SPECIFICATION CONTROL DRAWING
MATERIALS
1. INSULATION SLEEVE: Heat-shrinkable, transparent blue, radiation cross-linked modified polyvinylidene
flouride.
2. INTEGRAL MULTI-WIRE SEAL: Modified thermoplastic.
3. SEPARATE MULTI-WIRE SEAL: Modified thermoplastic.
4. CRIMP SPLICER: Base Metal: Copper Alloy 101 or 102 per ASTM B-75.
Plating: Tin per MIL-T-10727, Type 1.
Color Code: See table below.
Part
Name
D-436-42
D-436-43
Prod.
Rev.
F
A
Dimensions: Crimp Splice
I.D.±0.05
O.D.±0.08
Color
(I.D.±0.002) (O.D.±0.003)
Code
1.70 (0.067)
2.62 (0.103)
Blue
2.54 (0.100)
3.81 (0.150)
Yellow
Installation Data: Wire Size Range of Crimp Splicer
Two Wires
Three Wires
Minimum
Maximum
Minimum
Maximum
2 x 24
2 x 20
3 x 24
3 x 22
2 x 22
2 x 16
3 x 22
3 x 18
APPLICATION
1. These parts are designed to provide an immersion resistant in-line splices of 2 or 3 to 2 or 3 wires falling within
the size range listed above, having insulations rated for at least 135C.
2. Parts are available only as an assembly of one of each Item #1 and Item #2.
3. Crimp splicer may be installed with Raychem AD-1377 crimp tool or equivalent.
4. Inside diameter and outside diameter of splice are to be measured in crimp area, 2.54 to 5.08 (0.100 to 0.200)
from ends of part. Slight burr permitted on parted surfaces.
5. Acceptance sampling shall be in accordance with paragraph 4.6.1 of MIL-T-7928.
6 . Packing and packaging shall be in accordance with Section 5, Level C, of MIL-T-7928.
7. This document takes precedence over documents referenced herein.
1.0
TEST ASSEMBLIES
TE Connectivity
305 Constitution Drive
Menlo Park, CA 94025, USA
TITLE :
Raychem
Products
DOCUMENT NO.:
DATE:
IN-LINE SPLICE SEALING
SYSTEM, MULTI-WIRE
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS.
INCHES DIMENSIONS ARE BETWEEN BRACKETS.
TOLERANCES:
ANGLES: N/A
TE Connectivity reserves the right to amend this
0.00 N/A
drawing at any time. Users should evaluate the
0.0 N/A
ROUGHNESS IN
suitability of the product for their application.
0 N/A
MICRON
DRAWN BY:
REPLACES:
DCR NUMBER:
D-436-42/-43
DOC ISSUE:
15-Apr-11
PROD. REV.
SCALE:
SIZE:
2
SHEET:
M. FORONDA
N/A
D001303
SEE TABLE
None
A
1 of 4
If this document is printed it becomes uncontrolled. Check for the latest revision.
SPECIFICATION CONTROL DRAWING
The test assemblies for qualification testing shall be 3 to 3 in-line splices made in wire conforming
to MIL-W-81044/12 or MIL-W-16878/4. The assemblies shall be divided equally between the maximum
and minimum wire size as shown below:
Assembly
D-436-42
D-436-43
Minimum
24
22
Maximum
22
18
The qualification sample shall consists of 35 assemblies and 8 uninstalled sleeves.
1.1
Acceptance Testing:
Acceptance sampling shall be in accordance with ANSI/ASQC Z1.4, Inspection Level S-4. The
Acceptable Quality Level shall be 4.0 for all defects.
Acceptance tests shall consist of visual and dimensional examination.
2.0
QUALIFICATION TESTING:
.1
All sleeves shall be tested for compliance with Sheet 1 in regard to:
Property
Material and Appearance
Dimensions
2.2
Test Method
Visual Examination
MIL-I-23053, Paragraph 4.6.3
Test Group A: Ten assemblies shall pass the post conditioning tests after conditioning in the
sequence shown:
Post Conditioning
Insulation Resistance
Altitude Immersion
Insulation Resistance
Dielectric Withstanding
Conditioning
Altitude Immersion
Immersion
Temperature Cycling
Moisture Resistance
Fluid Immersion
Heat Aging
Requirement
5000 M @500V d-c
75,000 ft.
5000 M @500V d-c
2.5Kv (rms) for 1 min.
Parameters
75,000 ft.
Condition C
-65C to 150C (5 cycles)
Step 7b not required
MIL-H-5606, MIL-L-7808
96 hours @200C
Test Method
MIL-W-81044, Par. 4.7.5.2
MIL-C-26500, Par. 4.7.21
MIL-W-81044, Par. 4.7.5.2
MIL-W-81044, Par. 4.7.5.1
Test method
MIL-C-26500, Par. 4.7.21
Method 104*
Method 102*
Method 106*
MIL-T-7928, Par. 4.8.8
Method 108*
2.3
Test Group B: Ten Assemblies:
Requirement
TE Connectivity
305 Constitution Drive
Menlo Park, CA 94025, USA
Test Sequence
Test Method
TITLE :
Raychem
Products
DOCUMENT NO.:
DATE:
IN-LINE SPLICE SEALING
SYSTEM, MULTI-WIRE
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS.
INCHES DIMENSIONS ARE BETWEEN BRACKETS.
TOLERANCES:
ANGLES: N/A
TE Connectivity reserves the right to amend this
0.00 N/A
drawing at any time. Users should evaluate the
0.0 N/A
ROUGHNESS IN
suitability of the product for their application.
0 N/A
MICRON
DRAWN BY:
REPLACES:
DCR NUMBER:
D-436-42/-43
DOC ISSUE:
15-Apr-11
PROD. REV.
SCALE:
SIZE:
2
SHEET:
M. FORONDA
N/A
D001303
SEE TABLE
None
A
2 of 4
If this document is printed it becomes uncontrolled. Check for the latest revision.
SPECIFICATION CONTROL DRAWING
Insulation Resistance
Vibration
Insulation Resistance
Altitude Immersion
Insulation Resistance
Voltage Drop**
Tensile Strength
5000 M @500V d-c
MIL-STD-202, Method 201
5000 M @500V d-c
75,000 ft. (1 cycle)
5000 Megaohms
Wire Equivalent + 2.0
millivolts (maximum)
Table II
MIL-W-81044, Par. 4.7.5.2
MIL-T-7928, Par. 4.8.6
MIL-W-81044, Par. 4.7.5.2
MIL-C-26500, Par. 4.7.21
MIL-W-81044, Par. 4.7.5.2
MIL-T-7928, Par. 4.8.1
MIL-T-7928, Par. 4.8.7
* Test methods are per MIL-STD-202.
** Test current shall be equal to 3X the rated current fot the smallest gauge wire used.
2.4
Test Group C: Ten Assemblies:
Requirement
5000 M @500V d-c
5000 M @500V d-c
75,000 ft. (1 cycle)
5000 M @500V d-c
Wire Equivalent + 2.0
millivolts (maximum)
Table II
Test Method
MIL-W-81044, Par. 4.7.5.2
MIL-T-7928, Par. 4.8.4
MIL-W-81044, Par. 4.7.5.2
MIL-C-26500, Par. 4.7.21
MIL-W-81044, Par. 4.7.5.2
MIL-T-7928, Par. 4.8.1
MIL-T-7928, Par. 4.8.7
Test Sequence
Insulation Resistance
Salt Spray (Corrosion)***
Insulation Resistance
Altitude Immersion
Insulation Resistance
Voltage Drop**
Tensile Strength
*** Lead ends to be sealed prior to exposure.
2.5
Test
Flammability
Test Group D: Five Assemblies:
Requirement
Self Extinguishing
within 15 seconds
Test Method
MIL-T-7928, Par. 4.8.10
2.6
Test
Test Group E: Three Sleeves:
Requirement
Non-Corrosive
Test Method
MIL-I-23053, Par. 4.6.10.2
Corrosive Effect
2.7
Test
Test Group F: Five Sleeves:
Requirement
Sheet 1
TE Connectivity
305 Constitution Drive
Menlo Park, CA 94025, USA
Test Method
MIL-I-23053, Par. 4.6.3.2.2
TITLE :
Insulation Shrinkage
Raychem
Products
DOCUMENT NO.:
DATE:
IN-LINE SPLICE SEALING
SYSTEM, MULTI-WIRE
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS.
INCHES DIMENSIONS ARE BETWEEN BRACKETS.
TOLERANCES:
ANGLES: N/A
TE Connectivity reserves the right to amend this
0.00 N/A
drawing at any time. Users should evaluate the
0.0 N/A
ROUGHNESS IN
suitability of the product for their application.
0 N/A
MICRON
DRAWN BY:
REPLACES:
DCR NUMBER:
D-436-42/-43
DOC ISSUE:
15-Apr-11
PROD. REV.
SCALE:
SIZE:
2
SHEET:
M. FORONDA
N/A
D001303
SEE TABLE
None
A
3 of 4
If this document is printed it becomes uncontrolled. Check for the latest revision.
SPECIFICATION CONTROL DRAWING
Longitudinal Change
±10%
(5 minutes @ 300C)
MIL-I-23053, Par. 4.6.5.1
(5 minutes @ 300C)
TEHRMOFIT ASSEMBLY PROCEDURE:
1.0
SCOPE
This document outlines the procedure to be followed to obtain immersion resistant multiple wire butt splices using
Thermofit Multi-Wire In-Line Splice Sealing System D-436-42/-43.
2.0 PROCEDURE
a)
Pass the wires to be attached to one barrel through the separate three wire seal. (Item 3) Pass the wires
to be attached to the other barrel through the sealing sleeve from the three hole insert end.
b)
Strip wires 5/16” to 11/32” and crimp into splicer using one of the approved crimping tools (see
below). Care must be taken that the wires remain untwisted between the splice and the three wire seals or the
sealing sleeve cannot be positioned properly.
c)
Position the separate seal as close as possible to the splicer. Hold this piece in position by squeezing
the wires directly behind it, and slide the sealing sleeve over the assembly so that the separate seal is as far
inside the sleeve as possible.
d)
Apply heat, using the recommended heat source, first to the “separate” seal end, and then the other.
Heat should be applied until insert melts and flows axially along the wires.
3.0
RECOMMENDED TOOLS
a. Crimp Tools
Manufacturer
Raychem
Buchanan Electric Products
Daniels manufacturing Company
b. Heat Tools
Heater
Thermogun #500A
Shop Air Heater #CV-4504
Mini-Gun #CV-5300
Model Number
AD-1377
614080
OT-609
Reflector
TG-14
991180
991319
Heater should be operated to give an air stream temperature of at least 550F.
TE Connectivity
305 Constitution Drive
Menlo Park, CA 94025, USA
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS.
INCHES DIMENSIONS ARE BETWEEN BRACKETS.
TOLERANCES:
ANGLES: N/A
TE Connectivity reserves the right to amend this
0.00 N/A
drawing at any time. Users should evaluate the
0.0 N/A
ROUGHNESS IN
suitability of the product for their application.
0 N/A
MICRON
DRAWN BY:
REPLACES:
DCR NUMBER:
TITLE :
Raychem
Products
DOCUMENT NO.:
DATE:
IN-LINE SPLICE SEALING
SYSTEM, MULTI-WIRE
D-436-42/-43
DOC ISSUE:
15-Apr-11
PROD. REV.
SCALE:
SIZE:
2
SHEET:
M. FORONDA
N/A
D001303
SEE TABLE
None
A
4 of 4
If this document is printed it becomes uncontrolled. Check for the latest revision.
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