Wire-to-Wire Splicing - Stranco Products

1 8-22 Catalog 1654025 Dimensions are in millimeters Dimensions are shown forUSA: 1-800-522-6752 South America: 55-11-3611-1514 Revised 12-04and inches unless otherwise reference purposes : 1-905-470-4425 Japan: 81-44-900-5102specified. Values in bracketsSpecifications subject Mexico: 01-800-733-8926 Singapore: America: 52-55-5-729-0425UK: 44-1793-528171 Wire-to-Wire SplicingMiniSeal High-Performance, Immersion-Resistant Crimp SplicesApplicationsMiniSeal Wire-to-Wire splic-ing Products offer solutionsfor hundreds of aerospaceand defense environment-resistantsplices provide excellentreliability, long term per-formance, MIL-S-81824/1qualification, and a lowinstalled crimp splices con-sist of a plated coppercrimp barrel and a sepa-rate, heat-shrinkable, trans-parent sealing sleeve. Theycan be used on a combina-tion of wires, from 1:1 to10:10. MiniSeal splices areone of the smallest, lightest,and most environment-resistant splices preserve the electricalintegrity of the splice bypreventing the penetrationof liquids and the resultingchemical and galvanic Selection Process1.

2 Determine the type ofsplice required. nStub (parallel) splice:nButt (in-line) splice:2. Determine which crimpbarrel plating is required:nTin plating, recommended for tin or silverplated wirenNickel plating, recommended for nickel-plated wire, orsilver-plated wire inapplications above150 C [302 F].3. Calculate the size ofcrimp barrel the CMA/mm2worksheet on the nextpage, calculate the totalcross section to bespliced by adding thecircular mil area (CMA)or square millimeters(mm2) of each splice: Add theCMA or mm2of all wirestogether. Butt splice: Calculateeach side separately(see example on theworksheet).Table A provides theCMA of typical conduc-tors. (Both CMA and mm2give the same results, sochoose either CMA ormm2as your unit ofmeasure for selectionpurposes and continueto use it for all yourselection criteria.)4. Select the color code forthe size crimp barrelrequired. Using Table B(page 8-23), select thecrimp barrel color-coded red, blue, or yellow for the CMA ormm2you splice:Select thebarrel that will accommo-date the total cross splice:Select thesmallest barrel that willaccommodate thelargest CMA/mm2required.

3 (Refer to theexample in the work-sheet for a more specificdescription.) If theCMA/mm2of the smallerside of a butt splice istoo small for the size barrel required to fit thelarger side, increase theCMA/mm2 either bydoubling back one wire(stripping the conductortwice the length youwould ordinarily strip itand then folding it back)or by adding a filler Determine the type ofsealing sleeve wire insulations willnot fit in the holes of thesealing sleeve inserts, sobe sure to compare theinternal diameter of eachhole with the outer diameter of the wire(s)you intend to insert inthat hole. To create a reliable seal, place amaximum of two wires in any hole of the Select the part to the MiniSeal partnumber selection tables(Tables C and D, page 8-23 and 8-24) and findthe table for the type ofsplice (stub or butt) the appropriatetable, find the crimp barrel size range and the size and number ofwires for your applica-tion. Then select the part number for the typeof plating required.

4 Thecolor code accompany-ing that part numbershould match the colorcode you arrived at inTable B, confirming thatthe part number youhave selected is FactsnImmersion-resistant crimpsplices are on QPL for MIL-S-81824nMIL-Spec approvalnSmall sizenLight weightnInsulation and strain reliefnEasy installationAvailable in:AmericasnEuropenAsia Pacificn8 Electrical Interconnect Products8-23 Catalog 1654025 Dimensions are in millimeters Dimensions are shown forUSA: 1-800-522-6752 South America: 55-11-3611-1514 Revised 12-04and inches unless otherwise reference purposes : 1-905-470-4425 Japan: 81-44-900-5102specified. Values in bracketsSpecifications subject Mexico: 01-800-733-8926 Singapore: America: 52-55-5-729-0425UK: 44-1793-528171 Wire-to-Wire SplicingMiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued) Rangemm2 Range1:1 Splice (AWG Size)Color Code304 20 Red779 16 Blue1900 12 YellowExample:Application: A butt splicewith three AWG 22 wires inone side and one AWG 18wire in the other side: The CMA for AWG 22 wirein Table A is 754 ( mm2).

5 Side one is therefore calcu-lated as follows:CMA = 3 x 754 = 2262(mm2= 3 x = )The other side, where theCMA for AWG 18 is 1900, iscalculated as:CMA = 1 x 1900 = 1900(mm2= 1 x = )Using Table B to select thesmallest crimp barrel thatwill easily fit 2262 CMA( mm2), the blue barrelis the correct NumberCMAmm212345678910 Part Number:Total Table A. CMA of TypicalConductorsTable B. Crimp Barrel ColorCode SelectionCMA/mm2 WorksheetTable C. Stub (Parallel) SplicesCrimp RangeSide 1 Side 2 CMA [mm2]SealingMax. Plated Nickel PlatedMin. of WiresInsert of WiresD-436-0128 D-436-0119 304 151022 RedRed[ ]D-436-58 D-436-75 779 268022 BlueBlue[ ]D-436-59 D-436-76 1900 675522 YellowYellow[ ] D-436-60 D-436-77 779 2680102 BlueBlue[ ](2 per hole)D-436-61 D-436-78 1900 6755102 YellowYellow[ ](2 per hole) [.085] [.180] [.180] [.080] [.]

6 040] [.090] [.090] [.250] [.080] [.250]8-24 Catalog 1654025 Dimensions are in millimeters Dimensions are shown forUSA: 1-800-522-6752 South America: 55-11-3611-1514 Revised 12-04and inches unless otherwise reference purposes : 1-905-470-4425 Japan: 81-44-900-5102specified. Values in bracketsSpecifications subject Mexico: 01-800-733-8926 Singapore: America: 52-55-5-729-0425UK: 44-1793-528171 Wire-to-Wire SplicingMiniSeal High-Performance, Immersion-Resistant Crimp Splices(Continued)Table D. Butt (in-line) splicesCrimp RangeSide 1 Side 2 CMA [mm2]SealingMax. Plated Nickel PlatedMin. of WiresInsert of WiresD-436-36* D-436-82 304 151022 RedRed[ ]D-436-37* D-436-83 779 268022 BlueBlue[ ]D-436-38*D-436-84 1900 675522 YellowYellow[ ]D-436-0110D-436-85 304 151062 RedRed[ ]D-436-52 D-436-86 779 268062 BlueBlue[ ](2 per hole)D-436-53 D-436-871900 675562 YellowYellow[ ](2 per hole)D-436-0115D-436-88 304 151066 RedRed[ ](2 per hole)(2 per hole)D-436-42D-436-89779 268066 BlueBlue [ ](2 per hole)(2 per hole)D-436-43D-436-90 1900 675566 YellowYellow[ ](2 per hole)(2 per hole)*Qualified to MIL-S-81824 [.

7 085] [.110] [.170] [.085] [.110] [.170] [.093] [.093] [.160] [.160] [.093] [.160] [.093] [.093] [.093] [.093] [.093] [.093]Table E. Crimp Barrel OnlyCrimp Barrel Size RangeTypeColor CodeTin-PlatedNickel PlatedCMA [mm2] Min. - (in-line)RedD-609-06D-609-09304-1510 [ ]Butt (in-line)BlueD-609-07D-609-10779-2680 [ ]Butt (in-line)YellowD-609-08D-609-111900-6755 [ ]Stub (Parrel)RedD-609-03D-609-12304-1510 [ ]Stub (Parrel)BlueD-609-04D-609-13779-2680 [ ]Stub (Parrel)YellowD-609-05D-609-141900-6755 [ ]Table F. Sealing Sleeve OnlyPart CodeL [ ] [ ] [ ] [ ] [ ] [ ]L max. A Interconnect Products8-25 Catalog 1654025 Dimensions are in millimeters Dimensions are shown forUSA: 1-800-522-6752 South America: 55-11-3611-1514 Revised 12-04and inches unless otherwise reference purposes : 1-905-470-4425 Japan: 81-44-900-5102specified. Values in bracketsSpecifications subject Mexico: 01-800-733-8926 Singapore: America: 52-55-5-729-0425UK: 44-1793-528171 Wire-to-Wire SplicingMiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued)MaterialInsulationRadiation-c rosslinked, heat-shrinkable polyvinylidene fluoride Crimp barrelTin- or nickel-plated copper Meltable insertsMeltable thermoplasticTypical PerformanceVoltage mV at A vs mV for an equal length of wireTensile strengthExceeds strength of conductorDielectric kVTemperature rating-55 C to 150 C [-67 F to 302 F]Insulation resistance5000 megohmsSeriesMilitaryD-436 MIL-S-81824/1 for D-436-36/37/38 For proper installation ofthese devices, the correctcrimp tool (Raychem partnumber AD-1377) and aheating tool and reflectorattachment must be one of the followingRaychem heating tools isrecommended.

8 NHL1802 EnAA-400 Super Heater Refer to Raychem installa-tion procedure RCPS 200-20 for detailed instructionsand recommended will find ordering infor-mation for these tools inSection CharacteristicsSpecifications/ApprovalsI nstallatio