RINGS) Mechanism Assembly (Including electrode set) Description AD-5010-BENCH-STD-ELECT AD-5010-BENCH-SQ-ELECT AD-5010-BENCH-MECH Part No. 222899-000 727799-000 924079-000 N.B Electrodes are two per P.C.N. Ordering Information Description AD-5000-TINEL-ASSY Tinel installation tool Part No. 411993-000 10-10 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment CV-1981 and CV-1983 Heavy-Duty Hot-Air Heating Tools Product Facts n n n n n n n Robust, double-insulated, heavy-duty unit Highest-wattage unit (1600-2260 watts) Integral stand that allows use as bench tool Safe, quiet operation Precisely variable temperature Variety of reflectors available Easy fixturing for dual opposing heating 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. Technical Specification Electrical Supply CV-1981-MK2 CV-1983 CV-1981 PID 120 V and 230 V 120 V and 230 V 120 V and 230 V Power Consumption CV-1981-MK2 CV-1983 CV-1981 PID 1600 W 2260 W/3060 W 1600 W Total System Noise CV-1981-MK2 CV-1983 CV-1981 PID 65dB 65dB >70dB Length CV-1981-MK2 CV-1983 CV-1981 PID 340 [13] 320 [13] 350 [13] Weight CV-1981-MK2 CV-1983 CV-1981 PID 1.3 Kg [2.90 lb] 1.5 Kg [3.30 lb] 1.4 Kg [3.10 lb] Air Flow CV-1981-MK2 CV-1983 CV-1981 PID Max 230 l/min Max 500 l/min 230 l/min 10 Available in: Americas Europe Asia Pacific n n n Application Equipment Product Range All dual wall, single wall and molded part products. Various devices products. For other Raychem products , contact Tyco Electronics. 10-11 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment CV-1981 and CV-1983 Heavy-Duty Hot-Air Heating Tools (Continued) Ordering Information Equipment CV-1981-MK2 CV-1983 CV-1981-PID CV-1983 Barrel Adapter Accessories Description CV-1981-120V1600W-CANMK2 CV-1981-120V1600W-UKMK2 CV-1981-230V1600WMK2 CV-1981-230V1600W-SEVMK2 CV-1981-230V1600-UKMK2 CV-1983-110V-2260W-UK CV-1983-220V-2260W CV-1983-220V-2260W-UK CV-1983-220V-3060W CV-1983-220V-3060W-UK CV-1981-120V-1600W-CANPIDF CV-1981-120V-1600W-UKPID CV-1981-230V-1600WPID CV-1981-230V-1600W-SEVPIDF CV-1981-230V-1600W-UKPIDF AD-1962 Part No. A42716-000 E95798-000 813914-000 F25836-000 340970-000 441753-000 773898-000 985426-000 538361-000 231866-000 839218-000 928826-000 958770-000 434366-000 385828-000 989172-000 Voltage 120V 120V 230V 230V 230V 120V 230V 230V 230V 230V 120V 120V 230V 230V 230V -- Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz -- PR-12 reflector PR-13 reflector PR-13C reflector PR-21 reflector PR-24 reflector PR-24A reflector PR-25 reflector PR-25D reflector PR-26 reflector PR-33 reflector AD-1962 adapter for larger-barrel CV-1983 PR-34 reflector Application Tubing: 6.3-25.4 mm [0.25-1 in] Tubing: Up to 6 mm [0.25 in] Large SolderSleeve products Tubing: Up to 25.4 mm [1 in] Tubing/molded parts: 25.4-34.93 mm [1-1.38 in] Tubing/molded parts: 34.93-60.33 mm [1.38-2.38 in] SolderSleeve products: Up to 7 mm [0.28 in] SolderSleeve products: 6.3-12.7 mm [0.25-0.50 in] Small SolderSleeve products SolderSleeve products: 19.05-25.4 mm [0.75-1 in] -- SolderSleeve products: 12.0-20.0 mm [0.47-0.79 in] Part No. 991973-000 991963-000 991974-000 991984-000 991964-000 991989-000 991965-000 989523-000 991967-000 997768-000 989172-000 989111-000 PR-51 Special narrow reflector for molded part transitions (21.5 x 3.5 mm nozzle) [.85 x .14 in] 113069-000 *Note: A42716 supersedes and replaces 538005 340970 supersedes and replaces 923002 10-12 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment HL1802E and HL2005E Steinel(R) General Purpose Hot-Air Heating Tool Products Facts n Light weight Easy, quiet operation n Precise variable temperature n 1500 watts n Reflectors and stand (optional) n Wide variety of applications n CE approved (230 V only) n Applications Used for installing heatshrinkable tubings and molded parts, SolderSleeve devices, and SolderTacts contacts. Specifications Steinel(R) (120 V) power requirement Steinel(R) (230 V) power requirement Rated heater element power Weight Cord length Typical temperature output* 120 V, 60 Hz, 12.5 A 230 V, 50 Hz, 8.7 A 110V - 1500 W/230V-2000W 850 g [1.9 lb] Approx. 3 m [approx. 8 ft] 49C to 593C [120F to 1100F] *The Steinel(R) 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. 10 Americas Europe Asia Pacific n n n Application Equipment Available in: 10-13 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment HL1802E and HL2005E Steinel(R) General Purpose Hot-Air Heating Tool (Continued) Ordering Information Model /Description HL1802E-Kit-120 V** HL2005E-230V-Euro HL2005E-230V-UK HL2005E-Kit-230-Euro** Part No. 289759-000 910424-000 629014-000 849224-000 Accessories and Replacement Parts SolderSleeve reflector HL1802E-ADAPT for use with PR reflectors*** Tubing reflector Bench stand 9-mm-diameter reduction nozzle Description HL1802E-074616 HL1802E-ADAPT-PR HL1802E-070519 HL1802E-BENCH-STD HL1802E-070618 Part No. 832011-000 444817-000 022611-000 717083-000 930321-000 **Complete with SolderSleeve reflector. ***Selection of PR reflectors can be found in CV-1981/CV-1983 section. Accessories 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(R) heating tool. Optional tubing reflector (P/N 022611-000) for larger tubing and molded parts. Must be ordered separately. 10-14 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment IR-1891 Shuttle Machine -- Twin Workstation Heater for Multiple Installation of Short Length Tubing Products Product Facts n Automatic 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) n Automatic heating head retraction at end of cycle prevents damage to components n Multiple product fixture assemblies give increased process rates n Cooling fan above each fixture assembly maintains holding fixture at an acceptable temperature Applications The IR-1891 is suitable for the installation of a range of Raychem heat-shrinkable tubing products onto a variety of small components, e.g. ring terminals, FASTON terminals and small connectors etc. The machine is provided with two work stations and a moveable heating head. Available in: The IR-1891-220V-ShuttleRetn is provided with closed loop temperature control and in addition the heat head is `locked' into position by use of an electromagnet during the heating 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 Americas Europe taken by the operator to load unload the workpieces. The installation temperature/power can be varied according to product type/size and required cycle times. The heating elements, which are continuously energized, are of the infrared medium wave length type and consist of a coiled resistance wire contained in quartz glass tubes. The closed loop temperature control uses similar elements but having integral thermocouple sensors. 10 Application Equipment Each workstation is provided with supports for tooling fixtures (which must be specified and ordered separately). These support the workpieces and locate the tubing products. The operator loads the workpieces into the fixtures at one of the workstations, ensures that the tubing product is correctly 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. Asia Pacific n 10-15 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment IR-1891 Shuttle Machine -- Twin Workstation Heater for Multiple Installation of Short Length Tubing Products (Continued) Technical Specification Electrical Supply Power Consumption Operating Temperature Process Rate Heating Times System Noise Dimensions - 508636-000 Dimensions - 613148-000 / 167309-000 / 289588-000 Base Plate Dimensions 289588-000 / 167309-000 Base Plate Dimensions 613148-000 Product Range 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] 230 V Single Phase 1600 W 650C max 1200 / hour maximum depending on application and operator 3 to 20 seconds depending on application < 70 dB L1100 x H650 x D500 mm [L43 x H25 x D20 in] L1100 x H900 x D500 mm [L43 x H35 x D20 in] L1040 x D450 mm [L41 x D18 in] L1040 x D397 mm [L41 x D16 in] Ordering Information Part No. 289588-000 613148-000 Description * IR-1891-220VShttle-Retn * IR-1891-220V-Retn-Syl *Note: The descriptions given here DO NOT include the supply of the necessary tooling fixtures.These are designed for each individual application. Accessories Description Grippers: IR-1891-SI-GRP-165-RD-1mm IR-1891-SI-GRP-165-CL-2mm IR-1891-SI-GRP-165-BK-3mm IR-1891-SI-GRP-165-WT-6mm Part No. Red Gripper with 1mm hole Clear Gripper with 2mm hole Black Gripper with 3mm hole White Gripper with 6mm hole 629602-000 112676-000 F83221-000 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: A wider range of tooling fixtures and grippers designed for previous applications are available. Please contact Tyco Electronics for details. 10-16 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment Infrared Heating Tool IR-550 Mark II Product Facts n n n Lightweight, portable unit with pedestal base for benchtop operation Foot switch, so both hands can be free to hold parts Commercially available tungsten-halogen lamp n Fan-cooled housing n Instant on/off heat n n Viewing window that allows parts to be inspected during installation Quiet, focused IR operation Applications Used for installing small and large SolderSleeve devices and SolderTacts contacts. Specifications Ordering Information Input power Normal lamp life Weight Duty cycle 105-120 V, 50-60 Hz, 4.5 A More than 1000 hours of intermittent use Approximately 2.5 Kg [5.5 lb] 80%, 90-second max. heating times Model IR-550 heating tool* (120 V) with RG-2 reflector, viewing window, and foot switch Description Part No. IR-550-50-MARKII-HT-TOOL 994350-000 Note: For 230V CE-approved version, contact Tyco Electronics Accessories and Replacement Parts Available in: Americas IR-550-216 994375-000 IR-550-19 994590-000 IR-550-41 IR-550-39 993695-000 993693-000 IR-550-24 993770-000 IR-1000-P-N-13 IR-550-237 IR-550-238 993020-000 118902-000 007510-000 IR-550-240-Refurb 529600-000 Europe n 10 Application Equipment IR-550 foot switch (included with tool assembly 994350) RG-6 reflector for large-diameter SolderSleeve terminations; aperture is 25.4 mm [1.0 in] wide RG-11 reflector; aperture is 12.7 mm [.5 in] wide RG-9 reflector; aperture is 9.525 mm [.375 in] wide RG-2 reflector, included with 994350; aperture is 19.05 mm [.75 in] wide Lamp (120 V) Optical filter Viewing window (frame not included) IR-550 upgrade kit: filter, viewing window, inner reflector, outer reflector Asia Pacific n 10-17 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment IR-1759 MiniRay Infrared Heating Tool Product Facts n n Small, lightweight, fan-cooled unit Small profile for installation where space is restricted n Handheld operation n Focused heat n Quiet, efficient IR operation n CE approved Applications Used for installing SolderSleeve devices and SolderTacts contacts. * Control box not shown Specifications and Dimensions Fan Weight Cable length Tungsten-halogen Nominal power 250 W, 24 Vac, 50-60 Hz 12 Vac (supplied through control unit) .73 kg [1.6 lb] 2 m [6.5 ft] Electronic Control Unit Main supply Weight Dimensions 110/230 Vac, 50/60 Hz, 11 A/5.5A universal 3.4 kg [7.6 lb] 16.3 x 12.2 x 12.2 cm [6.4 x 4.8 x 4.8 in] Lamp Ordering Information Description Complete kit consisting of: Handtool/Reflector/Control Box (Manual control, Dual voltage) Accessories and Replacement Parts Handtool, standard aperture Handtool, large aperture Control box with time control-230 V Control box with time control-110 V Control box with manual control-110/230V Battery powered control box Conversion kit (AE-897) for adapting standardaperture MiniRay heating tool to wide-aperture MiniRay tool (includes reflector) Inner reflector (standard aperture) Inner reflector (wide aperture) Lamp (250 W, 24 V) Filter (standard aperture) Filter (large aperture) Part No. IR1759-MK3-AT3130-EDCont 898738-000 IR-1759-MK3/A IR-3104-MK3/A ED-7-001-MK2-230V-50HZ ED-7-002-MK2-110V-60HZ ED-7-CONT-230/110V ED-7-Batterybox-230/110V 986899-000 035343-000 869233-000 903553-000 684886-000 448969-000 AT-313/AE-897 934630-000 AE-424 AE-153 NAE-143-3 AES-IR1759-100-FILTER-DUL AES-IR1759-300-FLTR-LRG 547918-000 988285-000 988208-000 431468-000 F52511-000 *IR tools are not recommended for use with black wire or cable insulations. Available in: Americas Europe Asia Pacific n n n 10-18 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment Model 16B Belt Heater Product Facts n n n n n Controlled heating for installation of Raychem heat-shrinkable tubing at rates required for mass production Controlled repeatable heating: time and temperature settings can be fixed to maintain repeatable installation parameters Part positioning that is clearly defined and easy to maintain Operation that requires only minimal skill Efficient 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 Applications Designed for processing a broad range of heat-shrinkable tubing products up to 19 [75] in diameter and 101 [4.0] long. Suitable for either single-wall or adhesive-lined tubing. Heatingelement temperature is adjustable up to 600C [1112F] and the belt speed is adjustable to 2.28 [7.5] per minute. Operator simply positions the heatshrink tubing over the assembly and feeds it into the process chamber. Heating and cooling take place automatically with the cables or wires securely fixed. Americas Europe n Application Equipment Available in: 10 Asia Pacific n 10-19 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment Model 16B Belt Heater (Continued) Specifications and Dimensions Electrical Heating elements Part No. 827429-000 120 Vac, 1 O, 50/60 Hz, 20 A 875 W (upper and lower) Mechanical Conveyor belt system Machine dimensions Shipping dimensions Machine weight without crate Shipping weight with crate Two sets of pinch belts right and left, four belts total 48 cm [19 in] W x 110 cm [43 in] L x 33 cm [13 in] H 61 cm [24 in] W x 111 cm [44 in] L x 56 cm [42 in] H 55 Kg [120 lb] 91 Kg [200 lb] Tubing Sizes Inside diameter before recovery Length Up to 19 mm [0.75 in] Up to 101mm [4.0 in] Optional Attachment Ring terminal kit Part No. 060053-000 Power requirements Part No. 047143-000 220 Vac, 1 O, 50/60 Hz, 15 A, 3-wire 875 W (upper and lower) Part No. 584313-000 230 Vac, 1 O, 50/60 Hz, 15 A, 4-wire 875 W (upper and lower) 10-20 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment Model 19 Conveyor Heater for Processing Raychem Heat-Shrinkable Tubing and Termination Devices Product Facts n n n n Closed-loop speed and temperature control CE approved for worldwide use Adaptable for different applications Continuous controlled process Available in: Americas Europe Asia Pacific n n n n Applications The Model 19 conveyor heater is the latest generation 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 cooling 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, allowing for worldwide use. Options for this processor include: n Powered or unpowered extension tables to support long or heavy harnesses. n n a lockout on the thumbwheel to prevent unauthorized changes. Floor stand with wheels. Minimal Skill Requirements Wider heating elements for tubing up to 178 [7.0] long. 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. Narrow 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 elements mounted under a quartz face. Consistent heating chamber temperatures are obtained with a closed-loop temperature controller. There is a lockout on the controller to prevent 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 Economical Production The throughput rate is determined by the rate at which an operator can load the processor. 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 applications require a narrow heat width. Self-Diagnostic Circuitry There are several "selfdiagnostic" 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. 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 Other Features Include: n n n 10 Emergency stop. Application Equipment The processor is designed to operate on the following line voltages: 210 to 240 Vac, 20 A, 1 O, 50/60 Hz. n Kit for processing ring terminals and end terminations. Automatic cool-down circuit to extend the life of components. Lockout on temperature and speed controllers to prevent unauthorized changes. 10-21 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment Model 19 Conveyor Heater for Processing Raychem Heat-Shrinkable Tubing and Termination Devices (Continued) Specifications and Dimensions Electrical Power requirements Heating elements 210-240 Vac, 20 A, 1 O, 50/60 Hz Std = 3160 W/Wide = 3320 W/Narrow = 1760 W Mechanical Conveyor belt system Belt speed Processor dimensions Shipping dimensions Shipping weight with crate Double-sided timing belts, pitch - 9.5 [0.375] Up to 152 cm/min [5.0/min] 53 cm [21 in] W, 135 cm [53 in] L, 45 cm [18 in] H 66 cm [26 in] W, 147 cm [58 in] L, 58 cm [23 in] H 86 Kg [190 lb] Tubing sizes Tubing diameter (max) Tubing length (max) Work-piece length (min) Version Model 19 Standard Model 19 Wide Model 19 Narrow 25 mm [1.0 in] 102 mm [4.0 in] 178 mm [7.0 in] wide heating element tool 50 mm [2.0 in] narrow heating element tool 240 mm [9.5 in] Part No. 714529-000 075131-000 D43037-000 10-22 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment Model 81CE Discrete Heater Product Facts n n n n n n Closed-loop temperature control for a precise and repeatable thermal process Oven dwell time precisely set by a 3-digit thumb wheel digital timer Heat output can be controlled to accommodate a wide variety of applications Operation requires only minimal skill Contains numerous safety features Meets the requirements of CE, OSHA and the NEC 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 adhesivelined tubing. Two jaws grip the assembly or substrate, carry it into an infrared heating chamber for a userselectable predetermined period of time, then return the completed assembly back to the start position for removal. Americas Europe Asia Pacific n n n Application Equipment Available in: 10 10-23 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment Model 81CE Discrete Heater (Continued) Specifications and Dimensions Part No. 071965-000 120 VAC, 1O, 50/60 Hz, 15 A Two 400 watt infrared stamped foil with infrared heating elements, one top and bottom. Eagle digital timer, 1 to 999 seconds Part No. 704393-000 220 VAC, 1O, 50/60 Hz, 15 A Two 400 watt infrared stamped foil with infrared heating elements, one top and bottom. Eagle digital timer, 1 to 999 seconds 30-40 psi clean shop air 30-40 psi clean shop air 432 mm [17 in] 216 mm [9 in] 165 mm [7 in] 7.7 Kg [17 lb.] 432 mm [17 in] 216 mm [9 in] 165 mm [7 in] 7.7 kg [17 lb.] 380 mm [15 in] 240 mm [10 in] 343 mm [14 in] 18 Kg [40 lb.] 380 mm [15 in] 240 mm [10 in] 343 mm [14 in] 18 kg [40 lb.] Shipping Dimensions Length Width Height Shipping weight 610 mm [24 in] 610 mm [24 in] 530 mm [21 in] 41 Kg [90 lb.] 610 mm [24 in] 610 mm [24 in] 530 mm [21 in] 41 kg [90 lb.] Tubing Sizes Inside diameter before heat Length Up to 25.4 mm [1 in] Up to 127 mm [5 in] Up to 25.4 mm [1 in] Up to 127 mm [5 in] Electrical Power requirements Heating elements Timing system Pneumatic Requirements for jaw traverse Dimensions Control box dimensions: Length Width Height Control box weight Heating chamber dimensions: Length Width Height Heating chamber weight 10-24 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment Model 105 Tunnel Oven Product Facts n n n n n n Closed-loop temperature control for a precise and repeatable thermal process Conveyor speed precisely set by a 3-digit potentiometer Operation requires only minimal skill Contains numerous safety features Custom length conveyors for longer entry and/or exit sections available Optional accessories to customize the tunnel oven 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. 10 Americas Europe Asia Pacific n n n Application Equipment Available in: 10-25 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment Model 105 Tunnel Oven (Continued) Specifications and Dimensions Electrical Power requirements Heating elements Operating temperature Drive System Conveyor Speed Conveyor Belt Heater Oven Gap Effective heating width Dimensions Control box dimensions Length Width Height Control box weight Heating conveyor dimensions Length Width Height Heating conveyor weight 990 mm [39 in] 685 mm [27 in] 417 mm [17 in] 68 Kg [150 lb] Shipping Dimensions Length Width Height Shipping weight 1346 mm [53 in] 1168 mm [46 in] 635 mm [25 in] 146 Kg [320 lb] Tubing sizes Inside diameter before heat Length Perpendicular to belt travel Parallel to belt travel Optional Accessories n n n n Part number 955018-000 208/240 VAC, 1O, 50/60 Hz, 15 A Two 1500 watt infrared stamped foil with black quartz face, one top and bottom Ambient to 650C [1202F] DC motor with SCR drive controller and 3 digit speed potentiometer 0.06 M/min. to 1.5 M/min. [0.20 to 5.0 ft/min] Wire mesh 70% open 2 Position; 53.6 mm [2.11 in] Lower Position, 98 mm [3.86 in] Upper Position 356 mm [14 in] 515 mm [20 in] 210 mm [8 in] 178 mm [7 in] 7.7 Kg [17 lb] Up to 76.2 mm [3 in] 356 mm [14 in] Unlimited Powered outboard conveyor for processing large assemblies that require only a portion of the assembly to be heated (1 side only). Powered entry and exit conveyors for processing long and rigid assemblies requiring entry and exit support of the product. Ability to add additional heater chambers to extended custom length wire mesh conveyors. Custom floor stands. 10-26 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment RBK-ILS-Processor Mkll Installation of Splice Sealing Products Adjacent to Ultrasonic Welder Product Facts n n n n n n n n n n Increased heating element life Installation times, temperatures and product size information (individual selection) Sequenced installations Operator key lock/password protection levels Automatic heater retraction on mains failure Automatic calibration (single cycle) RS232 interface allows time, temperature and product sizes for the next installation to be transferred from a remote machine (e.g. an ultrasonic welding tool) Machine hours and installation cycle counters Software upgradeable to support special applications Air cooling can be provided to an optional stub splice fixture in the RBK-ProcMK2-Proc-Aircool version n 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: n n Stand-alone -- operator sets time and temperature. Available in: 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 Americas Europe Asia Pacific n n n Application Equipment Sequenced -- preset times and temperatures can be sequenced automatically (and can also be randomly selected from sequence stored.) Automatic -- 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 protection for the welded joint. The operator positions the splice sealing product centrally over the splice joint and then locates the assembly into the gripper mechanism. 10-27 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment RBK-ILS-Processor Mkll (Continued) Installation of Splice Sealing Products Adjacent to Ultrasonic Welder (Continued) Technical Specification Product Range Electrical Supply Power Consumption Operating Temperature Machine Cycle Times for splice sealing products used on typical range of automotive splices Total System Noise Dimensions Weight 220V-240V-50Hz 1.7 Amps (Max) 550C [1022F] (Max) (500C [932F] recommended) 6 to 20 seconds depending on wire size and the number or wires used <80dB 390 x 365 x 225 mm [15 x 14 x 9 in.] 18 Kg [40 lb] RBK-ILS-125 Products RBK-ILS-85 Products For Other Raychem Products (eg. RBK-VWS, RBK-ESS....) Sizes 1 to 3A Sizes 6/1 to 12/3 Contact Tyco Electronics Ordering Information Equipment Accessories Description RBK-Proc-Mk2-Processor RBK-Proc-MK2-Proc-Aircool Stub splice fixture - RBK-ILS-Proc-Stub-Sp-Fix Air cooled stub splice fixture - RBK-ILS-Proc-Air-Cool-Kit 8 mm ring terminal fixture - RBK-ILS-Proc-Termfix-08mm Part No. 740331-000 A96930-000 981721-000 843800-000 049857-000 10-28 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment ThermoGun HG Hot-Air Heating Tool Product Facts n n Stand-mounted or handheld, rugged unit for heavy-duty use Built-in stand and turbo-fandriven blower n Adjustable side vents n Adjustable temperature n 1680 to 2160 watts n Large reflector size n High heat output for fast installation Applications Used for installing molded parts onto adapters or harnesses and installing a broad range of heatshrinkable products, including boots and tubing up to three inches in diameter.. Specifications Model HG-501A HG-502A HG-751A-C HG-752A Power Requirements 120 V, 60 Hz, 14 A 230 V, 50/60 Hz, 7 A 120 V, 60 Hz, 18 A 230 V, 50/60 Hz, 9 A Input Watts 1680 1680 2160 1740 Temperature Range 260C-399C [500F-750F] 260C-399C [500F-750F] 399C-538C [750F-1000F] 399C-538C [750F-1000F] CFM* 23 23 23 23 RPM** 1700 1700 1700 1700 *CFM = Cubic feet per minute. **RPM = Revolutions per minute. 10 Americas Europe n Application Equipment Available in: Asia Pacific n 10-29 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Application Equipment ThermoGun HG Hot-Air Heating Tool (Continued) Accessories A-160-HG reflector (P/N 991017) for short lengths of tubing up to 19.05 [75] in diameter. Must be ordered separately. Ordering Information A-170-HG reflector (P/N 991018) for short lengths of tubing 19.05-50.8 [.75-2] in diameter. Must be ordered separately. Model* HG-501A HG-502A HG-751A-C HG-752A TG-23 reflector (P/N 991026) for boots up to 44.45 [1.75] in diameter. Must be ordered separately. Housing Color Red Red Red Red Accessories A-160-HG standard reflector A-170-HG large tubing reflector TG-23 small boot reflector TG-24 large boot reflector Part No. 462047-000 389363-000 926935-000 026239-000 Tubing Application Diameters up to 19.05 mm [0.75 in] Diameters of 19.05-50.8 mm [0.75-2 in] Diameters up to 44.5 mm [1.75 in] -- Part No. 991017-000 991018-000 991026-000 991027-000 *Complete with bench stand. 10-30 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Table of Contents Equivalents and Conversions ......................................................................................11-2, 11-3 Temperature Conversion Formula ................................................................................11-4, 11-5 Glossary ..............................................................................................................11-6 to 11-18 11 Supporting Information Part Index ..........................................................................................................11-19 to 11-21 11-1 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Equivalents and Conversions Decimal Equivalents Fraction of Inch 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 Decimal of Inch .0156 .0313 .0394 .0469 .0625 .0781 .0787 .0938 .1094 .1181 .1250 .1406 .1563 .1575 .1719 .1875 .1969 .2031 .2188 .2344 .2362 .2500 .2656 .2756 .2813 .2969 .3125 .3150 .3281 .3438 .3543 .3594 .3750 .3906 .3937 .4063 .4219 .4331 .4375 .4531 .4688 .4724 .4844 .5000 Decimal Millimeters 0.3969 0.7938 1.0000 1.1906 1.5875 1.9844 2.0000 2.3813 2.7781 3.0000 3.1750 3.5719 3.9688 4.0000 4.3656 4.7625 5.0000 5.1594 5.5563 5.9531 6.0000 6.3500 6.7469 7.0000 7.1438 7.5406 7.9375 8.0000 8.3344 8.7313 9.0000 9.1281 9.5250 9.9219 10.0000 10.3188 10.7156 11.0000 11.1125 11.5094 11.9063 12.0000 12.3031 12.7000 Fraction of Inch 33/64 17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29.32 59/64 15/16 61/64 31/32 63/64 1 Decimal of Inch .5118 .5156 .5313 .5469 .5512 .5625 .5781 .5906 .5938 .6094 .6250 .6299 .6406 .6563 .6693 .6719 .6875 .7031 .7087 .7188 .7344 .7480 .7500 .7656 .7813 .7874 .7969 .8125 .8268 .8281 .8438 .8594 .8661 .8750 .8906 .9055 .9063 .9219 .9375 .9449 .9531 .9688 .9843 .9844 1.0000 Decimal Millimeters 13.0000 13.0969 13.4938 13.8906 14.0000 14.2875 14.6844 15.0000 15.0813 15.4781 15.8750 16.0000 16.2719 16.6688 17.0000 17.0656 17.4625 17.8594 18.0000 18.2563 18.6531 19.0000 19.0500 19.4469 19.8438 20.0000 20.2406 20.6375 21.0000 21.0344 21.4313 21.8281 22.0000 22.2250 22.6219 23.0000 23.0188 23.4156 23.8125 24.0000 24.2094 24.6063 25.0000 25.0031 25.4000 11-2 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Equivalents and Conversions (Continued) Conversion Factors Area Sq. inches x 6.452 = Sq. centimeters Millimeters x 0.03937 = Inches Feet x 0.3048 = Meters Meters x 3.281 = Feet Miles x 1.609 = Kilometers Sq. centimeters x 0.1550 = Sq. inches Sq. feet x 0.0929 = Sq. meters Sq. meters x 10.76 = Sq. feet Sq. miles x 2.59 = Sq. kilometers Kilometers x 0.6214 = Miles Sq. kilometers x 0.3861 = Sq. miles Volume Cu. inches x 16.39 = Cu. centimeters Cu. cm. x 0.06102 = Cu. inches Cu. feet x 0.02832 = Cu. meters Cu. meters x 35.31 = Cu. feet Mass Ounces x 28.35 = Grams Grams x 0.03527 = Ounces Pounds x 0.4536 = Kilograms Kilograms x 2.205 = Pounds Kilograms/km x 0.6214 = Pounds/kft Pounds/kft x 1.4881 = Kilograms/km 11 Supporting Information Length Inches x 25.40 = Millimeters Ohms/km x 0.3048 = Ohms/kft Circular mils x 0.7854 = Sq. mil Prefixes (SI), Values, and Symbols Prefix Tera Giga Mega Kilo Hecto Deca Value 1012 109 106 103 102 101 Symbol T G M k h da Prefix Deci Centi Milli Micro Nano Pico Value 10-1 10-2 10-3 10-6 10-9 10-12 Symbol d c m n p 11-3 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Temperature Conversion Formula C = (F -32) / 1.8 F = (C x 1.8) + 32 F -103 -101.2 -99.4 -97.6 -95.8 -94.0 -92.2 -90.4 -88.6 -86.8 -85.0 -83.2 -81.4 -79.6 -77.8 -76.0 -74.2 -72.4 -70.6 -68.8 -67.0 -65.2 -63.4 -61.6 -59.8 -58.0 -56.2 -54.4 -52.6 -50.8 -49.0 -47.2 -45.4 -43.6 -41.8 -40 -38 -36 -34 -32 C -75.00 -74.00 -73.00 -72.00 -71.00 -70.00 -69.00 -68.00 -67.00 -66.00 -65.00 -64.00 -63.00 -62.00 -61.00 -60.00 -59.00 -58.00 -57.00 -56.00 -55.00 -54.00 -53.00 -52.00 -51.00 -50.00 -49.00 -48.00 -47.00 -46.00 -45.00 -44.00 -43.00 -42.00 -41.00 -40.00 -38.89 -37.78 -36.67 -35.56 C F -34.44 -33.33 -32.22 -31.11 -30.00 -28.89 -27.78 -26.67 25.56 -24.44 -23.33 -22.22 -21.11 -20.00 -18.89 -17.78 -17.22 -16.67 -16.11 -15.56 -15.00 -14.44 -13.89 -13.33 -12.78 -12.22 -11.67 -11.11 -10.56 -10.00 -0.44 -8.89 -8.33 -7.78 -7.22 -6.11 -6.11 -5.56 -5.00 -4.44 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 53 54 55 56 57 58 59 60 61 62 63 64 F -30 -28 -26 -24 -22 -20 -18 -16 -14 -12 -10 -8 -6 -4 -2 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 22 21 22 23 24 C F -3.89 -3.33 -2.78 -2.22 -1.67 -1.11 -0.56 0.00 0.56 1.11 1.67 2.22 2.78 3.33 3.89 4.44 5.00 5.56 6.11 6.67 7.22 7.78 8.33 8.89 9.44 10.00 10.56 11.11 11.67 12.22 12.78 13.33 13.89 14.44 15.00 15.56 16.11 16.67 17.22 17.78 65 66 67 68 69 70 71 72 73 74 75 77 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 C 18.33 18.89 19.44 20.00 20.56 21.11 21.67 22.22 22.78 23.33 23.89 25.00 25.00 25.56 26.11 26.67 27.72 27.78 28.33 28.89 29.44 30.00 30.56 31.11 31.67 32.22 32.78 33.33 33.89 34.44 35.00 35.56 36.11 36.67 37.22 37.78 38.33 38.88 39.44 40.00 11-4 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Temperature Conversion Formula (Continued) C = (F -32) / 1.8 F = (C x 1.8) + 32 (Continued) F C 40.55 41.11 41.66 42.22 42.77 43.33 43.88 44.44 45.00 45.55 46.11 46.66 47.22 47.77 48.33 48.89 49.44 50.00 50.55 51.11 51.67 52.22 52.77 53.33 53.88 54.44 55.00 56.11 56.11 56.66 57.22 57.77 58.33 58.88 59.44 60.00 60.55 61.11 61.66 62.22 F 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 C F 62.78 63.33 63.88 64.44 65.00 65.56 66.11 66.66 67.22 67.77 68.33 68.88 69.44 70.00 70.55 71.11 71.66 72.22 72.77 73.33 73.89 74.44 75.00 75.55 76.11 76.67 77.22 77.77 78.33 78.88 79.44 80.00 80.55 81.11 88.66 82.22 82.77 83.33 83.88 84.44 185 186 187 189 189 190 191 192 193 194 195 196 197 198 199 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 C 85.00 85.55 86.11 87.22 87.22 87.78 88.33 88.88 89.44 90.00 90.55 91.11 91.66 92.22 92.77 93.33 96.11 98.89 101.67 104.44 107.22 110.00 112.78 115.56 118.33 121.11 123.89 126.67 129.44 132.22 135.00 137.78 140.55 143.33 146.11 148.89 151.67 154.44 157.22 160.00 F 325 330 335 340 345 350 355 360 365 370 375 380 385 390 395 400 405 410 415 425 425 430 435 440 445 450 455 460 465 470 475 480 485 490 495 C 162.78 165.56 168.33 171.11 173.89 176.67 179.44 182.22 185.00 187.78 190.55 193.33 196.11 198.89 201.67 204.44 207.22 210.00 212.78 215.56 218.33 221.11 223.89 226.67 229.44 232.22 235.00 237.78 240.55 243.33 246.11 248.89 251.67 254.44 257.22 11 Supporting Information 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 133 133 134 135 136 137 138 139 140 141 142 143 144 11-5 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Glossary Abrasion-resistance A measure of the ability of a wire or wire covering to resist damage by mechanical means. Accelerated Aging A test 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 within the context of the test. Adapter A device usually attached to the rear of connectors that provides for the attachment of harnessing components, 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 precoated 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 mechanical bond to the substrate. Aging Change in the properties of a material over time and under specific conditions. Generally refers to environmental stimulus such as heat and light. Altitude Immersion Seal A seal able to withstand substantial pressure change (for example, from sea level to 75,000 feet). Amnesia The tendency over time for a heat-shrinkable elastomeric tubing or molded part to fail to recover completely to its specified recovered size. See Shelf Life. Ampacity See Current-carrying Capacity. ASTM (American Society for Testing and Materials) A nonprofit industry wide organization that formulates test methods and material specifications, and publishes standards, testing methods, recommended practices, definitions, and other materials. Attenuation Power loss resulting in weaker signals in an electrical 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 specifying conductor size. The higher the gauge number, the smaller the conductor size. Back-mounted A termination assembly mounted from the inside of a panel or box with its mounting flange inside the equipment. Band Marking A continuous circumferential band applied to a wire at regular intervals for identification. Bare Conductor A conductor 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 conductor insulation. 3.) Open barrel: The section of a cap that accommodates the conductor. Batch Number See Lot Number. Bayonet Coupling A quick-coupling device for plug and receptacle connectors. Mating is accomplished by rotation of the two parts under pressure. Beaming Crosslinking by means of high-energy electrons. Binder A spiral wrapping of a thread to hold together the members of a cable. Blocking The sticking together of insulated wires; usually caused by heat. Body A protective covering of resilient material over any portion of a cable, wire termination, or termination assembly in addition to normal jacketing of insulation, 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 A woven metallic or fiber layer applied over wire or cable to act as a protective barrier or shielding. 11-6 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Glossary (Continued) Braid Angle The angle between the braid strands and the axis of the cable. Breakout A region in a harness assembly where a wire or a group of wires is detached to form a separate, terminated 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 A method of twisting individual strands to form a finished stranded conductor. Specifically, a number of strands twisted together in a common direction and with a uniform pitch (or twist) per inch. Bus A communal circuit over which data or power is transmitted. Cable Two or more wires in a twisted or parallel configuration. Also, a shielded wire. Cable Clamp A mechanical 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 otherwise be transmitted by the cable terminations. Cable Clamp Adapter A mechanical adapter that attaches to the rear of a termination assembly to allow the attachment of a cable clamp. Cabler A machine that mechanically assembles a group of insulated wires. Cabling The act of twisting together two or more insulated components to form a cable. Capacitance The ability of an insulation to store electrical energy. This is a function of the permittivity (dielectric constant) of the insulation. Usually expressed in pico farads/foot for a cable. Carrier A group of strands or ends used to form a finished braid. Characteristic Impedance The impedance of a transmission line that is independent of length. Also, the ratio of voltage to current at any point along a transmission 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. Clocking The arrangement of connector inserts, jackscrews, polarizing pins, sockets, keys/keyways, or housing configurations to prevent the mismating or cross-mating of connectors. See also Polarization. 11 Supporting Information Breakdown Voltage The voltage at which an insulator or dielectric fails to maintain the applied voltage. Cable Sealing Clamp A device consisting of a gland nut designed to seal around the jacket of a cable. 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 A cable 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 A test conducted by wrapping tubing or cable around a mandrel or by bending it in an arc while at a low temperature. Cold Flow Permanent deformation of polymeric materials (insulation) at ambient temperature due to mechanical force or pressure (not due to heat softening). Cheminax Cables Raychem's registered trade name for coaxial cables. Cold Impact A test performed by subjecting a component to a specified impact during exposure to low temperature. It measures the brittleness of the material. Circuit The interconnection of a number of electrical elements or parts to accomplish a desired function. Cold Joint A soldered joint made with insufficient heat. (Solder hasn't completely flowed and wet the substrate.) 11-7 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Glossary (Continued) Color Code A means 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 A wire or cable that is combined with other wires or cables to make a multicomponent cable. Compound An insulating or jacketing material made by formulating polymeric materials and additives. Compound Under Strands (CUS) A problem that occurs when loose stranding, or overheating during extrusion, allows compounds to get under individual strands of conductor. Concentric Stranding A method 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 percentage) 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 percentage of copper conductivity (copper being 100%). Specifically, the ratio of the current flow to the potential difference causing the flow. The reciprocal of resistance. 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 20C [68F]). Conduit A tubular raceway for holding wires or cables. Configuration Arrangement of contacts in a multiple-contact connector. Connector A device used to physically and electrically connect two or more conductors. Connector Classes Categories based on shape, function, and smallest-size contact in a series. Connector Insert In connectors with metal shells, the part that holds contacts in proper arrangement while electrically insulating them from each other and from the shell. Contact The element in a connector that makes the actual electrical 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 A contact whose rear portion is a hollow cylinder that accepts the conductor. A crimping tool is applied to swage or form the contact metal firmly against the conductor. Sometimes referred to as a solderless contact. Contact Resistance The direct-current resistance 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 A continuous path for the flow of current in an electrical circuit. Continuous Operating Temperature Maximum temperature at which a component will maintain an acceptable lifetime performance, based on accelerated aging prediction. Continuous Service Conditions (time, temperature, environment) that describe the lifetime requirements of a component. Core 1.) In cables, a component or assembly of components over which additional 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 11-8 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Glossary (Continued) Crimp Final configuration of a terminal 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 A method of crosslinking polymers that makes a nonflowing material. This generally 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 mechanical 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. An agency that has developed standard specifications for products with particular emphasis on safety in the end use. Curing See Thermoset. Current A movement or flow of electrons. 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 insulationand /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 operation 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 controlled 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. The voltage required to cause an electrical failure or breakthrough of the insulation. Determined by a destructive test. See also Breakdown Voltage. 11 Supporting Information A calculated percentage that defines the completeness with which a braid or shield covers the surface of the underlying insulated conductor or conductors. 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) A test 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 A broken connection, or the loss of a specific connection characteristic. Also, the temporary interruption or variation in current or voltage. Dissipation Factor The ratio between the permittivity and the conductivity of a dielectric. Drain Wire CSA (Canadian Standards Association) Dielectric Breakdown 11-9 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Glossary (Continued) In a cable, an uninsulated conductor laid over the component, or components, in a foil-shield cable. Used as a ground connection. 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 A material that exhibits very low or zero crystallinity and a high 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 electromagnetic interference. Encapsulant Description related to the way dual-wall tubing products 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 a mechanical bond to the substrate. Encapsulation Covering and sealing. End The number of fibers or strands per carrier in braiding operations. Environmentally Sealed Description of a system to keep out moisture, dirt, air, or dust that might reduce performance. Epoxy A family of thermosetting resins usually used as adhesives or encapsulants. ETFE (Ethylenetetrafluoroethylene) A fluoropolymer 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 a tubing 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 A tool used for removing contacts from a connector body. Extrusion A process 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) A bushing in a wall or bulkhead with terminations on one or both sides. Filler A material 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. A descriptor applied to a material that is inherently resistant to burning. Flame Retardant A descriptor applied to a material that has been made or treated so as to resist burning. Flat Braid A braided shield composed of flat strands. Flat Cable A cable with each component in a single, flat plane. Flat Conductor A conductor having a rectangular cross section, as opposed to a round or square cross section. Flex Life A measure of the susceptibility of a conductor or other device to failure due to fatigue from repeated bending. Fluoropolymer A polymer that contains atoms of fluorine. Flux A liquid or solid that, when heated, exercises a cleaning and protective action upon surfaces. Used to promote or facilitate 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 A term used to denote the physical size of a wire. See also AWG. Flame-resistant 11-10 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Glossary (Continued) the substrate surface, and forms an adhesive bond. Reheating causes the adhesive to remelt. Hardness A general term that correlates with strength, rigidity, and resistance to abrasion or penetration. Measured on Shore or Rockwell scales. See also Shore. ID (Internal Diameter) The inside or internal diameter of a tubing. Harness A system providing electrical connection between two or more points. Heat Aging A test that subjects components or materials to temperatures above normal operating values to evaluate changes in performance in order to predict service life. See also Accelerated Aging. Heat Shock A test to determine the stability of a material by continuously exposing it to an extremely high temperature 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 A polymeric material capable of being reduced in size when exposed to heat. 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 impedance. Admittance is the reciprocal of impedance. Impulse Test A high-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) A defined hole in the connector 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. Hertz (Hz) A measure of frequency equal to one cycle per second. Insert Arrangement (Connector) The number, spacing, and arrangement of contacts in a termination assembly. Hookup Wire and Cable Wiring used to connect various points in electronic assemblies. Insertion Tool (Connector) A tool used to insert removable contacts into a connector. Inspection Hole A hole placed at one end of a contact barrel to permit visual inspection, to ensure that the conductor has been inserted to the proper depth in the barrel prior to crimping or soldering. 11 Supporting Information Grounding Conductor A conductor that provides a current return path from an electrical device to ground. Insulated Terminal A solderless terminal with an insulated sleeve over the barrel to prevent a short circuit in certain installations. Insulation, Electrical A nonconductive material usually surrounding or separating two conductive materials. Often called the dielectric in cables designed for highfrequency use. Insulation, Thermal A nonconductive material that prevents the passage of heat. Insulation Resistance Minimum electrical resistance 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 components. Irradiation In insulations, the exposure of the material to highenergy emissions for the purpose of favorably altering the molecular structure via crosslinking. Hot-Melt Adhesive An adhesive that becomes activated by heating. When heated, it melts, flows over 11-11 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Glossary (Continued) Jackscrew A screw attached to one half of a two-piece, multiple-contact connector and used to draw both halves together and to separate them. Lanyard A device, attached to certain quick-disconnect connectors, that permits uncoupling and separation of connector halves by a pull on a wire or cable. Jacket 1.) A material covering over a wire or cable assembly. Lay Refers to direction or sometimes the ratio of lay length to core diameter. 2.) Outer covering of a dual-wall heat-shrinkable tubing. Lay Length A term used in cable manufacturing to denote the distance of advance of one member, or a group of spirally twisted members in one turn, measured axially. The lay of any helical element of a cable or conductor is the axial length of a turn of the helix of that element. Kapton DuPont's trade name for polyimide film. Key (Connector) A short pin or other projection 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 connectors 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 a key slides. Life Cycle A test 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. kV (Kilovolt) A unit equal to 1000 volts. Loss Electrical energy that is dissipated as heat. Kynar Trade name (of Atofina Chemicals, Inc.) for polyvinylidene fluoride and its copolymers. Loss Factor The product of the power factor and dielectric constant of an insulating material. Lacing Cord or Twine Used for lacing and tying cable forms, hookup wires, cable ends, cable bundles, and wire harness assemblies. Available in various materials and impregnants. Lot Number The number that identifies one production run of material. Also known as a batch number. Low-loss Dielectric An insulating material that has a relatively low dielectric loss, such as polyethylene or Teflon(R). Lug A termination, usually crimped or soldered to a conductor, that allows connection to be made with a retaining screw. Marking A printed identification number or symbol applied to the surface of a wire or cable. Mate (Connections) To join connector halves in a normal engaging mode. Megarad A unit for measuring radiation 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 A unit equal to one onethousandth 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. TEFLON is a trademark of E.I. du Pont de Nemours and Company 11-12 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Glossary (Continued) Minimum Full Recovery Temperature See Recovery Temperature. MO (Manufacturing Order) A series of operation-workorder cards identifying materials to be used and the type and quantity of products to be manufactured. An MO is controlled and issued by Production Control to the manufacturing operation. MOD Code (Material Modification Code) A code designating a particular stage in the production process. Most MOD codes describe the way the product is packaged. MS (Manufacturing Specification) A set of process instructions used in the manufacturing of tubing products. Customer Logistics, Product Management, or Manufacturing Engineering initiate the MS; Manufacturing Engineering controls it. The product design and quality parameters are provided to Manufacturing Engineering by Product Development and Quality Assurance. Successful trial runs of a new product or design usually precede the initiation of an MS (see SMO). A proprietary Raychem document, an MS is not available to customers. Multiconductor More than one component within a single-cable complex. Multiple-Conductor Cable A combination of two or more components cabled together. Nick A small cut or notch in conductor strands or insulation. Nominal A descriptor applied to a dimension representing the center of the range of tolerance or a value if no tolerance is applied. OFT (Optional Flame Test) Canadian Standards Association's test for flameretardance. Tubing with an OFT rating is highly flameretardant. Ohm The unit of electrical resistance. Operating Temperature The maximum internal temperature at which a system, harness, or connector may operate in continuous service; generally expressed as a time and temperature. Operating Temperature Range The range between the maximum and the minimum internal temperature of insulation in a system, harness, or connector in continuous service. The lower limit is determined by low-temperature flex test. Optional Flame Test See OFT. Packaging The process of physically locating, connecting, and protecting devices or components. Panel The side or front (usually metal) of a piece of equipment on which connectors are mounted. Panel-mount Method of fixing one-half of a connector to a board, panel, or frame. Usually, the female half of the connector is the mounted portion and the male half is the removable portion. 11 Supporting Information Milking Off Action that occurs when the inner layer (the encapsulant or adhesive) of the tubing or molded part acts as a lubricant, allowing the tubing to slip off the substrate (because the tubing wants to recover to a smaller diameter). PC (Production Control) Group responsible for directing and regulating the movement of goods through the entire manufacturing cycle, from the requisitioning of raw materials to the delivery of the finished products. PCN See RPN. Peripheral Seal A seal provided around the periphery of connector inserts to prevent the ingress of fluids or contaminants at the perimeter of mated connectors. Permittivity See Dielectric Constant. Pick The number of crossovers of braiding units per inch of cable. Pigtail A short 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 termination than a lug. Plastic Deformation Change in dimensions under a load that does not recover when the load is removed. Plasticizer A softener or lubricant added to a compound to make it easier to process or more flexible in use. Plating 11-13 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Glossary (Continued) 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 connector that contains the pin contacts. Plug Connector An electrical connector that is intended to be attached to the free end of a conductor, wire, cable, or bundle, and that couples or mates to a receptacle connector. Poke Through A term describing stray wires in a solder joint that poke through the insulation. Polarization (Connectors) A mechanical arrangement of inserts or the shell configuration (referred to as clocking in some instances) that prohibits the mating of mismatched plugs and receptacles. See also Clocking. Polyamide A polymer formed by the reaction of a diamine and a diacid. Nylons are commercial polyamides characterized by toughness, solvent resistance, and sharp melting point. Polymer A material of high molecular weight formed by the chemical union of monomers. Polyolefin A family of polymers (such as polyethylene and polypropylene) made from olefin monomers. Potting The permanent sealing of the cable end of a connector with a compound or material that thermosets into an elastomer, to exclude moisture and/or to provide strain relief. A type of connector shell that permits rapid locking and unlocking of two connector halves. Pre-etching The act of surface preparation before encapsulating. Radiation Crosslinking The act of crosslinking a material with ionizing radiation. (Most Raychem products are radiation crosslinked, with an electron beam as the form of ionizing radiation.) See also Crosslinking by Irradiation. Pretinned Description of an electrical component to which solder has been applied prior to soldering. Pretinned Solder Cup Solder cup whose inner surfaces have been precoated with a small amount of solder. 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) A polymer compound used as wire insulation. PVDF Polyvinylidene fluoride. Quality Assurance Systematic, planned, and documented activities designed to provide confidence that a product will meet specifications. Quality Control Activities that monitor, measure, and control the characteristics of a material, component, or product to documented specifications. RA Flux Rosin-activated flux. Rated Temperature The maximum temperature at which a component can operate for extended periods with acceptable changes in its basic properties. Rated Voltage The maximum voltage at which an electric component 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 stationary half of a two-piece multiple contact connector. Also the connector half usually mounted on a panel and containing socket contacts. 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) Quick Disconnect 11-14 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Glossary (Continued) followed by a 1-digit MOD Code, and finally a 3-digit suffix. See also MOD Code and SMO. Recovery Temperature The minimum temperature required to fully shrink a product, that is, for the product to recover completely. RT and RW specifications Specification that describes standard product properties. Qualification and acceptance inspection criteria are incorporated into RT and RW specifications. RT and RW specifications are issued and controlled by the Specifications Group. Removable Contact A contact 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 A measure 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 structure is usually characterized by individual colors of insulation for each conductor, although a single color may be used for all conductors. SCD (Specification Control Drawing) Drawing that defines configuration and material parameters. Issued and controlled by the specifications group, SCDs are frequently used in conjunction with RT Specifications for Thermofit products. Scoop-proof A feature that prevents the damage of contacts during misaligned mating. Sealant Soft, tacky, pliable material that seals where mechanical strength is not required. RMA Flux Rosin-mildly-activated flux. Sealed Environmentally protected by the thermoplastic inserts or core of encapsulant/ adhesive that has melted down around the substrate. Rope Lay A type of conductor lay that uses stranded conductors as components to build a larger conductor. Sealing Plug A plug that is inserted to fill an unoccupied contact aperture in a termination assembly. RPN (Raychem Product Number) A 10-digit number (such as 123456-4-001) assigned to every standard product and every product manufactured on a special manufacturing order (SMO). The first 6 digits represent the PCN (Product Control Number), Secant Modulus A measure of material stiffness; stiffer material has a higher secant modulus. More specifically, the secant modulus is the ratio of stress (nominal) to corresponding strain at any specified point on the stress-strain curve.It is RID See Recovered ID. 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. 11 Supporting Information In heat-shrink tubing, the guaranteed maximum internal diameter of tubing after being freely recovered. Service Life Period of time during which the product is expected to perform satisfactorily. Service Loop The extra cable required at a breakout to facilitate maintenance and servicing. Service Rating The maximum voltage or current that a termination is designed to carry continuously. Shelf Life Generally, the length of time a product or material may be stored without deterioration. Specifically, the length of time during which shrink tubing will retain its expanded 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 A conducting layer placed around an insulated conductor or cable to limit the penetration, or escape, of electric or electromagnetic fields, thereby preventing electromagnetic interference. The shield may be formed of metallic braid, metal tape, metal-backed foil, metal tube, or conductive polymer. Usually grounded, the shielding is 11-15 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Glossary (Continued) carried through the connector shell, or through a special internal shell in the case of individual coaxial contacts. Shielding See Shield. Shielding Effectiveness (SE) The reduction in field strength resulting from interposing a metallic barrier between a source and receptor of electromagnetic energy. Shore A scale for comparing hardness. Higher Shore values represent harder materials. The hardness of a polymer, for example, is usually represented 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 A cable 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 manufacturing and production capability for a new or changed design for a customer and to provide development samples of potential products for customers. SMO products are separate and distinct from standard products. New, potential products are usually 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 relatively low temperatures and is used to join metals with higher melt points. Solder Contact A contact or terminal having a cup, hollow cylinder, eyelet, or hook to accept a wire for a conventional soldered termination. Solder Cup A tubular end of a terminal into which a wire conductor is inserted prior to being soldered. Solderability The property of a metal surface that allows it to be readily wetted by molten solder. See also Wetting. Soldering A process of joining metallic surfaces with solder without melting the base metal. SolderSleeve Device A device of flux-coated solder preform encapsulated in a heat-recoverable plastic sleeve. Upon the application 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 A conductor composed of one single strand. Solvent Resistance The ability of a material to retain physical and electrical properties after being immersed in specific solvents. SPC Silver-plated copper. SPC (Statistical Process Control) The use of statistical techniques 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 A joint connecting conductors 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 provide strain relief. Strain Relief Clamp See Cable Clamp. Strand A single unit of a conductor. Stranded Conductor A conductor 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 11-16 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Glossary (Continued) A continuous longitudinal or spiral color strip applied on the surface of a wire, cable, or tubing for identification. Surface Resistance The ratio of the direct current applied to an insulation system to the current that passes across the surface of the system. Tape Wrap A term 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 A test to determine the tear strength of an insulating material. Usually includes exposure to given thermal conditions or a programmed series of conditions for prescribed periods of time. Temperature Rating The maximum temperature at which the insulating material may be used in continuous operation without loss of its basic properties. Usually time dependent. Tensile Strength The pull stress (in force per unit area) required to break a given specimen. Thermal Rating The effect of heat or cold applied at such a rate that nonuniform thermal expansion or contraction occurs within a given material or combination of materials. In electrical terminations, the effect can cause inserts and other insulation material maximum and minimum limits. Thermal Shock The effect of high and low temperatures applied at a rapid rate such that nonuniform thermal expansion or contraction occurs within a given material or combination of materials. The result could be stress-cracking or -shattering of material. Traceability The ability to trace the history, 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. Thermochromic Indicator Special compound that changes color when the proper wetting temperature has been reached in the solder joint. Thermoplastic A material that softens (melts and flows) when heated and becomes firm when cooled. A type of plastic that can be remelted a number 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 A material that hardens or sets when heated and, once set, cannot be resoftened by heating. This application of heat is called "curing." Thermosetting Plastic A type of plastic in which an irreversible chemical reaction takes place while the plastic is being molded under heat and pressure. Thermosetting Adhesive A curing adhesive that requires heat to promote curing. This type of plastic will not soften when reheated. See Epoxy. Tolerance The total amount by which a quantity is allowed to vary from nominal; thus, the tolerance is half the algebraic difference between the 11 Supporting Information Substrate The material--such as a wire, post, or tab--over which an interconnection device is used. to pull away from the metal parts. Transmission Cable Two or more transmission lines. If the structure is flat, it is sometimes called flat transmission cable to differentiate it from a round structure such as a jacketed group of coaxial cables. See also Transmission Line. Transmission Line A signal-carrying circuit with controlled electrical characteristics; used to transmit high-frequency or narrowpulse signals. Triaxial Cable A concentrically constructed cable, with a common axis, composed of a center connector, first shield, and second shield, all insulated from each other. UL (Underwriters' Laboratories) A nonprofit 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 a cable or dielectric as compared with the same wave in free space. Voltage 11-17 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Glossary (Continued) 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 circuit 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 current, usually expressed in ohm-cm. VSWR (Voltage Standing Wave Ratio) A measure of the uniformity of impedance along a transmission line, or the quality of the impedance match between a line and the source or load. 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 surface to produce an adherent bond. Wicking The longitudinal flow of a liquid in a wire or cable construction due to capillary action. (This may also apply to solder.) Wire A single conductor covered with insulation. Wire Dress The orderly arrangement of wires and laced harnesses. Withstanding Voltage The test voltage an electrical 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. VW-1 A rating determined by the Underwriters' Laboratories' (UL) optional Vertical Wire Flame Test--the most difficult 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 A method to determine the water uptake of a material. It is time and temperature dependent. Water Blocking 11-18 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Part Index Product or Part Number Page Number Product or Part Number Page Number 4-25 AD-1377, AD-1522 Hand Operated Crimp Tools 10-4 -4 Material 4-27 AD-3050-SEAL-TEST-EQUIP 10-5 -12 Material 4-29 AD-5000 and RH-396X Tinel-Lock Tools 10-7 -25 Material 4-31 AD-5010-Tinel-Bench-230V -25S Material 4-33 Adhesives -50 Material 4-35 ATUM Tubing 3-33 -51 Material 4-37 B-02X/04X 8-51 -55 Material 4-39 B-046 8-53 -71 Material 4-41 B-106 8-27 to 8-31 -100 Material 4-43 B-202 8-64 -100S Material 4-45 BSTS/BSTS-FR -125 Material 4-47 C-203 101A011 to 094 4-49 CES 10612 8-78 CGPE-105 3-7 10613 8-78 CGPT 3-9 10614 8-78 Cheminax Coaxial Cables 202A111 to 196 4-53 Cheminax Twin Axial Cable 202C611 to 663 4-54 Code 18 MIL-C-5015 (MS3100) 202D121 to 196 4-55 Code 21 MIL-C-26482 Series 1 6-37 to 6-43 202D211 to 299 4-56 Code 32 MIL-C-22992 6-44 to 6-49 202D921 to 963 4-57 Code 40 MIL-C-38999 Series III and IV 6-50 to 6-57 202F211 to 274 4-58 Code 41 MIL-C-38999 Series I and II 6-58 to 6-65 202G211 to 253 4-59 202G611 to 653 4-60 6-66 to 6-73 6-74 to 6-76 11 Supporting Information -3 Material 10-9 5-2 to 5-7 3-53 8-20, 8-21 4-95 9-68 to 9-72 9-73, 9-74 6-28 to 6-36 202K121 to 185 4-61 Code 54 MIL-C-5015 (MS3400), MIL-C-26482 Series 2, MIL-C-83723 Series I and III, MIL-C-81703 Series III 202W302 to 342 4-91 Code 76 BS 9522 F0017 (Pattern 105) 207W213 to 256 4-75 Computer aided design 214A011 to 052 4-62 Conductor sizes, strandings and resistance 214A311 to 352 4-63 CRES-Lock Bands 6-27 214P009 to 037 4-64 CRN 3-11 222A111 to 196 4-65 CV-1981, CV-1983 222D121 to 196 4-66 CWT 222D211 to 299 4-67 CWT-15XX 222D921 to 963 4-68 CWT-900X 222F211 to 285 4-69 D-71X 8-41 222K121 to 185 4-70 D-110 8-6, 8-8, 8-41 234A011 to 071 4-71 D-129 8-40 to 8-42 234A111 to 152 4-72 D-141 8-40 to 8-42 234A611 to 671 4-73 D-150 8-62, 8-63, 8-64 8-90 242W042 to 63 4-74 D-181 8-51, 8-52 301A011 to 048 4-76 D-184 8-51, 8-52 301A511 to 514 4-77 D-406 8-18, 8-19 322A112 to 158 4-78 D-436 8-23, 8-24 342A012 to 058 4-79 D-500 8-79 to 8-86, 8-90, 8-97 362A014 to 114 4-80 D-600 8-75, 8-90 381A301 to 304 4-81 D-602 8-67 to 8-74 382A012 to 046 4-82 D-607 8-53 382C312, 322 & 332 4-83 D-609 8-24 400W242 4-93 D-621 8-90 to 8-93 462A011 to 060 4-84 D-1744 462A421 to 424 4-85 Data Bus Accessories 562A011 to 067 4-86 Data Bus Box Couplers 8-85, 8-86 7724 H 0664 8-78 Data Bus Cables 8-77, 8-78 AA-400 Super Heater 10-2 AD-1319-9 Holding Fixture Tool 10-3 Data Bus Customer-Specified Harness Assemblies and HarnWare Software 9-89 9-94, 9-95 10-11 8-6, 8-40, 8-44, 8-51 8-40 8-7 8-6, 8-9 8-89 to 8-93 8-98 11-19 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Part Index (Continued) Product or Part Number Page Number Product or Part Number Page Number Data Bus Discrete Connectors 8-87, 8-88 Data Bus In-line Microcouplers 8-79 to 8-81 Multiconductor, Custom-Designed, (multi) Cables Data Bus Space-Grade Components 8-95 to 8-97 Multiconductor (Multicore) Cables 9-76 8-94 NT 3-83 Data Bus Ultra Lightweight In-line Microcouplers 8-82 NT-MIL 3-85 DCPT 3-13 NTFR 3-87 DK-3716 8-93 PD Caps 3-89 DK-602 8-94 Power Cables (Type TR, FTR, AFR, ZHI, ZHPCG) 9-90 DK-621 8-87, 8-91, 8-92, 8-93, 8-97 Data Bus Triaxial Size 8 Contacts 3-65 DR-25 DuraSeal Crimp Terminals & Disconnects DuraSeal Crimp Splices 8-27 to 8-32 8-18, 8-19 3-35 ElectroLoss FilterLine 8-20, 8-21 QFT 4-87 RayBlock 85 Tubing 3-91 RayBlock 105 Tubing 3-93 Rayflex Polyester Sleeving 3-95 9-87, 9-88 Rayflex PETM 3-97 9-63 to 9-67 DWP-125 Electrical Shielding PolyCrimp Wire Splices 9-75 RayOLOn Kits 4-99 ES1000 3-37 Rayrim Edging Material 3-99 ES2000 3-39 Raythane, Neoprene, Rayolin, AFR 9-86 ES Caps 3-67 RBD 8-58 9-79 RBK-ILS-Processor MkII FDR 25 9-96 to 9-99 Fiber Optic Cables 10-27 RCW 9-19 to 9-24 8-55 to 8-60 FL2500 3-41 RF One-step BNC/TNC Connectors FlexLine Wire & Cable 9-25 RHW 3-59 FlexLite Wire & Cable 9-45 RMW 3-61 FlexLite DW Wire 9-47 RNF-100 3-17 FlexLite HT Wire 9-53 RNF-150 3-101 FlexLite MT Wire 9-51 RNF-3000 3-19 FlexLite TW Wire 9-49 RP-4800 3-21 FlexLite TX Wire 9-55 RPPM 3-45 FLT Wire 9-57 RT-3 3-23 FR-1000 Cable HarnWare Harness Design Software 9-27 to 9-34 RT-375 2-6 to 2-14 RT-555 HCTE 3-69 HexaShield High Performance Adapters 8-99 to 8-104 3-103 3-105 RTD 8-59, 8-60 RW-175 3-107 HF 3-55 S-1006 5-2 HFT5000 3-71 S-1009 5-2 HL1802E/HL2005E 10-13 S-1017 HRHF/HRNF/HRSR 3-57 S-1030, S-1048, S-1275 (Rayaten) HTAT 5-2 5-2, 7-9 3-43 S-1124 5-2 IR-1891 10-15 S-1125 5-2 IR-550 Mark II 10-17 S-1255 5-2 IR-1759 MiniRay 10-18 S-1278 5-2 7-2 S-1297 5-2 7-3 to 7-5 S-1305 5-2 KTKK Product Family Overview KTKK Assemblies LSTT 3-15 S01 8-44 to 8-49 MicroFit Tubing 3-73 S02 8-44 to 8-49 MiniSeal Crimp Splices 8-22 to 8-25 S03 8-46, 8-47 Model 16B Belt Heater 10-19 SCL 3-47 Model 19 Conveyor Heater 10-21 SCT Model 81CE Discrete Heater 10-23 SESK (Shipboard Electrical Splice Kits) Model 105 Tunnel Oven 10-25 SFR MT1000 3-49 7-10 to 7-12 3-109 3-75 SGRP MT2000 3-77 SGRS 8-12 to 8-17 MT3000 3-79 SGRT 8-33 to 8-36 3-81 Ship or Shore Breakout Kits MT5000 MTC Crimp Connectors 8-105 to 8-111 shrinkHOoP Grommet MTCP-122 8-106 to 8-108 SO63 8-12 to 8-17 7-13 4-101 8-44 to 8-49 11-20 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Part Index (Continued) Product or Part Number Page Number Product or Part Number SO96 8-44 to 8-49 TCFS/R Cable Feedthroughs SO175 8-44 to 8-49 TFE and TFE-R 3-113 Thermocouple Extension Cable 8-33 to 8-37 7-6 to 7-8 ThermoGun HG Hot-Air Heating Tool 10-29 SolderGrip Closed End Connector Splices 8-12 to 8-17 Thermorad HTF/Fluoroelastomer 9-84 SolderShield Shielded and Coaxial Cable Splices 8-62 to 8-65 Thermorad/Thermorad F 9-85 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 SolderSleeve Wire Splices SolderTacts Shielded One-piece Solder Contacts Tinel-Lock Ring 6-26 TUGA-GP 3-25 Type 99M Wire and Cable 9-35 to 9-38 Versafit Tubing 3-27 8-44 to 8-49 Versafit V2 Tubing 3-29 8-6 to 8-11 Versafit V4 Tubing 3-31 Viton(R) (E, HW, TW) 8-67 to 8-75 3-115 3-117 XFFR SPEC 44 Wire 9-3 to 9-9 SPEC 55 Wire 9-10 to 9-18 SPEC 80 Wire 9-25, 9-26 Zerohal 100A Wire and Cable 3-111 Zerohal 100G Wire and Cable SRFR 11 9-60 Supporting Information SolderGrip Self-fixturing Insulated Terminals Page Number XL Products 4-104, 4-105 Zerohal Wire and Cable 9-81 to 9-83 9-39 9-42 SSC 4-51 ZH-100 3-119 SSB, D, T, F to 8S 4-89 ZHTM 3-121 SST/SST-FR 3-63 TAT-125 3-51 VITON is a trademark of Dupont Dow Elastomers LLC. 11-21 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Engineering Notes 11-22 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Engineering Notes 11-23 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Engineering Notes 11-24 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Supporting Information Engineering Notes 11-25 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171