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