Raychem Electrical

Interconnect
Products
SAE AS81824 & SAE AS83519 Series II
Qualified Products Offer Robust
and Highly Reliable Wire Termination
in Demanding Environments

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS

 Electrical Interconnect
Products
Contents
Introduction 3
Typical SolderSleeve Device/Installation 4
Product Selection 5
WIRE-TO-WIRE SPLICING
Introduction 6
SolderSleeve Wire Splices 7
SolderGrip Closed End Connector Splices 13
DuraSeal Heat-Shrinkable, Environmentally-Sealed,
Nylon-Insulated Crimp Splices 19
Raychem Cold Applied Splices and Ring Terminals 21
MiniSeal High-Performance, Immersion-Resistant .
Crimp Splices 23
200˚C MiniSeal High-Performance Crimp Splices 27
INSULATED TERMINALS AND DISCONNECTS
Introduction 29
DuraSeal Heat-Shrinkable, Environmentally-Sealed,
Nylon-Insulated Crimp Terminals and Disconnects 30
SolderGrip Self-Fixturing Insulated Terminals 36
WIRE TERMINATION TO PIN/POST/TAB
Introduction 41
SolderSleeve Discrete Wire Terminators 42
SHIELD TERMINATION
Introduction 46
SolderSleeve Shield Terminators 47
Raychem S200 Shield Terminators 48
COAXIAL CABLE TERMINATION
Introduction 56
SolderSleeve Coaxial Cable Terminators 57
SolderSleeve PCB/Coaxial Cable Terminators 59
RF One Step 61
CABLE-TO-CABLE SPLICING
Introduction 67
SolderShield Shielded and Coaxial Cable Splices 68
Raychem C-Wrap Side Entry Repair Sleeve 71
Rayseal Repair Sleeve 73
D-200 Splice Kit 74
SHIELDED CONTACTS
Introduction 76
SolderTacts Shielded One-Piece Solder Contacts 77
ADDITIONAL REPAIR PRODUCTS
Matched Impedance Splices 84
Raychem Application Tooling 85

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 2

Electrical Interconnect Products

TE Connectivity’s (TE) dependable, economical wire and cable

termination products provide solutions for hundreds of wire and
cable interconnect requirements. All wire termination products
are housed inside transparent heat-shrinkable insulation sleeves,
which provide inspectability and can provide various levels of
environmental protection. Most Raychem brand termination
products incorporate a fluxed solder preform, which is essential
for a highly controlled soldering process. Other products
incorporate controlled crimping or a unique process of combining
a twist-on coil with controlled soldering to provide high-reliability
joints on the widest variety of conductor types and platings.
SolderSleeve technology ensures high-quality electrical and
mechanical performance time after time. Premeasured solder
and flux create repeatable, 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, strain-relieved, protected solder connection. Heat-
shrinkable tubing provides the benefits of insulation, strain relief,
and protection for our controlled crimp products. Many Raychem
brand interconnect products have earned UL recognition or
SAE AS83159 Mil-Spec approval.
Many SolderSleeve and related devices are made from
polyvinylidene fluoride tubings that meet the requirements of
AMS-DTL-23053/8 (formerly MIL-DTL-23053/8).
Raychem brand interconnect devices combine high-strength
materials with innovative design for consistent, long-life
performance. And because the insulation sleeve is transparent,
operators can easily inspect the connection.
TE 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.
TE interconnect products are designed for many applications,
from simple splices to terminators for sophisticated electronic
systems, either sealed or unsealed, and for high- or low-
temperature environments.

TE Components . . . TE Technology . . . TE Know-how . . .

AMP | AGASTAT | CII | HARTMAN | KILOVAC | MICRODOT | NANONICS | POLAMCO | Raychem
SEACON | Rochester | DEUTSCH
Empower Engineers to Solve Problems, Moving the World Forward.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 3

Electrical Interconnect Products

Product Selection

Transparent, heat-shrinkable Thermoplastic sealing ring

Typical SolderSleeve thermoplastic sleeve
Device (illustration
of shield terminator
concept) 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 Sealing rings melt to provide
strain relief environmental protection

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 4

Electrical Interconnect Products

Product Selection

Max. Operating Connection Page

Application Type Product Description Series
Temp. Type Number
125°C [257°F] Solder SolderSleeve wire splices B-155-900X 7
CWT

Wire-to-wire splicing 150°C [302°F] Solder SolderSleeve wire splices D-110, D-1744 7
125°C [257°F] Coil and solder SolderGrip closed end
connector splices (stub) SGRP Series X-58, SGRS 13

125°C [257°F] Crimp DuraSeal crimp splices D-406 19

125°C [257°F] Crimp Cold applied splices D-436 22
150°C [302°F] Crimp MiniSeal crimp splices D-436 (M81824) 24
200°C [392°F] Crimp MiniSeal crimp splices D-200 28
125°C [257°F] Crimp DuraSeal crimp terminals
Terminals and and disconnects B-106 31
disconnects
150°C [302°F] Coil and solder SolderGrip terminals SGRT 36
125°C [257°F] Solder SolderSleeve wire terminators B-155-15XX 43
Wire termination
150°C [302°F] Solder SolderSleeve wire terminators D-129, D-141,
to pin/post/tab
D-71X 43
125°C [257°F] Solder SolderSleeve shield terminators B-155-X 47
150°C [302°F] Solder SolderSleeve shield terminators S01, S02,
Shield termination 47
M83519, SO63
175°C [347°F] Solder SolderSleeve shield terminators SO96, SO175 47
200°C [392°F] Solder SolderSleeve shield terminators S200 47
125°C [257°F] Solder SolderSleeve coaxial cable terminators B-155, D-184 57
Coaxial cable
150°C [302°F] Solder SolderSleeve coaxial cable terminators B-02X, B-04X, D-181 57
termination
150°C [302°F] Solder SolderSleeve PCB/coaxial cable terminators D-607, B-046 59
135°C [275°F] Solder RF one-step BNC/TNC connectors RBD, RTD 61
Cable-to-cable splicing 150°C [302°F] Solder/Crimp SolderShield cable splices D-150 68
150°C [302°F] Solder/Crimp C-Wrap repair sleeve D-150 71
260°C [500°F] Solder/Crimp Rayseal repair sleeve D-260 73
200°C [392°F] Solder/Crimp D-200 flexible splice D-200 75
Shielded contacts 150°C [302°F] Solder SolderTacts shielded contacts D-602 80

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 5

 Wire-to-Wire
Splicing
Introduction
TE offers many products for wire-to-wire splicing:
SolderSleeve splicing devices; SolderGrip splices; and
DuraSeal and MiniSeal crimp splices.
Like all TE interconnect products, the wire-to-wire splicing
devices are rugged and reliable, yet easy to install.
Designed for applications with temperatures up to 200°C
[302°F], products in this section include:
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.
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 high-
performance crimp splices, which substantially reduce
wire bundle size and weight, are QPL-listed to the
SAE AS81824 specification, and are required by the
MIL-W-5088 specification.
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.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 6

Electrical Interconnect Products

SolderSleeve Wire Splices

Product Selection Process
From the Product Options table below, 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.
RUGGED 3. S
 elect part numbers from the appropriate table:
• Transparent polyvinylidene fluoride • F
 or B-155 and CWT series (low temperature): Use Table A on
or polyolefin sleeve provides page 8.
encapsulation, inspectability, strain
relief, and insulation • For D-110 series (splashproof): Use Table B on page 9.
• With one or two wires per end, • F
 or D-1744 series (immersion sealed): Use Table C on
the NAS 1744 splices meet 75,000 page 10.
ft [22,000 m] altitude immersion
requirement
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
CAPABLE CMA or mm2 sizes):
• Prefluxed solder preform provides a 1. T
 urn to “CMA/mm2 Calculation” on page 11 and use
controlled soldering process the workspace there to calculate the total cross section to
be spliced.
• UL and CUL recognized
(CWT + D-110) 2. U
 se Table E on page 12 to select the sleeve recommended for
See page 12 specifications that cross section.
and approvals
Notes:
EASY TO USE  hile all combinations listed will provide satisfactory solder joints, the degree
W
of strain relief obtained depends on the outer diameter of the wires being joined.
• One-piece design makes installation Refer to Table E for the recommended size ranges for the sleeves.
easy and lowers the installed cost
Wires 16 AWG (1.21 mm2) and larger, and wires having more than 19 strands,
• Thermochromic temperature should be pretinned prior to splicing, to obtain the optimum solder joint quality.
indicator in the NAS splices facilitates
Part selection for wires 26 AWG (0.15 mm2) and smaller is covered on page 11.
termination and inspection

Product Options
Minimum Wire Maximum Operating Intended Application
Product Series
Temperature Rating Temperature Environment
B-155 85°C [185°F] 125°C [257°F] (RoHS) Splashproof
CWT 85°C [185°F] 125°C [257°F] Splashproof
D-110 125°C [257°F] 150°C [302°F] Splashproof
D-1744 (NAS 1744) 125°C [257°F] 150°C [302°F] Immersion sealed
Note: Cadmium-free option (B-152 series) is available for operating temperature of 125˚C [257˚F].
Consult TE for details.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 7

Electrical Interconnect Products

Table
A: B-155 Series Selection
Side A: Side B: Size and Number of Conductors
Size and 26 AWG 24 AWG 22 AWG 20 AWG
Number of
Conductors 1 2 1 2 1 2 1 2

26 AWG 1 B-155-9001 B-155-9001 B-155-9001 B-155-9001 B-155-9001 B-155-9002 B-155-9002 B-155-9002
2 B-155-9001 B-1559001 B-155-9001 B-155-9002 B-155-9001 B-155-9002 B-155-9002 B-155-9002
24 AWG 1 B-155-9001 B-155-9001 B-155-9001 B-155-9001 B-155-9001 B-155-9002 B-155-9002 B-155-9002
2 B-155-9001 B-155-9002 B-155-9001 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002
22 AWG 1 B-155-9001 B-155-9001 B-155-9001 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002
2 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9003
20 AWG 1 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9003
2 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9003 B-155-9003 B-155-9003
18 AWG 1 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9003
2 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003
16 AWG 1 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9003 B-155-9003 B-155-9003
2 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003
14 AWG 1 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-1559003 B-155-9003 B-155-9003
2 B-155-9004 B-155-9004 B-155-9004 B-155-9004 B-155-9004 B-155-9004 B-155-9004 B-155-9004
12 AWG 1 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9004
2 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-1559005
10 AWG 1 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005
Side A: Side B: Size and Number of Conductors
Size and 18 AWG 16 AWG 14 AWG 12 AWG 10 AWG
Number of
Conductors 1 2 1 2 1 2 1 2 1

26 AWG 1 B-155-9002 B-155-9003 B-155-9002 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9005 B-155-9005
2 B-155-9002 B-155-9003 B-155-9002 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9005 B-155-9005
24 AWG 1 B-155-9002 B-155-9003 B-155-9002 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9005 B-155-9005
2 B-155-9002 B-155-9003 B-155-9002 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9005 B-155-9005
22 AWG 1 B-155-9002 B-155-9003 B-155-9002 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9005 B-155-9005
2 B-155-9002 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9005 B-155-9005
20 AWG 1 B-155-9002 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9005 B-155-9005
2 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9004 B-155-9004 B-155-9005 B-155-9005
18 AWG 1 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9004 B-155-9004 B-155-9005 B-155-9005
2 B-155-9003 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9004 B-155-9004 B-155-9005 B-155-9005
16 AWG 1 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9004 B-155-9004 B-155-9005 B-155-9005
2 B-155-9003 B-155-9004 B-155-9003 B-155-9004 B-155-9004 B-155-9005 B-155-9004 B-155-9005 B-155-9005
14 AWG 1 B-155-9003 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9004 B-155-9004 B-155-9005 B-155-9005
2 B-155-9004 B-155-9004 B-155-9004 B-155-9005 B-155-9004 B-155-9005 B-155-9005 B-155-9005 B-155-9005
12 AWG 1 B-155-9004 B-155-9004 B-155-9004 B-155-9004 B-155-9004 B-155-9005 B-155-9004 B-155-9005 B-155-9005
2 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005
10 AWG 1 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005

Table
A: CWT Series Selection
Side A: Side B: Size and Number of Conductors
Size and 26 AWG 24 AWG 22 AWG 20 AWG
Number of
Conductors 1 2 1 2 1 2 1 2

26 AWG 1 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002
2 CWT-9001 CWT9001 CWT-9001 CWT-9002 CWT-9001 CWT-9002 CWT-9002 CWT-9002
24 AWG 1 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002
2 CWT-9001 CWT-9002 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002
22 AWG 1 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002
2 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003
20 AWG 1 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003
2 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9003 CWT-9003
18 AWG 1 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003
2 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003
16 AWG 1 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9003 CWT-9003
2 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003
14 AWG 1 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT9003 CWT-9003 CWT-9003
2 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004
12 AWG 1 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004
2 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT9005
10 AWG 1 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005
Side A: Side B: Size and Number of Conductors
Size and 18 AWG 16 AWG 14 AWG 12 AWG 10 AWG
Number of
Conductors 1 2 1 2 1 2 1 2 1

26 AWG
1 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
2 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
24 AWG
1 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
2 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
22 AWG
1 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
2 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
20 AWG
1 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
2 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
18 AWG
1 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
2 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
16 AWG
1 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
2 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005
14 AWG
1 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
2 CWT-9004 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005 CWT-9005 CWT-9005
12 AWG
1 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005
2 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005
10 AWG
1 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 B-155-9005

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 8

Electrical Interconnect Products

Table
B: D-110 Series Selection
Side A: Side B: Size and Number of Conductors
Size and 26 AWG 24 AWG 22 AWG 20 AWG
Number of
Conductors 1 2 1 2 1 2 1 2
1 D-110-35 D-110-35 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41
26 AWG
2 D-110-35 D-110-35 D-110-35 D-110-41 D-110-35 D-110-41 D-110-41 D-110-41
1 D-110-35 D-110-35 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41
24 AWG
2 D-110-35 D-110-41 D-110-35 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41
1 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41
22 AWG
2 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181
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
20 AWG
2 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181 D-110-0181 D-110-0181
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
18 AWG
2 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0101
1 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181 D-110-0181 D-110-0181
16 AWG
2 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0101
1 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0101
14 AWG
2 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090
1 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101
12 AWG
2 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090
10 AWG 1 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0083 D-110-0083 D-110-0083
Side A: Side B: Size and Number of Conductors
Size and 18 AWG 16 AWG 14 AWG 12 AWG 10 AWG
Number of
Conductors 1 2 1 2 1 2 1 2 1
1 D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
26 AWG
2 D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
1 D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
24 AWG
2 D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
1 D-110-41 D-110-0181 D-110-41 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
22 AWG
2 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
1 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0090
20 AWG
2 D-110-0181 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
1 D-110-0181 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
18 AWG
2 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0090 D-110-0090 D-110-0083
1 D-110-0181 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
16 AWG
2 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090 D-110-0083 D-110-0083
1 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0090 D-110-0090 D-110-0083
14 AWG
2 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0083 D-110-0083
1 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0083 D-110-0083
12 AWG
2 D-110-0090 D-110-0090 D-110-0090 D-110-0083 D-110-0090 D-110-0083 D-110-0083 D-110-0083 D-110-0083
10 AWG 1 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083

Fine Wire Splices Part Inside Diameter

26 AWG (0.15 mm2) No. As Supplied* Fully Recovered** Length***
D-110-0071 0.9 [0.035] 0.6 [0.025] 4.7 [0.185]
and Smaller
D-110-0213 0.9 [0.035] 0.6 [0.025] 4.2 [0.165]
D-110-0214 0.6 [0.025] 0.3 [0.013] 6.3 [0.250]
D-110-0217 1.0 [0.040] 0.6 [0.025) 9.1 [0.360]
D-110-40 0.6 [0.025] 0.5 [0.021] 5.1 [0.200]
Note: Micro SolderSleeve terminations are used for splicing wires smaller than 26 AWG [0.15 mm2].
*Minimum. Wire insulation must be smaller than this.
**Maximum. Wire insulation and combined conductor diameters must be greater than this.
***Nominal. Wire strip length must be approximately one-half of this.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 9

Electrical Interconnect Products

Table
C: D-1744 Series Selection
Side A: Side B: Size and Number of Conductors
Size and 26 AWG 24 AWG 22 AWG 20 AWG
Number of
Conductors 1 2 1 2 1 2 1 2
1 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02
26 AWG
2 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02
1 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02
24 AWG
2 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-02 D-1744-02
1 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02
22 AWG
2 D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02
1 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-02
20 AWG
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
1 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03
18 AWG
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03
1 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03
16 AWG
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03
1 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03
14 AWG
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
1 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04
12 AWG
2 D-1744-04 D-1744-04 D-1744-04 — D-1744-04 — — —
Side A: Side B: Size and Number of Conductors
Size and 18 AWG 16 AWG 14 AWG 12 AWG
Number of
1 2 1 2 1 2 1 2
Conductors
1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
26 AWG
2 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
24 AWG
2 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 —
1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
22 AWG
2 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 —
1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-04 —
20 AWG
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04 —
1 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 —
18 AWG
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 —
1 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 —
16 AWG
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04 —
1 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 —
14 AWG
2 D-1744-03 D-1744-04 D-1744-04 D-1744-04 D-1744-04 — — —
12 AWG 1 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 — D-1744-04 —

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 10

Electrical Interconnect Products

CMA/mm2 Calculation To calculate the total 3. A

 dd together the values
circular mil or mm2 area listed in the workspace
of the conductors to be below to obtain the
terminated in a single total area.
splice, follow these steps: 4. F
 rom Table E on the next
1. C
 hoose either CMA or page, select the part
mm2 as your unit of number recommended
measure for selection for the total CMA or mm2
purposes and continue you have calculated.
to use it for all your 5. R
 efer to the examples on
selection criteria. this page for further
2. In the workspace below, clarification.
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 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]
2.50 [.100] 3.00 [.120] 2.25 [.090]

�
16 AWG (CMA 2426) 22 AWG (CMA 754) 1.50 [.060]
[1.21 mm2] [0.38 mm2] 2 at 22 AWG (CMA 1508) 18 AWG (CMA 1900)
[0.38 mm2] [0.24 mm2]

Total CMA = 3180 Total CMA = 3408

Total mm2 = 1.59 Total mm2 = 1.71
Correct part number selection from Table E Correct part number selection from Table E
(based on CMA/mm2 and nominal jacket wire OD) (based on CMA/mm2 and nominal jacket wire OD)
= B-155-9002, CWT-9002, D-110-41 or D-1744-02. = B-155-9003, CWT-9003, D-110-0181 or D-1744-03.

Table D. CMA of Typical AWG Conductors

AWG 28 26 24 22 20 18 16 14 12
CMA 177 304 475 754 1216 1900 2426 3831 5874
mm2 0.09 0.15 0.23 0.38 0.62 0.96 1.23 1.44 2.97

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 11

Electrical Interconnect Products

Installation For proper installation of Refer to TE installation

Requirements these devices the correct procedure RPIP-850-00
heating tool and reflector for D-1744 Series
attachment must be used. and RPIP- 824-00 for
Any one of the following B-155 Series.
TE heating tools is
recommended:
n HL1920E/HL2020E
n IR-1759 MiniRay
n AA-400 Super Heater
n CV-1981

Table E: CMA mm 2

Product Wire Jacket OD Combined Total Combined Total

Multiwire Splice Series
Min. Max. Min. Max. Min. Max.
Selection B-155-9001 0.4 [0.015] 1.7 [0.066] 450 1500 0.3 0.8
B-155-9002 1.3 [0.05] 2.7 [0.106] 1500 4000 0.8 2.0
B-155-9003 1.8 [0.07] 4.5 [0.18] 4000 7800 2.0 4.0
B-155-9004 2.8 [0.11] 6.0 [0.236] 7800 12000 4.0 6.0
B-155-9005 3.2 [0.125] 7.0 [0.275] 12000 19000 6.0 10.0
D-1744-01 0.50 [0.020] 1.90 [0.075] 350 2000 – –
D-1744-02 0.80 [0.031] 2.80 [0.110] 2000 4000 – –
D-1744-03 1.30 [0.050] 4.57 [0.180] 4000 10000 – –
D-1744-04 2.00 [0.080] 7.11 [0.280] 10000 13000 – –
D-110-35 0.51 [0.020] 1.78 [0.070] 500 1500 – –
D-110-41 1.27 [0.050] 2.54 [1.00] 1200 3500 – –
D-110-0181 1.9 [0.075] 4.5 [0.177] 3600 6000 – –
D-110-0101 2.41 [0.095] 4.32 [0.17] 4800 9000 – –
D-110-0090 3.56 [0.140] 7.11 [0.28] 8500 16200 – –
D-110-0083 4.0 [0.160] 8.76 [0.345] 16200 25000 – –

Product Material
Characteristics Insulation (D-110, D-1744) Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Insulation (B-155) Radiation-crosslinked, heat-shrinkable polyolefin
Solder and flux (D-110, D-1744) Solder: Sn63 Pb37 Flux: ROL1 per ANSI-J-004 (RMA flux)
Solder and flux (B-155) Solder: Sn42Bi58 Flux: ROM1 per ANSI-J-004 (RA Flux)
Solder and flux (CWT) Solder: Sn50 Pb32 Cd18 Flux: ROM1 per ASNI-J-004 (RA flux)
Meltable inserts (B-155, D-1744) Meltable thermoplastic
Typical Performance
Voltage drop 2.0 mV
Tensile strength Exceeds strength of conductor
Dielectric strength 2.0 kV
Temperature rating (B-155) -55°C to +125°C [-67°F to +257°F]
Temperature rating (D-110, D-1744) -55°C to +150°C [-67°F to +302°F]
Insulation resistance 1000 megohms

Specifications/ Series Agency TE

Approvals B-155 n/a RT-1404
CWT UL E87681 D-5023
D-110 UL E87681 RT-1404
D-1744 NAS-1744 RT-1404

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 12

Electrical Interconnect Products

SolderGrip Closed End Connector Splices

Applications
SolderGrip heat-shrinkable solder-type closed-end connectors are
designed for electrical termination of multiple-wire combinations.
They provide a reliable alternative to crimping, welding, or
conventional twist-on-style closed-end connectors.
Their unique combination of wire fixturing and controlled-
soldering technology 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
RUGGED with a prefluxed solder band.
• Sealed for immersion (SGRS-X-58, This innovation design allows SolderGrip products to reliably
SGRS)
terminate as many as 10 wires of different sizes and types in a
• Excellent strain relief single device.
The capability of SolderGrip terminators encompasses single or
EASY TO USE
multi-stranded, bare or tinned copper wires with low- or high-
• Simple installation temperature insulation.

CAPABLE The termination is environmentally protected and strain relieved.

• Soldered connection
SolderGrip splice terminators are color-coded for easy
identification.
• Electrical insulation

Product Options
Product Series Environmental Protection Max. Operating Temp.
SGRP Splashproof 125°C [257°F]
SGRS-X-58 Sealed 125˚C [257˚F]
SGRS Sealed 125°C [257°F]

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 13

Electrical Interconnect Products

Product Selection 1. From the Product Options Example: For connecting 4. Verify that the wire bundle
Process table on the previous a bundle with one 12 (with wire insulation) does
page, select the product AWG wire (1 #12) and not exceed the maximum
series appropriate for two 14 AWG wires diameter allowed for the
your application. (+2 #14), you need an connector you selected.
2. Determine the wire SGRP-3 connector. For Simply check the bundle’s
combination (number of sealed parts, select the diameter against the
wires and size) of the wire SGRS series. maximum diameter that
bundle you wish to splice. *If the wire combination is not Table A (below) lists for
listed in Table C, use the CMA that part.
3. Use Table C (page 16) (mm2) method of determining
to select the correct wire bundle size (see “CMA/ 5. V
 erify that the total
connector for AWG wire mm2 Calculation” on page 15). amperage to be applied
combinations.* For
Using Table B (page 15, does not exceed the
select the smallest size
mm2 wire combinations connector that will fit your total
maximum amp rating for
use Table A to select a wire CMA (mm2) value. the part.
SolderGrip part number.

Insulated Closed-End Connectors (SGRP series) Insulated and Sealed Closed-End Connectors (SGRS series)

L L

ØA ØA

Sealing insert

Table A - Product
Dimensions and Part
Number Descriptions
Product Dimensions (Min.) Product Dimensions (Min.)
Part Color Part Color
Wire Range (Min.-Max.) Wire Range (Min.-Max.)
No. Code L ØA No. Code L ØA
CMA/mm2 CMA/mm2
1.370 .120 1400 - 4800 1.370 0.130 1400 - 4800
SGRP-1 Green
[34.8] [2.9] [0.7 - 2.4] SGRS-1 Green [34.8] [3.4] [0.7 - 2.4]
1.350 .150 4000 - 8000 1.350 0.190 4000 - 8000
SGRP-2
Red [34.2] [3.7] [2.0 - 4.0] SGRS-2 Red [34.2] [4.8] [2.0 - 4.0]
1.610 .200 7000 - 16000 1.650 0.290 7000 - 16000
SGRP-3 Blue
[41.0] [5.1] [3.5 - 8.0] SGRS-3 Blue [42.0] [7.3] [3.5 - 8.0]
1.650 .270 15000 - 24000 1.630 0.360 15000 - 24000
SGRP-4
Yellow [42.0] [6.8] [7.5 - 12.0] SGRS-4 Yellow [41.5] [9.1] [7.5 - 12.0]

Product Dimensions (Min.)

Part Color
Wire Range (Min.-Max.)
No. Code L ØA
CMA/mm2
1.370 0.130 1400 - 4800
SGRS-1-58 Green
[34.8] [3.4] [0.7 - 2.4]
1.350 0.190 4000 - 8000
SGRS-2-58 Red
[34.2] [4.8] [2.0 - 4.0]
1.650 0.290 7000 - 16000
SGRS-3-58 Blue
[42.0] [7.3] [3.5 - 8.0]
1.630 0.360 15000 - 24000
SGRS-4-58 Yellow
[41.5] [9.1] [7.5 - 12.0]

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 14

Electrical Interconnect Products

CMA/mm2 Calculation To calculate the total 2. In the workspace below,

circular mil or mm area
2
list the CMA or mm2
of the wire bundle to for each conductor in
be terminated, follow the bundle. (Table B
these steps: provides the CMA of
1. Choose either CMA typical conductors.)
or mm2 as your unit of 3. Add together the values
measure for selection listed in the workspace
purposes and continue below to obtain the
to use it for all your total area.
selection criteria. (Both 4. Use Table A to select the
measures provide the smallest terminator that will
same results.) fit the total CMA (mm2).

Wire Number CMA mm
2
1
2
3
4
5
6
7
8
9
10 Solder Grip Part No.
Total

CMA/mm2 Example

22 AWG/.38 OD Bundle Insulation

CMA 754

22 AWG/.38
CMA 754

18 AWG/.95 Conductor
CMA 1900

16 AWG/1.21
CMA 2426

Total CMA = 5834 Bundle diameter must not exceed 6.0

Total mm2 = 2.92 mm (0.24 in) for SGRP-2 or 0.18 mm
Correct part number (based on CMA of 5834 (4.5 in) for SGRS-2 or SGRS-2-58
or mm2 of 2.92): SGRP-2, SGRS-2 or SGRS-2-58

Table B. CMA AWG 30 28 26 24 22 20 18 16 14 12 10 8

CMA 112 177 304 475 754 1216 1900 2426 3831 5874 9354 16983
of Typical Copper
mm2 0.05 0.09 0.15 0.24 0.38 0.61 0.95 1.21 1.92 2.94 4.74 8.61
Conductors

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 15

Electrical Interconnect Products

Table
C. SolderGrip Wire Combinations
Wire Splash- Wire Splash- Wire Splash-
Sealed Sealed Sealed
Combinations proof Combinations proof Combinations proof
1 # 8 + 1 # 12 SGRP-4 SGRS-4-58 1 # 14 + 3 # 20 SGRP-2 SGRS-2-58 2 # 16 + 1 # 18 + 3 # 20 SGRP-3 SGRS-3-58
1 # 8 + 1 # 16 SGRP-4 SGRS-4-58 1 # 14 + 4 # 20 SGRP-3 SGRS-3-58 2 # 16 + 1 # 18 + 2 # 20 SGRP-3 SGRS-3-58
2 # 8 + 2 # 16 SGRP-4 SGRS-4-58 1 # 14 + 1 # 18 SGRP-2 SGRS-2-58 2 # 16 + 1 # 18 + 1 # 20 SGRP-2 SGRS-2-58
1 # 8 + 1 # 14 SGRP-4 SGRS-4-58 1 # 14 + 1 # 18 + 1 # 20 SGRP-2 SGRS-2-58 2 # 16 + 1 # 18 SGRP-2 SGRS-2-58
1 # 8 + 1 # 14 + 1 # 16 SGRP-4 SGRS-4-58 1 # 14 + 2 # 18 SGRP-2 SGRS-2-58 2 # 16 + 4 # 20 SGRP-3 SGRS-3-58
1 # 10 + 1 # 18 SGRP-3 SGRS-3-58 1 # 14 + 3 # 18 SGRP-3 SGRS-3-58 2 # 16 + 3 # 20 SGRP-3 SGRS-3-58
1 # 10 + 2 # 18 SGRP-3 SGRS-3-58 1 # 14 + 4 # 18 SGRP-3 SGRS-3-58 2 # 16 + 2 # 20 SGRP-2 SGRS-2-58
1 # 10 + 3 # 18 SGRP-3 SGRS-3-58 1 # 14 + 5 # 18 SGRP-3 SGRS-3-58 2 # 16 + 1 # 20 SGRP-2 SGRS-2-58
1 # 10 + 1 # 16 SGRP-3 SGRS-3-58 1 # 14 + 1 # 16 SGRP-2 SGRS-3-58 2 # 16 SGRP-2 SGRS-2-58
1 # 10 + 1 # 16 + 1 # 18 SGRP-3 SGRS-3-58 1 # 14 + 1 # 16 + 1 # 20 SGRP-2 SGRS-2-58 1 # 16 + 5 # 18 SGRP-3 SGRS-3-58
1 # 10 + 1 # 16 + 2 # 18 SGRP-3 SGRS-3-58 1 # 14 + 1 # 16 + 1 # 18 SGRP-3 SGRS-3-58 1 # 16 + 4 # 18 + 1 # 20 SGRP-3 SGRS-3-58
1 # 10 + 2 # 16 SGRP-3 SGRS-3-58 1 # 14 + 1 # 16 + 2 # 18 SGRP-3 SGRS-3-58 1 # 16 + 4 # 18 SGRP-3 SGRS-3-58
1 # 10 + 3 # 16 SGRP-4 SGRS-4-58 1 # 14 + 1 # 16 + 3 # 18 SGRP-3 SGRS-3-58 1 # 16 + 3 # 18 + 2 # 20 SGRP-3 SGRS-3-58
1 # 10 + 4 # 16 SGRP-4 SGRS-4-58 1 # 14 + 1 # 16 + 4 # 18 SGRP-3 SGRS-3-58 1 # 16 + 3 # 18 + 1 # 20 SGRP-3 SGRS-3-58
1 # 10 + 5 # 16 SGRP-4 SGRS-4-58 1 # 14 + 2 # 16 SGRP-3 SGRS-3-58 1 # 16 + 2 # 18 + 3 # 20 SGRP-3 SGRS-3-58
1 # 10 + 1 # 14 SGRP-3 SGRS-3-58 1 # 14 + 2 # 16 + 1 # 18 SGRP-3 SGRS-3-58 1 # 16 + 2 # 18 + 1 # 20 SGRP-2 SGRS-2 -58
1 # 10 + 1 # 14 + 1 # 18 SGRP-3 SGRS-3-58 1 # 14 + 2 # 16 + 2 # 18 SGRP-3 SGRS-3-58 1 # 16 + 2 # 18 SGRP-2 SGRS-2-58
1 # 10 + 1 # 14 + 1 # 16 SGRP-3 SGRS-3-58 1 # 14 + 2 # 16 + 3 # 18 SGRP-3 SGRS-3-58 1 # 16 + 1 # 18 + 4 # 20 SGRP-3 SGRS-3-58
1 # 10 + 1 # 14 + 2 # 16 SGRP-3 SGRS-3-58 1 # 14 + 3 # 16 SGRP-3 SGRS-3-58 1 # 16 + 1 # 18 + 3 # 20 SGRP-2 SGRS-2-58
1 # 10 + 1 # 14 + 3 # 16 SGRP-4 SGRS-4-58 1 # 14 + 3 # 16 + 1 # 18 SGRP-3 SGRS-3-58 1 # 16 + 1 # 18 + 2 # 20 SGRP-2 SGRS-2 -58
1 # 10 + 2 # 14 SGRP-4 SGRS-4-58 1 # 14 + 3 # 16 + 2 # 18 SGRP-3 SGRS-3-58 1 # 16 + 1 # 18 + 1 # 20 SGRP-2 SGRS-2-58
1 # 10 + 3 # 14 SGRP-4 SGRS-4-58 1 # 14 + 4 # 16 SGRP-3 SGRS-3-58 1 # 16 + 1 # 18 SGRP-1 SGRS-1-58
1 # 10 + 1 # 12 SGRP-3 SGRS-3-58 1 # 14 + 4 # 16 + 1 # 18 SGRP-3 SGRS-3-58 1 # 16 + 4 # 20 SGRP-2 SGRS-2-58
1 # 10 + 1 # 12 + 1 # 14 SGRP-4 SGRS-4-58 1 # 14 + 5 # 16 SGRP-3 SGRS-3-58 1 # 16 + 3 # 20 SGRP-2 SGRS-2-58
1 # 10 + 2 # 12 SGRP-4 SGRS-4-58 2 # 14 SGRP-2 SGRS-2 -58 1 # 16 + 1 # 20 + 1 # 22 SGRP-1 SGRS-1-58
2 # 10 SGRP-4 SGRS-4-58 2 # 14 + 1 # 16 SGRP-3 SGRS-3-58 1 # 16 + 1 # 20 SGRP-1 SGRS-1-58
2 # 10 + 1 # 16 SGRP-4 SGRS-4-58 2 # 14 + 1 # 16 SGRP-3 SGRS-3-58 1 # 16 + 3 # 22 SGRP-1 SGRS-1-58
1 # 12 + 1 # 18 SGRP-2 SGRS-2-58 2 # 14 + 1 # 16 SGRP-3 SGRS-3-58 1 # 16 + 2 # 22 SGRP-1 SGRS-1-58
1 # 12 + 2 # 18 SGRP-3 SGRS-3-58 2 # 14 + 1 # 16 SGRP-3 SGRS-3-58 1 # 16 + 1 # 22 SGRP-1 SGRS-1-58
1 # 12 + 3 # 18 SGRP-3 SGRS-3-58 2 # 14 + 2 # 16 SGRP-3 SGRS-3-58 1 # 18 + 1 # 22 SGRP-1 SGRS-1-58
1 # 12 + 4 # 18 SGRP-3 SGRS-3-58 2 # 14 + 2 # 16 SGRP-3 SGRS-3-58 1 # 18 + 2 # 22 SGRP-1 SGRS-1-58
1 # 12 + 5 # 18 SGRP-3 SGRS-3-58 2 # 14 + 3 # 16 SGRP-3 SGRS-3-58 1 # 18 + 3 # 22 SGRP-1 SGRS-1-58
1 # 12 + 1 # 16 SGRP-3 SGRS-3-58 2 # 14 + 4 # 16 SGRP-4 SGRS-4-58 1 # 18 + 1 # 20 SGRP-1 SGRS-1-58
1 # 12 + 1 # 16 + 1 # 18 SGRP-3 SGRS-3-58 3 # 14 SGRP-3 SGRS-3-58 1 # 18 + 1 # 20 + 1 # 22 SGRP-1 SGRS-1-58
1 # 12 + 1 # 16 + 2 # 18 SGRP-3 SGRS-3-58 3 # 14 + 1 # 16 SGRP-3 SGRS-3-58 1 # 18 + 1 # 20 + 2 # 22 SGRP-1 SGRS-1-58
1 # 12 + 1 # 16 + 3 # 18 SGRP-3 SGRS-3-58 3 # 14 + 2 # 16 SGRP-4 SGRS-4-58 1 # 18 + 2 # 20 SGRP-1 SGRS-1-58
1 # 12 + 1 # 16 + 4 # 18 SGRP-4 SGRS-4-58 3 # 14 + 3 # 16 SGRP-4 SGRS-4-58 1 # 18 + 3 # 20 SGRP-2 SGRS-2-58
1 # 12 + 2 # 16 SGRP-3 SGRS-3-58 4 # 14 SGRP-3 SGRS-3-58 1 # 18 + 4 # 20 SGRP-2 SGRS-2-58

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 16

Electrical Interconnect Products

Table
C. SolderGrip Wire Combinations (Continued)
Wire Splash- Wire Splash- Wire Splash-
Sealed Sealed Sealed
Combinations proof Combinations proof Combinations proof
1 # 12 + 2 # 16 + 1 # 18 SGRP-3 SGRS-3-58 4 # 14 + 1 # 16 SGRP-4 SGRS-4-58 1 # 18 + 5 # 20 SGRP-2 SGRS-2-58
1 # 12 + 2 # 16 + 2 # 18 SGRP-3 SGRS-3-58 4 # 14 + 2 # 16 SGRP-4 SGRS-4-58 2 # 18 SGRP-1 SGRS-1-58
1 # 12 + 3 # 16 SGRP-3 SGRS-3-58 5 # 14 SGRP-4 SGRS-4-58 2 # 18 + 1 # 22 SGRP-1 SGRS-1-58
1 # 12 + 4 # 16 SGRP-3 SGRS-3-58 5 # 14 + 1 # 16 SGRP-4 SGRS-4-58 2 # 18 + 1 # 20 SGRP-2 SGRS-2-58
1 # 12 + 5 # 16 SGRP-4 SGRS-4-58 1 # 16 + 3 # 18 SGRP-3 SGRS-3-58 2 # 18 + 2 # 20 SGRP-2 SGRS-2-58
1 # 12 + 1 # 14 + 1 # 18 SGRP-3 SGRS-3-58 1 # 16 + 2 # 18 + 2 # 20 SGRP-3 SGRS-3-58 2 # 18 + 3 # 20 SGRP-2 SGRS-2-58
1 # 12 + 1 # 14 + 2 # 18 SGRP-3 SGRS-3-58 1 # 16 + 5 # 20 SGRP-3 SGRS-3-58 2 # 18 + 4 # 20 SGRP-3 SGRS-3-58
1 # 12 + 1 # 14 + 3 # 18 SGRP-3 SGRS-3-58 1 # 16 + 2 # 20 SGRP-2 SGRS-2-58 3 # 18 SGRP-2 SGRS-2-58
1 # 12 + 1 # 14 + 1 # 16 SGRP-3 SGRS-3-58 6 # 16 SGRP-3 SGRS-3-58 3 # 18 + 1 # 20 SGRP-2 SGRS-2-58
1 # 12 + 1 # 14 + 2 # 16 SGRP-3 SGRS-3-58 5 # 16 + 1 # 18 SGRP-3 SGRS-3-58 3 # 18 + 2 # 20 SGRP-3 SGRS-3-58
1 # 12 + 1 # 14 + 3 # 16 SGRP-4 SGRS-4-58 5 # 16 + 1 # 20 SGRP-3 SGRS-3-58 3 # 18 + 3 # 20 SGRP-3 SGRS-3-58
1 # 12 + 1 # 14 + 4 # 16 SGRP-4 SGRS-4-58 5 # 16 SGRP-3 SGRS-3-58 4 # 18 SGRP-2 SGRS-2-58
1 # 12 + 2 # 14 SGRP-3 SGRS-3-58 4 # 16 + 2 # 18 SGRP-3 SGRS-3-58 4 # 18 + 1 # 20 SGRP-3 SGRS-3-58
1 # 12 + 2 # 14 + 1 # 18 SGRP-3 SGRS-3-58 4 # 16 + 1 # 18 + 1 # 20 SGRP-3 SGRS-3-58 4 # 18 + 2 # 20 SGRP-3 SGRS-3-58
1 # 12 + 2 # 14 + 1 # 16 SGRP-4 SGRS-4-58 4 # 16 + 1 # 18 SGRP-3 SGRS-3-58 5 # 18 SGRP-3 SGRS-3-58
1 # 12 + 2 # 14 + 2 # 16 SGRP-4 SGRS-4-58 4 # 16 + 2 # 20 SGRP-3 SGRS-3-58 5 # 18 + 1 # 20 SGRP-3 SGRS-3-58
1 # 12 + 2 # 14 + 3 # 16 SGRP-4 SGRS-4-58 4 # 16 + 1 # 20 SGRP-3 SGRS-3-58 6 # 18 SGRP-3 SGRS-3-58
1 # 12 + 3 # 14 SGRP-4 SGRS-4-58 4 # 16 SGRP-3 SGRS-3-58 1 # 20 + 1 # 22 SGRP-1 SGRS-1-58
1 # 12 + 3 # 14 + 1 # 16 SGRP-4 SGRS-4-58 3 # 16 + 3 # 18 SGRP-3 SGRS-3-58 1 # 20 + 2 # 22 SGRP-1 SGRS-1-58
1 # 12 + 4 # 14 SGRP-4 SGRS-4-58 3 # 16 + 2 # 18 + 1 # 20 SGRP-3 SGRS-3-58 1 # 20 + 3 # 22 SGRP-1 SGRS-1-58
2 # 12 SGRP-4 SGRS-4-58 3 # 16 + 2 # 18 SGRP-3 SGRS-3-58 1 # 20 + 4 # 22 SGRP-1 SGRS-1-58
2 # 12 + 1 # 18 SGRP-3 SGRS-3-58 3 # 16 + 1 # 18 + 2 # 20 SGRP-3 SGRS-3-58 2 # 20 SGRP-1 SGRS-1-58
2 # 12 + 1 # 18 SGRP-3 SGRS-3-58 3 # 16 + 1 # 18 + 1 # 20 SGRP-3 SGRS-3-58 2 # 20 + 1 # 22 SGRP-1 SGRS-1-58
2 # 12 + 1 # 16 SGRP-3 SGRS-3-58 3 # 16 + 1 # 18 SGRP-3 SGRS-3-58 2 # 20 + 2 # 22 SGRP-1 SGRS-1-58
2 # 12 + 2 # 16 + 1 # 18 SGRP-4 SGRS-4-58 3 # 16 + 3 # 20 SGRP-3 SGRS-3-58 2 # 20 + 3 # 22 SGRP-1 SGRS-1-58
2 # 12 + 3 # 16 SGRP-4 SGRS-4-58 3 # 16 + 2 # 20 SGRP-3 SGRS-3-58 3 # 20 SGRP-1 SGRS-1-58
2 # 12 + 1 # 14 + 1 # 18 SGRP-4 SGRS-4-58 3 # 16 + 1 # 20 SGRP-3 SGRS-3-58 3 # 20 + 1 # 22 SGRP-1 SGRS-1-58
2 # 12 + 1 # 14 + 1 # 16 SGRP-4 SGRS-4-58 3 # 16 SGRP-2 SGRS-2-58 4 # 20 SGRP-2 SGRS-2-58
3 # 12 + 1 # 14 SGRP-4 SGRS-4-58 2 # 16 + 4 # 18 SGRP-3 SGRS-3-58 5 # 20 SGRP-2 SGRS-2-58
2 # 12 + 2 # 14 SGRP-4 SGRS-4-58 2 # 16 + 3 # 18 + 1 # 20 SGRP-3 SGRS-3-58 6 # 20 SGRP-2 SGRS-2-58
3 # 12 + 1 # 18 SGRP-4 SGRS-4-58 2 # 16 + 3 # 18 SGRP-3 SGRS-3-58 3 # 22 SGRP-1 SGRS-1-58
3 # 12 + 1 # 16 SGRP-4 SGRS-4-58 2 # 16 + 2 # 18 + 2 # 20 SGRP-3 SGRS-3-58 4 # 22 SGRP-1 SGRS-1-58
1 # 14 + 1 # 22 SGRP-1 SGRS-1-58 2 # 16 + 2 # 18 + 1 # 20 SGRP-3 SGRS-3-58 5 # 22 SGRP-1 SGRS-1-58
1 # 14 + 1 # 20 SGRP-2 SGRS-2-58 2 # 16 + 2 # 18 SGRP-3 SGRS-3-58 6 # 22 SGRP-1 SGRS-1-58
1 # 14 + 2 # 20 SGRP-2 SGRS-2-58 — — — — — —

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 17

Electrical Interconnect Products

Product Characteristics

Material
Insulation Radiation-crosslinked, transparent heat-shrinkable polyvinylidene fluoride
Solder preform with flux (SGRS-X-58) SN42Bi58, ROM1 flux per ANSI-J-STD-004 (RA flux).
Solder preform with flux (SGRP, SGRS) Sn 60 Pb 40, ROM1 flux per ANSI-J-STD-004 (RA flux).
Sealing insert (SGRS-X-58, SGRS) Hot melt adhesive
Spiral wound insert Copper alloy
Physical Unit Method of test Requirement
Dimensions inches RB-109 See product dimensions.
Electromechanical Unit Method of test Typical values
Dielectric withstand voltage kilovolts RB-109 2.0
Static heating degrees RB-109 Less than 50°C rise
Environmental* Unit Method of test Requirement
Insulation resistance after water immersion (SGRS only) megohms RB-109 100
Contact resistance after testing milliohms RB-109 Less than 6 milliohms
Operating condition Unit Method of test Value
Temperature rating — — -55°C to 125°C [-67°F to 257°F]
Voltage rating volts — 600
*Immersion resistance sealing is dependent on the wire combinations used. The user should test specific wire combinations. Refer to RB-109
TE specification for procedures.

Agency Approvals UL, CUL E87681

Approvals and
Reference documents TE Specification RB-109 for splices
Reference Documents Specification Control Drawings
Splices—Non Sealed (SGRP-X), Splices—Sealed (SGRS-X)
Note: SGRS-X-58 is not UL approved.

Installation The SolderGrip product Refer to TE installation

Requirements is pushed onto the procedure RPIP-820-00 for
conductors with a twisting detailed instructions and
motion. With the product in recommended reflector
place, installation can be attachments.
completed with the proper
selection and use of heating
tools and reflectors.
Either of the following
TE heating tools is
recommended:
n HL1920E/HL2020E
n CV-1981

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 18

Electrical Interconnect Products

DuraSeal Heat-Shrinkable, Environmentally

Sealed, Nylon-Insulated Crimp Splices

Specifications/Approvals
Series Agency TE
D-406 UL and CUL listed 91J4, File E87681 RB-107
— Lloyd’s listed, File 65 247 HH 02-93 —
Note: D406-0034 is not UL approved.

Product Dimensions
RUGGED Butt Splices
• Protects splices from water,
condensation,

salt, and corrosion
L
• Provides strain relief

• Protects against vibration in rugged ØA min.

environments

CAPABLE
Butt Splice Dimensions Wire Dimensions
• C ompletely insulates and protects Part
A L Insulation Insulation
No.
Color Conductor O.D. (Max.)

electrical connections Min. Nom. O.D. (Min.)
D-406-0034 3.00 [.118] 31.5 [1.24] Yellow 26-24 3.00 [.118] 1.40 [.055]
• Has

adhesive lining for protection D-406-0001 3.70 [.146] 31.5 [1.24] Red 22–18 3.70 [.146] 1.40 [.055]
that

is more reliable than D-406-0002 4.60 [.181] 31.5 [1.24] Blue 16–14 4.60 [.181] 2.00 [.080]
conventional

splices D-406-0003 6.50 [.255] 37.5 [1.48] Yellow 12–10 6.50 [.255] 2.80 [.110]
• UL, CUL, and Lloyd’s listed

APPLICATIONS
• Automotive/truck wiring repair
and maintenance

• Automotive accessory installations.

• OEM automotive/truck/RV wire

harness fabrication

• Marine electronics

• Fleet maintenance

• Commercial wiring (pumps/

pools/spas)

• Appliances

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 19

Electrical Interconnect Products

Product Selection Wire Size

mm2 Part No.

Process Color
AWG
1. Determine wire size. 26-24 0.15-0.25 D-406-0034 Yellow
22–18 0.5-1.0 D-406-0001 Red
2. Select part number. 16–14 1.2–2.5 D-406-0002 Blue
12–10 3–6 D-406-0003 Yellow

Product Operating temperature -55°C to 125°C [-67°F to 257°F]

Characteristics Shrink ratio Approximately 2:1
(Typical) 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];
Physical properties yellow: 27.2 kg [60 lb]
Not flame-retardant
No cracking after heat aging for 168 h at 160°C [320°F]
Chemical properties Solvent resistance: isopropyl alcohol, trichloroethylene, gasoline, battery acid,
diesel fuel, motor oil, antifreeze, brake fluid, 5% salt water
Electrical properties Dielectric strength: 2500 Vac
Insulation resistance: 1000 megohms at 100 Vdc

Installation Installation
Requirements 1. S
 elect splice of
For proper installation of appropriate size. Strip
these devices, the correct wire 7.5 mm (5/16 in).
crimp tool and a heating Insert into crimp barrel.
tool with a reflector
attachment must be used.
The AD-1522 crimp tool and
HL1920E/HL2020E heating
tool are recommended.
Refer to TE installation 2. C
 rimp using AD-1522
procedure RPIP-821-00 for crimp tool for
detailed instructions. preinsulated crimps.

3. H
 eat crimped splice
with heat gun until
tubing recovers and
adhesive flows.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 20

Electrical Interconnect Products

Raychem Cold Applied Splices and

Ring Terminals
TE Connectivity’s (TE) cold applied splice and terminals
product line is designed as a single-component in-line splice
that requires no heat to install. It seals the termination and
prevents the ingress of moisture which can lead to insulation
failure and breakdown of the electrical connection.
In this product, sealing is achieved by replacing traditional
methods, such as grommets, greases, and tapes with
a novel gel technology. A polymer outer layer provides
VERSATILE
electrical isolation.
• Easy installation and application
flexibility MECHANICAL/ENVIRONMENTAL
• Tensile Strength: Exceeds that of spliced wire
• One-step termination and
• Temperature Range: -65°C to 150°C
environmental protection
• Dielectric Strength: 2500 V maximum
• No heating required for • Insulation Resistance: 5000 megohms minimum
installation — safe for use on • Altitude Immersion: 75,000 feet
fueled aircraft •F
 luid Resistance: MIL-L-7808, MIL-L-3699, MIL-H-5605 (Hydraulic),
MIL-A-8243, MIL-C-59769, and MIL-T-5624 (JP-5)
PROVEN TECHNOLOGY •C
 urrent Rating: Defined by the size of the crimp, gauge of wire,
and specification
• Reliable in a wide variety of
environmental conditions PHYSICAL
• Prevents water ingress under •C
 ross-Linked Gel Technology:
- Well-established gel sealing system
permanent pressure/weight
- Versatile gel closure
• Achieves environmental performance - Non-flowing gel

while maintaining: • Protects

 and seals on all conventional Mil Spec and commercial wire
insulation systems
- Small profile
- Electrical performance
MATERIALS
• Insulation Sleeve: Transparent polyvinylidene fluoride
• Metal Crimp Splice or Terminal: Tin-plated copper
• End Caps: Thermoplastic, color coded
• Gel: Clear, flame-retardant silicone-based gel

STANDARDS
• SAE AMS-DTL-23053/8 (Insulation sleeve)
•S
 AE AS81824/12 for Splices
SAE AS7928/14 for Terminals

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 21

Electrical Interconnect Products

Specifications
DIMENSION
• Overall Length: 230 mm (9”) approx.

WEIGHT
• 350 g (12.3 oz.)

COLD-APPLIED SPLICE PRODUCT RANGE

AD-1381 Hand Crimping Tool • D-436-36-COLD: 26 to 20 AWG wire range
Tool is used to crimp cold-applied • D-436-37-COLD: 18 to 16 AWG wire range
gel-filled splices with wires ranging • D-436-38-COLD: 14 to 12 AWG wire range
from 26 to 12 AWG.

Ordering Information
AD-1381 Hand Crimping Tool
Model Description Part No.
AD-1381 Hand Crimping Tool AD-1381 CS1660-000
Calibration Gauge AD-1382 992013-000
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/

This product must not be disposed of as municipal waste.

ORDERING INFORMATION
Mini-Seal Crimp Wire Splices – Cold Applied (Gel Filled)
TE Description TE RPN QPL P/N Specification
D-436-36-COLD CN1020-000 M81824/12-1 SAE AS81824
D-436-37-COLD CN1021-000 M81824/12-2 SAE AS81824
D-436-38-COLD CN1022-000 M81824/12-3 SAE AS81824

Ring Tongue Terminal – Cold Applied (Gel Filled)

TE Description TE RPN QPL P/N Specification
D-436-1101-COLD CW8662-000 M7928/14-004 SAE AS7928
D-436-1102-COLD CW0419-000 M7928/14-008 SAE AS7928
D-436-1103-COLD CW0421-000 M7928/14-016 SAE AS7928
D-436-1122-COLD TBD M7928/14-012 SAE AS7928
D-436-1123-COLD TBD M7928/14-020 SAE AS7928
D-436-1142-COLD TBD M7928/14-009 SAE AS7928
D-436-1143-COLD TBD M7928/14-017 SAE AS7928
D-436-1162-COLD TBD M7928/14-010 SAE AS7928
D-436-1163-COLD TBD M7928/14-018 SAE AS7928
D-436-1382-COLD TBD M7928/14-011 SAE AS7928
D-436-1383-COLD TBD M7928/14-019 SAE AS7928
D-436-1401-COLD TBD M7928/14-001 SAE AS7928
D-436-1402-COLD TBD M7928/14-005 SAE AS7928
D-436-1403-COLD TBD M7928/14-013 SAE AS7928
D-436-1601-COLD TBD M7928/14-002 SAE AS7928
D-436-1602-COLD TBD M7928/14-006 SAE AS7928
D-436-1603-COLD TBD M7928/14-014 SAE AS7928
D-436-1801-COLD CW8661-000 M7928/14-003 SAE AS7928
D-436-1802-COLD CW0418-000 M7928/14-007 SAE AS7928
D-436-1803-COLD CW0420-000 M7928/14-015 SAE AS7928

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 22

Electrical Interconnect Products

MiniSeal High-Performance, Immersion-

Resistant Crimp Splices
Applications so choose either CMA or mm2 as
MiniSeal wire-to-wire splicing your unit of measure for selection
products offer solutions for purposes and continue to use it
hundreds of aerospace and defense for all your selection criteria.)
applications. These environment- 4.  Select the color code for the size
resistant splices provide excellent crimp barrel required. Using Table
reliability, long term performance, B (page 24), select the crimp
MIL-S-81824/1 qualification, and a barrel—color-coded red, blue, or
low installed cost. yellow—for the CMA or mm2
you calculated.
RUGGED MiniSeal crimp splices consist
of a plated copper crimp barrel Stub splice: Select the barrel
• Insulation and strain relief and a separate, heat-shrinkable, that will accommodate the total
transparent sealing sleeve. They can cross section.
CAPABLE be used on a combination of wires, Butt splice: Select the smallest
from 1:1 to 10:10. MiniSeal splices are barrel that will accommodate the
• MIL-Spec approval one of the smallest, lightest, and largest CMA/mm2 required. (Refer
• Small size most environment-resistant splices to the example in the worksheet
available. They preserve the for a more specific description.) If
• Light weight electrical integrity of the splice by the CMA/mm2 of the smaller side
preventing the penetration of liquids of a butt splice is too small for the
EASY TO USE and the resulting chemical and size barrel required to fit the larger
galvanic corrosion. side, increase the CMA/mm2 —
• Immersion-resistant crimp splices are
Product Selection Process either by doubling back one wire
on QPL for SAE-AS81824
1. D
 etermine the type of (stripping the conductor twice the
• Easy installation splice required. length you would ordinarily strip
it and then folding it back) or by
• Stub (parallel) splice: adding a filler wire.
5. Determine the type of sealing
• Butt (in-line) splice: sleeve required. Some wire
insulations will not fit in the holes
of the sealing sleeve inserts, so
2. Determine which crimp barrel be sure to compare the internal
plating is required: diameter of each hole with the
• T
 in plating, recommended for outer diameter of the wire(s)
tin or silverplated wire you intend to insert in that hole.
To create a reliable seal, place a
• N
 ickel plating, recommended maximum of two wires in any hole
for nickel-plated wire, or silver- of the sealing sleeve.
plated wire in applications
above 150°C [302°F]. 6. Select the part number. Turn to
the MiniSeal part number selection
3. Calculate the size of crimp tables (Tables C and D, page
barrel required. 24 and 25) and find the table for
Using the CMA/mm2 worksheet on the type of splice (stub or butt)
the next page, calculate the total required.
cross section to be spliced by
adding the circular mil area (CMA)  sing the appropriate table, find
U
or square millimeters (mm2) of the crimp barrel size range and
each wire. the size and number of wires
for your application. Then select
Stub splice: Add the CMA or mm2 the part number for the type of
of all wires together. plating required. The color code
Butt splice: Calculate each accompanying that part number
side separately (see example on should match the color code you
the worksheet). arrived at in Table B, confirming
that the part number you have
Table A provides the CMA of
selected is correct.
typical conductors. (Both CMA
and mm2 give the same results,

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 23

Electrical Interconnect Products

Table A. CMA of Strands 7 19 19 19 19 19 19 19 37

Typical Conductors AWG 28 26 24 22 20 18 16 14 12
CMA 177 304 475 754 1216 1900 2426 3831 5874
mm2 0.09 0.15 0.24 0.38 0.61 0.95 1.21 1.92 2.94

Table B. Crimp Barrel CMA Range 1:1 Splice (AWG Size) Color Code
Color Code Selection 304–1510 26–20 Red
1058–2680 20–16 Blue
2375–6755 16–12 Yellow

CMA/mm2 Worksheet Example:

Application: A butt splice The other side, where the
with three AWG 22 wires in CMA for AWG 18 is 1900, is
one side and one AWG 18 calculated as:
wire in the other side: CMA = 1 x 1900 = 1900
The CMA for AWG 22 wire Using Table B to select the
in Table A is 754. smallest crimp barrel that
Side one is therefore will easily fit 2262 CMA,
calculated as follows: the blue barrel is the
correct choice.
CMA = 3 x 754 = 2262

Wire Number CMA mm2

1
2
3
4
5
6
7
8
9
10 Part Number:
Total

Table C. Stub (Parallel) Splices

Crimp Barrel I.D.dimensions

Part No. Size Range Side 1 Side 2
Illustration CMA

Tin Plated Nickel Plated Sealing Max. No. Sealing Max. No.
Min.–Max. Insert of Wires Insert of Wires
D-436-0128 D-436-0119
Red Red 304–1510 2
2.16 [.085] 1.01 [.040] 2

D-436-58 D-436-75
Blue Blue 1058–2680 4.56 [.180]
2 2.28 [.090]
2

D-436-59 D-436-76
Yellow Yellow 2375—6755 4.56 [.180]
2 2
2.28 [.090]

D-436-60 D-436-77 10
Blue Blue 1058–2680 2.03 2
(2 per hole)
[.080] 6.35 [.250]

D-436-61 D-436-78 10
Yellow Yellow 2375–6755 2.03 2
(2 per hole)
[.080] 6.35 [.250]

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 24

Electrical Interconnect Products

Table D. Butt (in-line) splices

Crimp Barrel I.D.dimensions

Part No. Size Range Side 1 Side 2
Illustration CMA

Tin Plated Nickel Plated Sealing Max. No. Sealing Max. No.
Min.–Max. Insert of Wires Insert of Wires
D-436-36* D-436-82
Red D-200-82
304–1510 2 2
2.16 [.085] 2.16 [.085]
Red
D-436-37* D-436-83
Blue D-200-83
1058–2680 2
2.79 [.110] 2.79 [.110] 2
Blue
D-436-38* D-436-84
Yellow D-200-84
2375–6755 2 2
4.32 [.170] 4.32 [.170]
Yellow
D-436-0110 D-436-85
Red Red 304–1510 6 2.36 2
4.06 [.160]
[.093]

D-436-52 D-436-86
Blue Blue 1058–2680 2.36 6 2
[.093] (2 per hole) 4.06 [.160]

D-436-53 D-436-87
Yellow Yellow 2375–6755 6
2.36 2
4.06 [.160]
[.093] (2 per hole)
D-436-0115 D-436-88
Red Red 304–1510 6 2.36 2.36 6
[.093] (2 per hole) [.093] (2 per hole)
D-436-42 D-436-89
Blue Blue 1058–2680 6
2.36 2.36 6
[.093] (2 per hole) [.093] (2 per hole)
D-436-43 D-436-90
Yellow Yellow 2375–6755 6
2.36 2.36 6
[.093] (2 per hole) [.093] (2 per hole)
*Qualified to MIL-S-81824/1.

Table E. Crimp Barrel Only

Crimp Barrel Size Range

Type Color Code Tin-Plated Nickel Plated CMA Min. - Max.
Butt (in-line) Red D-609-06 D-609-09 304-1510
Butt (in-line) Blue D-609-07 D-609-10 1058-2680
Butt (in-line) Yellow D-609-08 D-609-11 2350-6755
Stub (Parrel) Red D-609-03 D-609-12 304-1510
Stub (Parrel) Blue D-609-04 D-609-13 1058-2680
Stub (Parrel) Yellow D-609-05 D-609-14 2350-6755

Table F. Sealing Sleeve Only

L max.

∅A min.

Part No. Color Code L Max. A Min.

D-436-0096 Red 29.2 [1.15] 2.16 [0.085]
D-436-0097 Blue 29.2 [1.15] 2.8 [0.110]
D-436-0098 Yellow 29.2 [1.15] 4.32 [0.170]

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 25

Electrical Interconnect Products

Product Material
Insulation Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride (D-436)
Characteristics
Crimp barrel Tin- or nickel-plated copper
Meltable inserts Meltable thermoplastic (D-436)
Typical Performance
Voltage drop 6.9 mV at 4.5 A vs 8.1 mV for an equal length of wire
Tensile strength Exceeds strength of conductor
Dielectric strength 2.5 kV
Temperature rating -55°C to 150°C [-67°F to 302°F] (D-436 Series)
Insulation resistance 5000 megohms

Specifications/ Series Military

D-436 SAE-AS-81824/1 for D-436-36/37/38
Approvals

Installation For proper installation of Any one of the following

Requirements these devices, the correct TE heating tools is
crimp tool (TE part number recommended:
AD-1377) and a heating tool n HL1920E/HL2020E
and reflector attachment
must be used. n AA-400 Super Heater
Refer to TE installation
procedure RCPS-200-20 for
detailed instructions and
recommended reflector
attachments.

Specifications
DIMENSION
• Overall Length: 230 mm (9”) approx.

WEIGHT
• 350 g (12.3 oz.)

AD-1377 Hand Crimping Tool

Tool is used for crimping wire
terminations with MiniSeal splices.

Ordering Information
AD-1377 Crimp Tool for MiniSeal Splices
Model Description Part No.
AD-1377 Crimp Tool AD-1377-CRIMP-TOOL-3-CVTY 992008-000
Commercial Crimp Tool AD-1377-S-SPEC-CRIMP-TOOL 959025-000
Calibration Gauge AD-1386-CALIBRATION-GAUGE 992013-000

Accessories and Replacement Parts

Parts Description Part No.
Crimp Locator AD-1377-103-CRIMP-LOCATOR 994855-000
Spring AD-1377-P-E118-TOR-SPRNG 994123-000

ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/

This product must not be disposed of as municipal waste.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 26

Electrical Interconnect Products

200˚ MiniSeal High-Performance,

Immersion-Resistant Crimp Splices
In-line nickel plated sealed crimp splices for 200˚C applications
were developed for the growing needs of high temperature
applications in the aerospace and defense industry.
200˚C MiniSeal crimp splices provides the smallest, lightest,
and the most environmental-resistant splices available, while
meeting all requirements of SAEAS81812/11.

Applications
MiniSeal wire-to-wire splicing products are ideal for aerospace
RUGGED and defense applications where performance, reliability or size
• Transparent heat-shrinkable insulation
reduction is essential.
sleeve provides environmental Designed to provide an immersion resistant in-line splice on 1:1
protection and strain relief wires for the following: wire range from 26 AWG to 12 AWG;
nickel-plated conductors and insulation rated for at least 135˚C.
EASY TO USE
• No need to staffer wire splices

VERSATILE
• Small size

• Light weight

• Immersion-resistant crimp splices

while meeting all requirements
of SAE AS81824/11

• Splices provide sealing to unetched

wire insulations

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 27

Electrical Interconnect Products

Product Material
Characteristics Insulation Heat-shrinkable, transparent blue, radiation cross-linked
modified fluoropolymer
Crimp splicer Base Metal: Copper alloy 101 or 102 per ASTM B75
Plating:  Nickel per SAE AMS-QQ-N-290
Color Code: see table below
Meltable rings Environment resistant modified thermoplastic fluoroelastomer
Color: Light blue
Typical Performance
Voltage drop 6.9 mV at 4.5 A vs 8.1 mV for an equal length of wire
Tensile strength Exceeds strength of conductor
Dielectric strength 2.5 kV
Temperature rating -55˚C to 200°C [-67°F to 392°F]
Insulation resistance 5000 megohms

Specifications/ Series Military

D-200 Meets the requirements of SAE AS81824/11
Approvals

Part Numbers Part No. Color Code Part Number

D-200-82 Red D17660-000
D-200-83 Blue A36675-000
D-200-84 Yellow C60253-000

Product Dimensions

Product Product I.D.* Crimp Splicer
Color
Name Rev. a. min øA øB C D E Code
b. max max.
D-200-82 A 2.16 (0.085) 1.27 (0.050) 2.03 (0.080) 12.95 (0.510) 6.22 (0.245) 0.38 Red
0.64 (0.025) 1.14 (0.045) 1.91 (0.075) 12.45 (0.490) 5.72 (0225) (0.015)
D-200-83 A 2.79 (0.110) 1.75 (0.069) 2.70 (0.106) 14.86 (0.585) 7.11 (0.280) 0.51 Blue
0.64(0.025) 1.63 (0.064) 2.57 (0.101) 14.35 (0.565) 6.60 (0.260) (0.020)
D-200-84 A 4.32 (0.170) 2.60 (0.102) 3.89 (0.153) 14.86 (0.585) 7.11 (0.280) 1.27 Yellow
0.64 (0.025) 2.46 (0.097) 3.73 (0.147) 14.35 (0.565) 6.60 (0.260) (0.050)
*I.D.: a- As received; b- After unrestricted recovery thru meltable insert.

Product MIL Spec Wire Wgt. Lbs/Mpc

Name Equivalent Size Range max.
D-200-82 M81824/11-1 26-20 1.02
D-200-83 M81824/11-2 20-16 1.61
D-200-84 M81824/11-3 16-12 2.72

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 28

 Insulated Terminals
and Disconnects
Introduction
TE 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
brand 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:
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 color-coded for easy identification, yet
are transparent for visual inspection of the finished splice.
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.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 29

Electrical Interconnect Products

DuraSeal Heat-Shrinkable Environmentally

Sealed, Nylon Insulated Crimp Terminals
and Disconnects
Applications
DuraSeal products insulate and protect electrical connections
from mechanical abuse, wire pull-out, and abrasion while
resisting water, salt, and other contaminant’s.
DuraSeal devices provide a tough, environmentally sealed wire
connection. Their crimp barrel or terminal, encased in rugged,
DURABLE heat-shrinkable nylon tubing lined with a special hot-melt
• Resistance to moisture and abrasion adhesive, resists damage from abrasions and cuts.
• Strain relief
DuraSeal devices retain flexibility and impact-resistance long
CAPABLE after similar products have become brittle.
• Protection from wire pull-out DuraSeal devices accommodate wire gauge sizes 22 to 10.
• UL and CUL listed They are color-coded for easy identification of gauge sizes, yet
transparent for inspection of the finished splice.
EASY TO USE
• Easy installation
Approvals and Reference Documents

Agency approvals UL listed component, file E87681, terminals except quick connect terminals;
file E157833, quick connect terminals
Reference documents TE specifications RB-108,
Specification DuraSeal crimp terminals
DuraSeal selection guide (H54153)
DuraSeal installation guidelines (H54154)

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 30

Electrical Interconnect Products

Product Characteristics
Property Unit Requirement Method of Test
Dimensions Inches None See product dimensions
Physical Tensile strength Pounds 8 to 40 lbs depending on AWG UL486C, IEC512-8
Property Unit Typical value Method of Test
Voltage drop Millivolts Less than equal length of wire MIL-S-81824, IEC512-2
Electrical Insulation resistance Megohms 103 min. MIL-STD-202 method 302
Dielectric withstand Kilovolts 2.5 MIL-STD-202F method 301,
voltage IEC512-2
Property Unit Requirement Method of Test
Diesel fuel ASTM D 3032, ESA-603D
Brake fluid
Chemical Antifreeze — Meet electrical test listed above
5% salt water after conditioning.
Motor oil
Humidity MIL-STD-202F method 106, IEC68-2-30
Immersion MIL-STD-202F condition C, IEC68-2-14 test NC
Vibration Meet electrical test MIL-STD-202F method 201, IEC68-2-6
Environmental Bending — listed above after UL486C, IEC512-8
(Fluid) Thermal shock conditioning. MIL-STD-202F method 107, IEC68-2-14 test N
Heat aging (168h @ 85°C [185°F) MIL-STD-202F, IEC68-2-2
Salt spray MIL-STD-202F method 101, IEC68-2-11

Operating Temperature rating -55°C to +125°C [-67°F to -257°F] None

conditions Minimum shrink temperature — 180°C [356°F] None
Voltage rating 600 Volt max None

Fork Terminals
L max.

ØA min. ØB nom. C nom.

Fork Terminal Dimensions Wire Dimensions

Insulation
Part Color Conductor Insulation O.D.
No. A Stud C L O.D. (Min.)
Min. Size Nom. Max. (AWG) (Max.)

Metric Imperial
B-106-2401 3.81 [.15] M4 8 7.87 [.31] 32.00 [1.26] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-2402 4.57 [.18] M4 8 7.87 [.31] 35.05 [1.38] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-2403 6.35 [.25] M4 8 7.87 [.31] 38.10 [1.50] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-2502 4.57 [.18] M5 10 9.91 [.39] 35.05 [1.38] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-2503 6.35 [.25] M5 10 9.91 [.39] 40.15 [1.58] Yellow 12–10 6.35 [.250] 2.79 [.110]

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 31

Electrical Interconnect Products

Ring Terminals L max.

ØA min. B nom. ØC nom.

Ring Terminal Dimensions Wire Dimensions

Part Insulation
Color Conductor Insulation
No. A Stud C L O.D.
(AWG) O.D. (Min.)
Min. Size Nom. Max.
(Max.)
Metric Imperial
B-106-1401 3.81 [.15] M4 8 7.88 [.31] 32.00 [1.26] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-1501 3.81 [.15] M5 10 9.91 [.39] 34.04 [1.34] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-1601 3.81 [.15] M6 1/4 11.94 [.47] 36.07 [1.42] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-1801 3.81 [.15] M8 5/16 13.97 [.55] 39.12 [1.54] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-1991 3.81 [.15] M10 3/8 17.78 [.70] 43.18 [1.70] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-1402 4.57 [.18] M4 8 7.88 [.31] 33.02 [1.30] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-1502 4.57 [.18] M5 10 9.91 [.39] 35.05 [1.38] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-1602 4.57 [.18] M6 1/4 11.94 [.47] 36.58 [1.44] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-1802 4.57 [.18] M8 5/16 13.97 [.55] 40.13 [1.58] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-1992 4.57 [.18] M10 3/8 17.78 [.70] 43.94 [1.73] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-1403 6.35 [.25] M4 8 7.88 [.31] 38.10 [1.50] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-1503 6.35 [.25] M5 10 9.91 [.39] 40.13 [1.58] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-1603 6.35 [.25] M6 1/4 11.94 [.47] 41.66 [1.64] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-1803 6.35 [.25] M8 5/16 13.97 [.55] 45.21 [1.78] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-1993 6.35 [.25] M10 3/8 17.78 [.70] 46.99 [1.85] Yellow 12–10 6.35 [.250] 2.79 [.110]

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 32

Electrical Interconnect Products

Push-on Terminals
L max.

C nom.
A min. B nom.

Push-on Terminal Dimensions Wire Dimensions

Insulation
Part Tab Insulation
A B C L Color Conductor O.D.
No. Size O.D.
Min. Nom. Nom. Max. (AWG) (Min.)
(inches) (Max.)
B-106-3631 .250 x .032 3.81 [.150] 6.35 [.250] .81 [.032] 30.48 [1.200] Red 22­–18 3.81 [.150] 1.40 [.055]
B-106-3632 .250 x .032 4.57 [.180] 6.35 [.250] .81 [.032] 32.00 [1.260] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-3633 .250 x .032 6.35 [.250] 6.35 [.250] .81 [.032] 33.02 [1.300] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-3281 .110 x .020 3.81 [.150] 2.79 [.110] .51 [.020] 22.86 [.900] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-3481 .187 x .020 3.81 [.150] 4.75 [.187] .51 [.020] 30.48 [1.200] Red 22–18 3.81 [.150] 1.40 [.055]

Tab Terminals
L max.

C nom.

ØA min. B nom.

Tab Terminal Dimensions Wire Dimensions

Insulation
Part Tab Insulation
A B C L Color Conductor O.D.
No. Size O.D.
(AWG) (Min.)
(inches) Min. Nom. Nom. Max. (Max.)
B-106-4631 .250 x .032 3.81 [.150] 6.35 [.250] .81 [.032] 30.48 [1.20] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-4632 .250 x .032 4.57 [.180] 6.35 [.250] .81 [.032] 32.00 [1.26] Blue 16–14 4.45 [.175] 2.00 [.080]

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 33

Electrical Interconnect Products

Pin Terminals L max.

ØA min.

ØB
Pin Terminal Dimensions Wire Dimensions
Part Insulation Insulation
A B L Color Conductor
No. O.D. O.D.
Min. Nom. Max. (AWG)
(Max.) (Min.)
B-106-6201 3.81 [.150] 2.00 [.080] 30.99 [1.220] Red 22–18 3.81 [.150] 1.40 [.055]

Bullet Terminals
L max.

Fig. 1 ØA min. B nom.

L max.

Fig. 2 ØA min. ØB ØC min.

Bullet Terminal Dimensions Wire Dimensions

Part Conductor Insulation Insulation
A B C L Color (AWG) O.D. O.D.
No. Fig. Type
Min. Nom. Min. Max. (Max.) (Min.)
B-106-7401 1 M 3.81 [.150] 3.81 [.150] — 33.53 [1.32] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-7502 1 M 4.57 [.180] 5.08 [.200] — 34.54 [1.36] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-8401 2 F 3.81 [.150] 3.81 [.150] 5.59 [.220] 30.48 [1.20] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-8502 2 F 4.57 [.180] 5.08 [.200] 6.10 [.240] 32.51 [1.28] Blue 16–14 4.45 [.175] 2.00 [.080]

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 34

Electrical Interconnect Products

Product Characteristics
(Typical)
Operating temperature -55°C to 125°C [-67°F to 257°F]
Shrink ratio Approximately 2:1
Physical properties Cut-through resistance: 31.7 kg [70 lb]
Wire pullout after crimping and recovery: red: 11.3 kg [25 lb]; blue: 22.7 kg [50 lb]; yellow: 27.2 kg [60 lb]
Not flame-retardant
No cracking after heat aging for 168 hr at 160°C [320°F]
Chemical properties Solvent resistance: isopropyl alcohol, trichloroethylene, gasoline, battery acid, diesel fuel, motor oil,
antifreeze, brake fluid, 5% salt water
Electrical properties Dielectric strength: 1000 V
Insulation resistance: 10 megohms

Specifications/
Series Agency TE
Approvals UL and CUL 91J4, File E87681
B-106 Lloyd’s listed, File 65 247 HH 02-93 RB-108
Installation UL and CUL E157833
(B-106-3XXX/B-106-4XXX)
Requirements
1. Select appropriate
size. For terminal For proper installation of
and disconnect these devices, the correct
terminations, strip wire crimp tool and heating tool
6.5 mm (1/4 inch). with reflector attachment
must be used. The AD-1522
crimp tool and HL1920E/
2. Crimp using AD-1522 HL2020E heating tools are
crimp tool for recommended. Refer to
preinsulated crimps. TE installation procedure
RPIP-684-00 for detailed
3. Heat terminal or instructions.
disconnect with heat gun
until tubing recovers and
adhesive flows. Avoid
heating ring or fork
metallic parts.

Specifications
DIMENSION
• Overall Length: 230 mm (9”) approx.

WEIGHT
• 350 g (12.3 oz.)

PRODUCT RANGE
AD-1522-1 Hand Crimping Tool • DuraSeal Crimp Splices and Terminals
Tool is used for completing wire
terminations using DuraSeal splices.

Ordering Information
AD-1522-1 Crimp Tool for DuraSeal Splices
Product Description Part No.
Crimp Tool AD-1522-1 047011-000
Calibration Gauge AE-2245 020435-000

ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/

This product must not be disposed of as municipal waste.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 35

Electrical Interconnect Products

SolderGrip Self-Fixturing Insulated Terminals

Product Selection Process
1. D
 etermine the wire combination (number of wires and size) of
the wire bundle you wish to terminate.
2. U
 se 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.
3. Determine the correct stud size.
RUGGED 4. S
 elect the correct part number from Table A for that stud size
• Transparent insulation sleeve in the terminal series and size you selected in Step 2. Example:
provides encapsulation,
If the stud size is 1/4, select part number SGRT-4-06.
inspectability, strain relief, and
insulation 5. V
 erify that the wire bundle (with wire insulation) does not
exceed the maximum diameter allowed for the part you
VERSATILE
selected. Simply check the bundle’s diameter against the
• Spiral copper coil grips and
maximum diameter that Table A lists for that part.
compresses the conductors for
optimum solder connection 6. V
 erify that the total amperage to be applied does not exceed
• Prefluxed solder preform provides a the maximum amp rating for the part as specified in Table A.
controlled soldering process
*If the wire combination is not listed in Table B, use the CMA
• Accommodates a wide variety of
(mm2) method of determining wire bundle size (see “CMA/mm2
conductor types, quantities, sizes,
and plating types unmatched by any Calculation” on page 37).
other termination technique Using Table B, select the smallest size part that will fit your total
HIGH PERFORMANCE wire CMA (mm2) value.
• Parts meet the performance
requirements of MIL-T-7928G Product Option
EASY TO USE Product Series Environmental Protection
SGRT Splashproof (not RoHS compliant)
• One-piece design for easy
installation

APPLICATIONS Table A. Part Number Selection

• Used for terminating Maximum Maximum Wire Range
SolderGrip Stud Typical
Bundle Amp (Min.–Max.)
multiple wires to terminals Part No. Size Length
Diameter† Rating CMA [mm2]
1400–5000
SGRT-1-02
2 [2] 4.1 [.161] 12.5 A [0.7–2.5] 38 [1 1/2]
2400–6000
SGRT-2-03
3 [6] 5.0 [.195] 15 A [1.2–3.0] 38 [1 1/2]
2400–6000
SGRT-2-04
4 [8] — 15 A [1.2–3.0] 38 [1 1/2]
2400–6000
SGRT-2-05
5 [10] — 15 A [1.2–3.0] 38 [1 1/2]
2400–6000
SGRT-2-06
6 [1/4] — 15 A [1.2–3.0] 38 [1 1/2]
5000–13,200
SGRT-3-06
6 [1/4] 6.5 [.255] 33 A [2.5–6.6] 44.5 [1 3/4]
5000–13,200
SGRT-3-08
8 [5/16] — 33 A [2.5–6.6] 51.0 [2]
12,000–22,400
SGRT-4-06
6 [1/4] 9.0 [.355] 56 A [6.0–11.2] 44.5 [1 3/4]
12,000–22,400
SGRT-4-08
8 [5/16] — 56 A [6.0–11.2] 51 [2]

†Maximum bundle diameter is measured over wire insulation.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 36

Electrical Interconnect Products

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 3. A
 dd together the
or mm2 as your unit of values listed in the
measure for selection workspace below to
purposes and continue obtain the total area.
to use it for all your 4. U
 se Table A to select
selection criteria. (Both the smallest terminator
measures provide the that will fit the total
same results.) 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

OD Bundle Insulation
CMA/mm2 Example 22 AWG/.38
CMA 754

22 AWG/.38
CMA 754

18 AWG/.95 Conductor
CMA 1900

16 AWG/1.21
CMA 2426

Total CMA = 5834 Bundle diameter must not

Total mm2 = 2.92 exceed 5.0 mm [0.195 in] for
Correct part number (based on CMA this example
of 5834 or mm2 of 2.92):
SGRT-2-XX if bundle OD is less
than 5.0 mm (0.195 in).

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 37

Electrical Interconnect Products

Table B. CMA of Typical

Copper Conductors

Strands 7 19 19 19 19 19 19 19 37
AWG 28 26 24 22 20 18 16 14 12
CMA 177 304 475 754 1216 1900 2426 3831 5874
mm2 0.09 0.15 0.24 0.38 0.61 0.95 1.21 1.92 2.94

Table C. SolderGrip Wire

Combinations (see Table A for
Terminal Size [-XX])

Wire Part Wire Part Wire Part

Combinations No. Combinations No. Combinations No.
1 # 8 SGRT-4-XX 1 # 12 + 1 # 16 + 4 # 18 SGRT-4-XX 1 # 14 + 4 # 20 SGRT-3-XX
1 # 8 + 1 # 16 SGRT-4-XX 1 # 12 + 2 # 16 SGRT-3-XX 1 # 14 + 1 # 18 SGRT-2-XX
2 # 8 + 2 # 16 SGRT-4-XX 1 # 12 + 2 # 16 + 1 # 18 SGRT-3-XX 1 # 14 + 1 # 18 + 1 # 20 SGRT-3-XX
1 # 8 + 1 # 14 SGRT-4-XX 1 # 12 + 2 # 16 + 2 # 18 SGRT-4-XX 1 # 14 + 2 # 18 SGRT-3-XX
1 # 10 SGRT-3-XX 1 # 12 + 3 # 16 SGRT-4-XX 1 # 14 + 3 # 18 SGRT-3-XX
1 # 10 + 1 to 3 # 18 SGRT-3-XX 1 # 12 + 4 # 16 SGRT-4-XX 1 # 14 + 4 # 18 SGRT-3-XX
1 # 10 + 2 # 18 SGRT-3-XX 1 # 12 + 5 # 16 SGRT-4-XX 1 # 14 + 5 # 18 SGRT-4-XX
1 # 10 + 3 # 18 SGRT-4-XX 1 # 12 + 1 # 14 + 1 # 18 SGRT-3-XX 1 # 14 + 1 # 16 SGRT-3-XX
1 # 10 + 1 # 16 SGRT-3-XX 1 # 12 + 1 # 14 + 2 # 18 SGRT-4-XX 1 # 14 + 1 # 16 + 1 # 20 SGRT-3-XX
1 # 10 + 1 # 16 + 1 # 18 SGRT-4-XX 1 # 12 + 1 # 14 + 3 # 18 SGRT-4-XX 1 # 14 + 1 # 16 + 1 # 18 SGRT-3-XX
1 # 10 + 1 # 16 + 2 # 18 SGRT-4-XX 1 # 12 + 1 # 14 + 1 # 16 SGRT-3-XX 1 # 14 + 1 # 16 + 2 # 18 SGRT-3-XX
1 # 10 + 2 # 16 SGRT-4-XX 1 # 12 + 1 # 14 + 2 # 16 SGRT-4-XX 1 # 14 + 1 # 16 + 3 # 18 SGRT-3-XX
1 # 10 + 3 # 16 SGRT-4-XX 1 # 12 + 1 # 14 + 3 # 16 SGRT-4-XX 1 # 14 + 1 # 16 + 4 # 18 SGRT-4-XX
1 # 10 + 4 # 16 SGRT-4-XX 1 # 12 + 1 # 14 + 4 # 16 SGRT-4-XX 1 # 14 + 2 # 16 SGRT-3-XX
1 # 10 + 5 # 16 SGRT-4-XX 1 # 12 + 2 # 14 SGRT-4-XX 1 # 14 + 2 # 16 + 1 # 18 SGRT-3-XX
1 # 10 + 1 # 14 SGRT-3-XX 1 # 12 + 2 # 14 + 1 # 18 SGRT-4-XX 1 # 14 + 2 # 16 + 2 # 18 SGRT-3-XX
1 # 10 + 1 # 14 + 1 # 18 SGRT-4-XX 1 # 12 + 2 # 14 + 1 # 16 SGRT-4-XX 1 # 14 + 2 # 16 + 3 # 18 SGRT-4-XX
1 # 10 + 1 # 14 + 1 # 16 SGRT-4-XX 1 # 12 + 2 # 14 + 2 # 16 SGRT-4-XX 1 # 14 + 3 # 16 SGRT-3-XX
1 # 10 + 1 # 14 + 2 # 16 SGRT-3-XX 1 # 12 + 2 # 14 + 3 # 16 SGRT-4-XX 1 # 14 + 3 # 16 + 1 # 18 SGRT-3-XX
1 # 10 + 1 # 14 + 3 # 16 SGRT-4-XX 1 # 12 + 3 # 14 SGRT-4-XX 1 # 14 + 3 # 16 + 2 # 18 SGRT-4-XX
1 # 10 + 2 # 14 SGRT-4-XX 1 # 12 + 3 # 14 + 1 # 16 SGRT-4-XX 1 # 14 + 4 # 16 SGRT-4-XX
1 # 10 + 3 # 14 SGRT-4-XX 1 # 12 + 4 # 14 SGRT-4-XX 1 # 14 + 4 # 16 + 1 # 18 SGRT-4-XX
1 # 10 + 1 # 12 SGRT-4-XX 2 # 12 + 1 # 18 SGRT-4-XX 1 # 14 + 5 # 16 SGRT-4-XX
1 # 10 + 1 # 12 + 1 # 14 SGRT-4-XX 2 # 12 + 1 # 16 SGRT-4-XX 2 # 14 SGRT-3-XX
1 # 10 + 2 # 12 SGRT-4-XX 2 # 12 + 2 # 16 + 1 # 18 SGRT-4-XX 2 # 14 SGRT-3-XX
2 # 10 SGRT-4-XX 2 # 12 + 3 # 16 SGRT-4-XX 2 # 14 SGRT-3-XX
2 # 10 + 1 # 16 SGRT-4-XX 2 # 12 + 1 # 14 + 1 # 18 SGRT-4-XX 2 # 14 SGRT-3-XX
1 # 12 SGRT-3-XX 2 # 12 + 1 # 14 + 1 # 16 SGRT-4-XX 2 # 14 SGRT-3-XX
1 # 12 + 1 # 18 SGRT-3-XX 2 # 12 + 2 # 14 SGRT-4-XX 2 # 14 + 1 # 16 SGRT-3-XX
1 # 12 + 2 # 18 SGRT-3-XX 3 # 12 + 1 # 18 SGRT-4-XX 2 # 14 + 1 # 16 SGRT-3-XX
1 # 12 + 3 # 18 SGRT-3-XX 3 # 12 + 1 # 16 SGRT-4-XX 2 # 14 + 1 # 16 SGRT-3-XX
1 # 12 + 4 # 18 SGRT-4-XX 3 # 12 + 1 # 14 SGRT-4-XX 2 # 14 + 1 # 16 SGRT-3-XX
1 # 12 + 5 # 18 SGRT-4-XX 1 # 14 SGRT-2-XX 2 # 14 + 2 # 16 SGRT-3-XX
1 # 12 + 1 # 16 SGRT-3-XX 1 # 14 + 1 # 22 SGRT-2-XX 2 # 14 + 2 # 16 SGRT-3-XX
1 # 12 + 1 # 16 + 1 # 18 SGRT-3-XX 1 # 14 + 1 # 20 SGRT-2-XX 2 # 14 + 3 # 16 SGRT-4-XX
1 # 12 + 1 # 16 + 2 # 18 SGRT-3-XX 1 # 14 + 2 # 20 SGRT-3-XX 2 # 14 + 4 # 16 SGRT-4-XX
1 # 12 + 1 # 16 + 3 # 18 SGRT-4-XX 1 # 14 + 3 # 20 SGRT-3-XX 3 # 14 SGRT-3-XX

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 38

Electrical Interconnect Products

Table C. SolderGrip Wire

Combinations (see Table A for
Terminal Size [-XX]) (Continued)

Wire Part Wire Part Wire Part

Combinations No. Combinations No. Combinations No.
3 # 14 + 1 # 16 SGRT-4-XX 2 # 16 + 4 # 20 SGRT-3-XX 1 # 18 + 1 # 20 + 2 # 22 SGRT-2-XX
3 # 14 + 2 # 16 SGRT-4-XX 2 # 16 + 1 # 18 SGRT-3-XX 1 # 18 + 2 # 20 SGRT-2-XX
3 # 14 + 3 # 16 SGRT-4-XX 2 # 16 + 1 # 18 + 1 # 20 SGRT-3-XX 1 # 18 + 3 # 20 SGRT-2-XX
4 # 14 SGRT-4-XX 2 # 16 + 1 # 18 + 2 # 20 SGRT-3-XX 1 # 18 + 4 # 20 SGRT-3-XX
4 # 14 + 1 # 16 SGRT-4-XX 2 # 16 + 1 # 18 + 3 # 20 SGRT-3-XX 1 # 18 + 5 # 20 SGRT-3-XX
4 # 14 + 2 # 16 SGRT-4-XX 2 # 16 + 2 # 18 SGRT-3-XX 2 # 18 SGRT-2-XX
5 # 14 SGRT-4-XX 2 # 16 + 2 # 18 + 1 # 20 SGRT-3-XX 2 # 18 + 1 # 22 SGRT-2-XX
5 # 14 + 1 # 16 SGRT-4-XX 2 # 16 + 2 # 18 + 2 # 20 SGRT-3-XX 2 # 18 + 1 # 20 SGRT-2-XX
1 # 16 SGRT-2-XX 2 # 16 + 3 # 18 SGRT-3-XX 2 # 18 + 2 # 20 SGRT-3-XX
1 # 16 + 1 # 22 SGRT-2-XX 2 # 16 + 3 # 18 + 1 # 20 SGRT-3-XX 2 # 18 + 3 # 20 SGRT-3-XX
1 # 16 + 2 # 22 SGRT-2-XX 2 # 16 + 4 # 18 SGRT-3-XX 2 # 18 + 4 # 20 SGRT-3-XX
1 # 16 + 3 # 22 SGRT-2-XX 3 # 16 SGRT-3-XX 3 # 18 SGRT-2-XX
1 # 16 + 1 # 20 SGRT-2-XX 3 # 16 + 1 # 20 SGRT-3-XX 3 # 18 + 1 # 20 SGRT-3-XX
1 # 16 + 1 # 20 + 1 # 22 SGRT-2-XX 3 # 16 + 2 # 20 SGRT-3-XX 3 # 18 + 2 # 20 SGRT-3-XX
1 # 16 + 2 # 20 SGRT-2-XX 3 # 16 + 3 # 20 SGRT-3-XX 3 # 18 + 3 # 20 SGRT-3-XX
1 # 16 + 3 # 20 SGRT-3-XX 3 # 16 + 1 # 18 SGRT-3-XX 4 # 18 SGRT-3-XX
1 # 16 + 4 # 20 SGRT-3-XX 3 # 16 + 1 # 18 + 1 # 20 SGRT-3-XX 4 # 18 + 1 # 20 SGRT-3-XX
1 # 16 + 5 # 20 SGRT-3-XX 3 # 16 + 1 # 18 + 2 # 20 SGRT-3-XX 4 # 18 + 2 # 20 SGRT-3-XX
1 # 16 + 1 # 18 SGRT-2-XX 3 # 16 + 2 # 18 SGRT-3-XX 5 # 18 SGRT-3-XX
1 # 16 + 1 # 18 + 1 # 20 SGRT-2-XX 3 # 16 + 2 # 18 + 1 # 20 SGRT-3-XX 5 # 18 + 1 # 20 SGRT-3-XX
1 # 16 + 1 # 18 + 2 # 20 SGRT-3-XX 3 # 16 + 3 # 18 SGRT-3-XX 6 # 18 SGRT-3-XX
1 # 16 + 1 # 18 + 3 # 20 SGRT-3-XX 4 # 16 SGRT-3-XX 1 # 20 + 2 # 22 SGRT-2-XX
1 # 16 + 1 # 18 + 4 # 20 SGRT-3-XX 4 # 16 + 1 # 20 SGRT-3-XX 1 # 20 + 3 # 22 SGRT-2-XX
1 # 16 + 2 # 18 SGRT-3-XX 4 # 16 + 2 # 20 SGRT-3-XX 1 # 20 + 4 # 22 SGRT-2-XX
1 # 16 + 2 # 18 + 1 # 20 SGRT-3-XX 4 # 16 + 1 # 18 SGRT-3-XX 2 # 20 SGRT-2-XX
1 # 16 + 2 # 18 + 2 # 20 SGRT-3-XX 4 # 16 + 1 # 18 + 1 # 20 SGRT-3-XX 2 # 20 + 1 # 22 SGRT-2-XX
1 # 16 + 2 # 18 + 3 # 20 SGRT-3-XX 4 # 16 + 2 # 18 SGRT-4-XX 2 # 20 + 2 # 22 SGRT-2-XX
1 # 16 + 3 # 18 SGRT-3-XX 5 # 16 SGRT-3-XX 2 # 20 + 3 # 22 SGRT-2-XX
1 # 16 + 3 # 18 + 1 # 20 SGRT-3-XX 5 # 16 + 1 # 20 SGRT-4-XX 3 # 20 SGRT-2-XX
1 # 16 + 3 # 18 + 2 # 20 SGRT-3-XX 5 # 16 + 1 # 18 SGRT-4-XX 3 # 20 + 1 # 22 SGRT-2-XX
1 # 16 + 4 # 18 SGRT-3-XX 6 # 16 SGRT-4-XX 4 # 20 SGRT-2-XX
1 # 16 + 4 # 18 + 1 # 20 SGRT-3-XX 1 # 18 + 1 # 22 SGRT-2-XX 5 # 20 SGRT-3-XX
1 # 16 + 5 # 18 SGRT-3-XX 1 # 18 + 2 # 22 SGRT-2-XX 6 # 20 SGRT-3-XX
2 # 16 SGRT-2-XX 1 # 18 + 3 # 22 SGRT-2-XX 4 # 22 SGRT-2-XX
2 # 16 + 1 # 20 SGRT-3-XX 1 # 18 + 1 # 20 SGRT-2-XX 5 # 22 SGRT-2-XX
2 # 16 + 2 # 20 SGRT-3-XX 1 # 18 + 1 # 20 + 1 # 22 SGRT-2-XX 6 # 22 SGRT-2-XX
2 # 16 + 3 # 20 SGRT-3-XX — — — —

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 39

Electrical Interconnect Products

Installation The SolderGrip product Refer to TE installation

Requirements is pushed onto the procedure RPIP-820-01 for
conductors with a twisting detailed instructions and
motion. With the product in recommended reflector
place, installation can be attachments.
completed with the proper
selection and use of heating
tools and reflectors.
Either of the following
TE heating tools is
recommended:
n HL1920E/HL2020E
n CV-1981

Product Material
Insulation Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride (Kynar®)
Characteristics Solder and flux Sn60 Pb40 with RA flux
Typical Performance
Tensile strength Exceeds strength of individual wires
Temperature rating -55°C to +150°C [-67°F to +302°F]
Voltage Drop Not to exceed that of equivalent length of wire by more than 1 mV
Dielectric Withstanding Voltage Current leakage less than 2 mA (1.5 kV)

Kynar is a trademark of Arkema, Inc.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 40

 Wire Termination to
Pin/Post/Tab
Introduction
TE SolderSleeve terminators offer easy, one-step
solutions for wire connections to pins, posts, and tabs and
for mass wire terminations.
Designed for applications with temperatures up to 150°C
[302°F], the products in this section include SolderSleeve
discrete wire terminators, which are heat-shrinkable
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 TE termination products, provide
reliability and economical installation for greater
productivity. They can be supplied either in bulk or on
carrier tape.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 41

Electrical Interconnect Products

SolderSleeve Discrete Wire Terminators

Product Selection Process
1. Determine the application operating temperature.
2. F
 rom the Product Options table on the next page, select the
product series appropriate for the application, based on the
temperature required.
3. Determine your component connection point type (pin, post,
or tab) and dimensions.

DURABLE
4. Determine your wire gauge.

• Transparent polyvinylidene
5. O
 ptional: Select tape carrier center-to-center spacing
(D-71X series only). This should match center spacing of
fluoride or polyolefin insulation
component terminals.
sleeve provides encapsulation,
inspectability, strain relief, 6. Select part number from the appropriate table:
and insulation •F
 or B-155 and CWT series (applications with low-
temperature wires—below 125°C [257°F]), use Table A.
CAPABLE
•F
 or D-129/141/71X series (applications with wires rated higher
• Prefluxed solder preform offers a
than 125°C [257°F]), use Table B.
controlled soldering process
Installation Requirements
HIGH PERFORMANCE
For proper installation of these devices, the correct heating tool
• UL and CUL Recognized
and reflector attachment must be used. Either of the following
EASY TO USE TE heating tools is recommended:
• One-piece design means easy • HL1920E/HL2020E
installation and low installed cost • AA-400 Super Heater
• Optional tape carrier provides Refer to TE installation procedure RCPS-200-12 (for D-129,
convenience and ease of installation D-141, D-71X) or RPIP-824-00 (for B-155 and CWT) for detailed
instructions and recommended reflector attachment.
APPLICATIONS
• Used for terminating wires to
component terminals, such as
motor tabs, connector pins, and
switch terminals

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 42

Electrical Interconnect Products

Product Options Product Series Max. Operating Temperature Min. Wire Temperature Rating
B-155, CWT 125°C [257°F] 85°C [185°F]
D-129, D-141, D-71X 150°C [302°F] 125°C [257°F]
Note: Cadmium-free option (B-152 series) is available for operating temperature of 125˚C [257˚F].
Consult TE for details.

Table A. B-155 Series

(125°C [257°F] rated)

Connection-point
Terminal Dimensions Wire AWG/mm Part No.
2

Type and Size

W = up to 0.63 [.025] 24 [0.24] B-155-1501
W 20 [0.61] B-155-1502

24 [0.24] B-155-1501
W = 0.63 [.025] to
22 [0.38] B-155-1502
0.89 [0.035]
pin 20 [0.61] B-155-1503

W = 0.89 [0.035] to 24–22 [0.24–0.38] B-155-1502

W 1.14 [.045] 20–18 [0.61–0.95] B-155-1503

W = 1.14 [.045] to
24–22 [0.24–0.38] B-155-1503
1.52 [.060] 20–18 [0.61–0.95] B-155-1504
post

W = up to1.52 [.060] 24–20 [0.24–0.61] B-155-1501

W = 1.27 [.050] to
24-18 [0.24–0.95] B-155-1502
2.28 [.090]

W
W = 1.77 [.070] to
24-18 [0.24–0.95] B-155-1503
2.79 [.110]

tab

W = 2.54 [.100] to
24-18 [0.24–0.95] B-155-1504
3.80 [.150]

W = 2.28 [.090] to
22-16 [0.38–1.21] B-155-1505
4.70 [.187]

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 43

Electrical Interconnect Products

Table B. D-129/141/71X Series (up to 150°C [302°F] rated)

Connection-point
Type and Size

Wire Tape Carrier Spacing of Sleeves (Center-to-Center)

Terminal
2
1.27 2.54 3.17 4.0
Dimensions AWG mm None
[0.050] [0.100] [0.125] [0.156]
30–26 [0.05–0.15] D-141-30 D-713-03 — — —
W
W = up to 0.61 [.024]
24–22 [0.24–0.38] D-141-07 — D-711-00 — —

W = 0.63 [.025] to
20 [0.61] D-141-31 — D-711-04 D-711-07 D-711-08
pin 0.81 [.032]

W W = 0.76 [.030] to
24–20 [0.24–0.61] D-141-56 — — — —
1.27 [.050]

W = up to 1.52 [.060] 24–20 [0.24–0.61] D-129-05 — D-714-01 — —

post
W W = 1.27 [.050] to
24–20 [0.24–0.61] D-129-03 — — — D-714-00
2.28 [.090]
W = 2.28 [.090] to
24–20 [0.24–0.61] D-129-0043 — — — —
tab 3.55 [.140]

For Fine Wire Part Inside Diameter Fully

Length††
No.* As Supplied** Recovered†
Terminations D-110-0062 1.0 [0.040] 0.6 [0.025] 16.0 [0.630]
0.15 mm2 (26 AWG) D-110-0217 1.0 [0.040] 0.6 [0.025] 9.0 [0.360]
and Smaller* D-141-13 0.75 x 1.65 [0.030 X 0.065] 0.75 [0.030] 4.7 [0.185]
D-141-22 0.75 x 1.65 [0.030 X 0.065] 0.75 [0.030] 6.0 [0.240]
D-141-30 0.75 x 1.65 [0.030 X 0.065] 0.75 [0.030] 9.5 [0.375]
Note: Micro SolderSleeve terminators are used for attaching leads smaller than 26 AWG (0.15 mm2) to terminals less than
0.6 [.025] wide.
*The D-110 series sleeves are primarily for single wire terminations and do not have a wire stop. The D-141 series will
accept either one or two wires; the parts have a built-in wire stop that will locate the wire approximately 0.76 [0.03] from
bottom of terminal.
**Minimum. Wire insulation must be smaller than this. When using the D-141 parts for two-wire terminations, the
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.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 44

Electrical Interconnect Products

Product Material
Characteristics Insulation [D-129, D-141, D-71X] Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Insulation [B-155, CWT] Radiation-crosslinked, heat-shrinkable polyolefin
Solder and flux [D-129, D-141, D-71X] Solder: Sn63 Pb37 Flux: ROL1 per ANSI-J-004 [RMA flux]
Solder and flux [B-155] Solder: Sn42Bi58 Flux: ROM1 per ANSI-J-004 [RA flux]
Solder and flux [CWT] Solder: Sn50 Pb32 Cd 18 Flux: ROM1 per ANSI-J-004 [RA flux]
Typical Performance
Voltage drop 2.0 mV
Tensile strength Exceeds strength of conductor
Dielectric strength 2.0 kV
Temperature rating [B-155, CWT] -55°C to 125°C [-67°F to 257°F]
Temperature rating [D-129, D-141, D-71X] -55°C to 150°C [-67°F to 302°F]
Insulation resistance 1000 megohms

Specifications/ Series Agency TE

B-155 RoHS RT-1404
Approvals CWT UL and CUL E87681 D-5023
D-129, D-141 UL and CUL E87681 RT-1404

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 45

 Shield
Termination
Introduction
TE 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 -65°C to 200°C [-85°F to 392°F], the
products in this section include:
•B  -155-X and CWT-X SolderSleeve terminators,
designed for low-temperature cables with operating
temperatures up to 125°C [257°F] and suitable for most
commercial environments.
• MIL-S-83519 SolderSleeve terminators, which are
immersion resistant and available with or without a
preinstalled ground lead.
• SO Series SolderSleeve terminators, which also
are immersion resistant and feature the TE BiAlloy
temperature indication system.
• S200 Shield terminators are offered in various sizes
and ground lead configurations.
All SolderSleeve products are reliable, versatile, and easy
to install, resulting in lower installed costs.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 46

 Electrical Interconnect Products

SolderSleeve Shield Terminators

Product Selection Process
1. Select product series from the Product Options table below.
2. Determine cable dimensions.
3. Optional: Select preinstalled wire lead type (see Table G on
page 53 for type descriptions).
4. S
 elect part number (use the selection table indicated for your
product series in the Product Options table below).
RUGGED 5. Refer to Table H on page 53 for cross-reference information.
• Transparent insulation sleeve
provides encapsulation,
inspectability, strain relief, and
insulation

VERSATILE
• Prefluxed solder preform provides a Jacket OD (max.) Shield OD (min.)
controlled soldering process

EASY TO USE
• One-piece design means easy
installation and lower installed cost

• Optional preinstalled ground

leads provide convenience and
ease of installation

APPLICATIONS
• Used for shield-to-ground
termination

Product Options (Refer to Table G on Page 53 for Additional Information)

System Oper. Used on Part No.

Product Environmental Solder Flux Insulation
Temperature Cables Rated Selection
Series Protection Alloy Type Material
(Max.) (Min.) Table
B-155 125°C [257°F] 85°C [185°F] Splash resistant Bi58 PA Polyolefin A
CWT 125°C [257°F] 85°C [185°F] Splash resistant Cd18 RA Polyolefin A
SO63* 150°C [302°F] 125°C [257°F] Immersion resistant Sn63 RMA Polyvinylidene fluoride B
S01/S02**, S03 150°C [302°F] 125°C [257°F] Immersion resistant Sn63 RMA Polyvinylidene fluoride C, D
SO96*** 175°C [347°F] 150°C [302°F] Immersion resistant Sn96 RA Polyvinylidene fluoride E
SO175**** 175˚C [347°F] 150˚C [302°F] Immersion resistant Sn96 RA Polyvinylidene fluoride F
S200**** 200°C [392°F] 150˚C [302°F] Immersion resistant Sn96 RA Fluoropolymer G
*Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) and NAS 1747, supplied with BiAlloy temperature indicator.
**Qualified to SAE-AS83519 (formerly MIL-S-83519), supplied with thermochromic temperature indicator.
***Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) and NAS 1747, supplied with thermochromic temperature indicator.
****Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519), supplied with BiAlloy temperature indicator.
Note: Cadmium-free option (B-152 series) is available for operating temperature of 125˚C [257˚F]. Consult TE for details.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 47

Electrical Interconnect Products

Raychem S200 Shield Terminators

HIgh-Performance, High-Temperature Cable Terminators
An important extension of the Raychem SolderSleeve family,
S200 shield termination devices were developed specifically
to address the need for high-temperature connecting,
insulating, and sealing for applications in the aerospace and
defense industry.
Wide Selection
Offered in various sizes and ground lead configurations, our
S200 shield termination devices provide environmentally
ECONOMICAL
protected shield termination on cables with a minimum
• One-piece design allows for a single- temperature rating of 150°C, and silver or nickel-plated shields.
step, simplified installation and a low They are also available with bi-alloy or thermochromic indicators
total installed cost Fast Installation and Lower Costs
Convenient to use, the one-piece design of S200 shield
• Bi-alloy or thermochromic
termination devices help ensure reliable environmental
temperature indicator works as a
protection and greatly simplified installation for a lower total
process control aid and simplifies
installed cost.
operator training

• Offered in various sizes and ground MATERIALS

lead configurations • Solder: Tin 96%/Silver 4% bi-alloy solder
• Tubing: Heat-shrinkable modified fluoropolymer
CAPABLE
• Inserts: Thermoplastic fluoropolymer
• Provides a completely soldered,
strain-relieved termination STANDARDS AND SPECIFICATIONS
• I ndustry Standards:
• Heat-shrinkable sleeve helps
SAE-AMS-DTL-23053/13 (applies to heat-shrinkable insulation sleeve only)
provide insulation, inspectability, and
SAE-AS83519 (modified for 200°C applications)
strain relief
EU RoHS/ELV compliant
• Designed for high-temperature •T
 E Instruction Sheet: RCPS-100-71
applications up to 200°C • TE Qualification and Test Report: Available on request
• Sealing inserts helps ensure reliable,
MECHANICAL/ENVIRONMENTAL
environmental protection
• Operating Temperature: 150°C to 200°C
APPLICATIONS •D
 urability: Heat-shrinkable sleeve adheres and seals to provide a completely
soldered, strain-relieved termination
• Shield termination of cables
subjected to a minimum temperature
rating of 150°C and maximum
operating temperature of 200°C

• Protecting and sealing for BMS 13-60

PTFE wrapped cables and M27500
cables with PTFE/polyimide jackets

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 48

Electrical Interconnect Products

ORDERING INFORMATION (TC indicates that this part has a thermochromic indicator)
Without ground lead
Jacket OD (mm) Shield (mm) Product Description Raychem Part Number SAE AS83519
1.90 0.90 S200-1-00 F92583-000
1.90 0.90 S200-1-00-TC CN5417-000
2.67 1.40 S200-2-00 F94898-000
2.67 1.40 S200-2-00-TC CN5418-000
4.32 2.15 S200-3-00 A65903-000
4.32 2.15 S200-3-00-TC CN5419-000
5.97 3.30 S200-4-00 E32454-000
5.97 3.30 S200-4-00-TC CN5420-000
6.98 4.30 S200-5-00 D12074-000
6.98 4.30 S200-5-00-TC CN5421-000

With pre-installed braid: Nickel-plated copper strands in accordance to AA59569F36N0031. (6 Inches)

Jacket OD (mm) Shield (mm) Product Description Raychem Part Number SAE AS83519
1.90 0.90 S200-1-01 CS5526-000 M83519/5-1
2.67 1.40 S200-2-01 D08259-000 M83519/5-2
4.32 2.15 S200-3-01 A77145-000 M83519/5-3
5.97 3.30 S200-4-01 F26506-000 M83519/5-4
6.98 4.30 S200-5-01 A18826-000 M83519/5-5

With pre-installed braid: Ni-plated copper strands per ASTM B355, Class 4. CMA = 1200. (6 Inches)
Jacket OD (mm) Shield (mm) Product Description Raychem Part Number SAE AS83519
1.90 0.90 S200-1-9020 CJ1037-000 M83519/5-11
1.90 0.90 S200-1-9020-TC CP7589-000 M83519/5-16
2.67 1.40 S200-2-9020 CJ1039-000 M83519/5-12
2.67 1.40 S200-2-9020-TC CP4262-000 M83519/5-17
4.32 2.15 S200-3-9020 CJ1041-000 M83519/5-13
4.32 2.15 S200-3-9020-TC CP6063-000 M83519/5-18
5.97 3.30 S200-4-9020 CJ1042-000 M83519/5-14
5.97 3.30 S200-4-9020-TC CP6893-000 M83519/5-19
6.98 4.30 S200-5-9020 CJ1043-000 M83519/5-15
6.98 4.30 S200-5-9020-TC CP7313-000 M83519/5-20

With pre-installed braid: Ni-plated copper strands per ASTM B355, Class 4. CMA = 1800. (6 Inches)
Jacket OD (mm) Shield (mm) Product Description Raychem Part Number SAE AS83519
1.90 0.90 S200-1-9030 CA7639-000
2.67 1.40 S200-2-9030 CA7640-000
4.32 2.15 S200-3-9030 CA7641-000
5.97 3.30 S200-4-9030 CA7642-000
6.98 4.30 S200-5-9030 CA7643-000
6.98 4.30 S200-5-9030-TC CP7417-000

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Electrical Interconnect Products

With pre-installed braid: High nickel-plated copper strands per ASTM-B355 Class 7. CMA = 640. (10 Inches)
Jacket OD (mm) Shield (mm) Product Description Raychem Part Number SAE AS83519
1.90 0.90 S200-1-01-100HN D89883-000
2.67 1.40 S200-2-01-100HN A87947-000
4.30 2.15 S200-3-01-100HN A59779-000
5.95 3.30 S200-4-01-100HN C69495-000
6.90 4.30 S200-5-01-100HN D92195-000

With pre-installed braid: Stranded nickel-plated copper wire in accordance with SAE-AS22759/41.
Jacket OD (mm) Shield (mm) Product Description Raychem Part Number SAE AS83519
1.90 0.90 S200-1-55-22-9 EH1934-000
2.67 1.40 S200-2-55-22-9 EH1935-000
4.30 2.15 S200-3-55-22-9 EH1936-000
5.95 3.30 S200-4-55-22-9 EH1938-000
6.90 4.30 S200-5-55-22-9 EH1939-000

With pre-installed braid: Stranded nickel-plated copper wire in accordance with SAE-AS22759/41.
Jacket OD (mm) Shield (mm) Product Description Raychem Part Number SAE AS83519
1.90 0.90 S200-1-55-20-9 EH1940-000
2.67 1.40 S200-2-55-20-9 EH1941-000
4.30 2.15 S200-3-55-20-9 EH1942-000
5.95 3.30 S200-4-55-20-9 EH1943-000
6.90 4.30 S200-5-55-20-9 EH1944-000

With pre-installed braid: Stranded nickel-plated copper wire in accordance with SAE-AS22759/41.
Jacket OD (mm) Shield (mm) Product Description Raychem Part Number SAE AS83519
1.90 0.90 S200-1-55-18-9 EH1945-000
2.67 1.40 S200-2-55-18-9 EH1946-000
4.30 2.15 S200-3-55-18-9 EH1948-000
5.95 3.30 S200-4-55-18-9 EH1949-000
6.90 4.30 S200-5-55-18-9 EH1950-000

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Electrical Interconnect Products

Table A. B-155 Series

(125°C [257°F] rated)

Cable OD Part Nos.

Jacket Shield No Preinstalled With Preinstalled Lead
OD Max. OD Min. Lead (22AWG/0.38 mm2 green)
1.7 [.065] 0.9 [.035] B-155-3801 —
1.95 [.075] 1.1 [.043] B-155-3802 —
2.7 [.105] 1.5 [.059] B-155-3 B-155-03-35-22-5
4.5 [.180] 2.0 [.079] B-155-5 B-155-05-35-22-5
6.0 [.235] 3.3 [.130] B-155-6 B-155-06-35-22-5
7.0 [.275] 3.3 [.130] B-155-7 B-155-07-35-22-5
8.7 [.340] 4.5 [.177] B-155-9 B-155-09-35-22-5
10.7 [.420] 4.5 [.177] B-155-11 B-155-11-35-22-5
13.0 [.510] 7.0 [.276] B-155-13 B-155-13-35-22-5
*See Table G on page 53 for lead description.
Note: The B-155 series is suitable for applications using low-temperature wires (typically rated at 85°C [185°F] to 125°C [257°F]) with bare copper or tin plating.

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.

Cable OD Part Nos.

No Preinstalled Lead Option* Braid Strap
Jacket OD Shield OD
Preinstalled
Max. Min.
Lead 20 AWG 22 AWG 24 AWG 26 AWG Nickel Plated Tin Plated
1.95 [0.075] 0.90 [.035] SO63-1-00 SO63-1-55-20-90 SO63-1-55-22-90 SO63-1-55-24-90 SO63-1-55-26-90 SO63-1-01 SO63-1-9030
2.7 [0.105] 1.40 [.055] SO63-2-00 SO63-2-55-20-90 SO63-2-55-22-90 SO63-2-55-24-90 SO63-2-55-26-90 SO63-2-01 SO63-2-9030
4.3 [0.170] 2.15 [.085] SO63-3-00 SO63-3-55-20-90 SO63-3-55-22-90 SO63-3-55-24-90 SO63-3-55-26-90 SO63-3-01 SO63-3-9030
6.0 [0.235] 3.30 [.130] SO63-4-00 SO63-4-55-20-90 SO63-4-55-22-90 SO63-4-55-24-90 SO63-4-55-26-90 SO63-4-01 SO63-4-9030
7.0 [0.275] 4.30 [.170] SO63-5-00 SO63-5-55-20-90 SO63-5-55-22-90 SO63-5-55-24-90 SO63-5-55-26-90 SO63-5-01 SO63-5-9030
*See Table G on page 53 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 TE BiAlloy temperature indication system, and meets the performance requirements of SAE-AS83519
(formerly MIL-S-83519) .

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Electrical Interconnect Products

Table C. S01/S02 Thermochromic Temperature Indicator

M83519 Series 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 TE Part No.) by Lead Option
Preinstalled Lead Option*
No Preinstalled Lead
Jacket OD Shield OD 20 AWG 22 AWG
Max Min MIL TE MIL TE MIL TE

1.95 [0.075] 0.9 [.035] M83519/1-1 S01-01-R M83519/2-1 S02-01-R M83519/2-6 S02-06-R
2.7[0.105] 1.40 [.055] M83519/1-2 S01-02-R M83519/2-2 S02-02-R M83519/2-7 S02-07-R
4.3 [0.170] 2.15 [.085] M83519/1-3 S01-03-R M83519/2-3 S02-03-R M83519/2-8 S02-08-R
6.0 [0.235] 3.30 [.130] M83519/1-4 S01-04-R M83519/2-4 S02-04-R M83519/2-9 S02-09-R
7.0 [0.275] 4.30 [.170] M83519/1-5 S01-05-R M83519/2-5 S02-05-R M83519/2-10 S02-10-R
Jacket OD Shield OD Preinstalled Lead Option*
Max. Min. 24 AWG 26 AWG
1.95 [0.075] 0.9 [.035] M83519/2-11 S02-11-R M83519/2-16 S02-16-R
2.7 [0.105] 1.40 [.055] M83519/2-12 S02-12-R M83519/2-17 S02-17-R
4.3[0.170] 2.15 [.085] M83519/2-13 S02-13-R M83519/2-18 S02-18-R
6.0 [0.235] 3.30 [.130] M83519/2-14 S02-14-R M83519/2-19 S02-19-R
7.0 [0.275] 4.30 [.170] M83519/2-15 S02-15-R M83519/2-20 S02-20-R
*See Table G for lead description.
M83519 is the qualified product listed in SAE-AS83519 (formerly MIL-S-83519) . The series features a thermochromic temperature indicator to assist in
termination and inspection. The part number is permanently marked on the sleeve.

Table D. S03 Thermochromic Temperature Indicator These parts now have qualification to /3
Series SOLDER SLEEVE SHIELD TERMINATORS
The S03 series terminators contain a colored S03-01-R 257305-000 M83519/3-1 SAE AS83519
thermochromic temperature indicator that exhibits a S03-02-R 065762-000 M83519/3-2 SAE AS83519
distinct color change when surfaces have reached S03-03-R 676516-000 M83519/3-3 SAE AS83519
wetting temperature. This color change gives both S03-04-R 689088-000 M83519/3-4 SAE AS83519
Manufacturing and Quality Control an aid in the S03-05-R 531872-000 M83519/3-5 SAE AS83519
inspection of the completed termination. S03-06-R 022926-000 M83519/3-6 SAE AS83519
S03-07-R 101273-000 M83519/3-7 SAE AS83519
S03-08-R 587725-000 M83519/3-8 SAE AS83519
S03-09-R 751586-000 M83519/3-9 SAE AS83519
S03-10-R 621833-000 M83519/3-10 SAE AS83519

Cable OD Part No.

Jacket OD Preinstalled Lead Option*
Shield OD
Min.
Max. Tin plated Braid Strap Nickel plated Braid Strap
1.95 [0.075] 0.9 [.035] S03-01-R S03-06-R
2.7 [0.105] 1.40 [.055] S03-02-R S03-07-R
4.3 [0.170] 2.15 [.085] S03-03-R S03-08-R
6.0 [0.235] 3.30 [.130] S03-04-R S03-09-R
7.0 [0.275] 4.30 [.170] S03-05-R S03-10-R
*See Table G for lead description.

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Electrical Interconnect Products

Table E. SO96 Series Thermochromic Temperature Indicator

(175°C [347°F] rated) 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 Preinstalled Lead Option*
Shield OD No
Min. Preinstalled Lead
Max. 22 AWG Braid Strap
1.95 [0.075] 0.9 [.035] SO96-1-00 SO96-1-55-22-90 SO96-1-01
2.7 [0.105] 1.40 [.055] SO96-2-00 SO96-2-55-22-90 SO96-2-01
4.3 [0.170] 2.15 [.085] SO96-3-00 SO96-3-55-22-90 SO96-3-01
6.0 [0.235] 3.30 [.130] SO96-4-00 SO96-4-55-22-90 SO96-4-01
7.0 [0.275] 4.30 [.170] SO96-5-00 SO96-5-55-22-90 SO96-5-01
*See Table G for lead description.
The SO96 series is designed for high-temperature applications with operating temperature requirements up to 200°C [392°F]. This series features a
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 BiAlloy Temperature Indication System

(175°C [347°F] rated) 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.

Jacket OD Preinstalled Lead Option*
Shield OD No
Min. Preinstalled Lead
Max. 22 AWG Braid Strap
1.95 [0.075] 0.90 [0.035] SO175-1-00 SO175-1-55-22-90 SO175-1-01
2.7 [0.105] 1.40 [0.055] SO175-2-00 SO175-2-55-22-90 SO175-2-01
4.3 [0.170] 2.15 [0.085] SO175-3-00 SO175-3-55-22-90 SO175-3-01
6.0 [0.235] 3.30 [0.130] SO175-4-00 SO175-4-55-22-90 SO175-4-01
7.0 [0.275] 4.30 [0.170] SO175-5-00 SO175-5-55-22-90 SO175-5-01
*See Table H for lead description.

Table G. S200 Series BiAlloy Temperature Indication System

(200°C [392°F] rated) This system greatly enhances the reliability and repeatability of S200 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.

Jacket OD Preinstalled Lead Option*
Shield OD No
Min. Preinstalled Lead
Max. 22 AWG Braid Strap
1.95 [0.075] 0.90 [0.035] S200-1-00 S200-1-55-22-9 S200-1-01
2.7 [0.105] 1.40 [0.055] S200-2-00 S200-2-55-22-9 S200-2-01
4.3 [0.170] 2.15 [0.085] S200-3-00 S200-3-55-22-9 S200-3-01
6.0 [0.235] 3.30 [0.130] S200-4-00 S200-4-55-22-9 S200-4-01
7.0 [0.275] 4.30 [0.170] S200-5-00 S200-5-55-22-9 S200-5-01
*See Table H for lead description.

Table H. Preinstalled Lead Description

Series Lead Type Remarks Plating Stranding Min. Length
S200 M22759/91 MIL-W-22759/91 Silver Stranded 150 (6.00)
M83519, SO63 55A0111 MIL-W-22759/32 Tin Stranded 150 [6.00]
SO96, SO175 55A0813 MIL-W-22759/41 Nickel Stranded 150 [6.00]
SO63, SO96, S03 Braid strap Uninsulated Nickel 40 x 38 AWG 150 [6.00]
B-155 XL polyethylene RoHS Tin Stranded (W2) 150 [6.00]
CWT XL polyethylene UL Listed Tin Stranded (W1) 150 [6.00]
SO63, S03 Braid Strap Uninsulated Tin Stranded 150 [6.00]

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 53

Electrical Interconnect Products

Product Material
Characteristics Insulation
S200 Radiation-crosslinked, heat-shrinkable, modified fluoropolymer
SO, M83519 Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
B-155 Radiation-crosslinked, heat-shrinkable polyolefin
Solder and flux
SO63, M83519, S03 Solder: Sn63 Pb37 Flux: ROL1 per ANSI - J - 004 (RMA Flux)
S200, SO96, SO175 series Solder: Sn96 Ag4 Flux: ROM1 per ANSI - J - 004 (RA Flux)
B-155 Solder: SN42Bi58 Flux: ROM1 per ANSI - J - 004 (RA Flux)
Ground lead
B-155 series XL polyethylene
S200 series MIL-C-22759/91 or /87
SO, M83519, SO175 MIL-W-22759/32 or /41
Typical Performance
Voltage drop 2.5 mV
Tensile strength Exceeds strength of ground lead
Dielectric strength 1.0 kV immersed
Temperature rating
B-155 -55°C to 125°C [-67°F to 257°F]
SO63/M83519/S03 -55°C to 150°C [-67°F to 302°F]
SO96/SO175 series -55°C to 175°C [-67°F to 347°F]
S200 -55°C to 200°C [-67°F to 392°F]
Insulation resistance 1000 megohms

Specifications/ Series Agency TE

Approvals B-155 — RT-1404
SO63* NAS 1747 RT-1404
M83519** MIL-S-83519/1&/2 RT-1404
SO96*** NAS 1747 RT-1404
SO175 RT-1404
S200** — 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 For detailed instructions and recommended reflector
Requirements these devices, the correct attachments, refer to the appropriate TE installation
heating tool and reflector procedure:
attachment must be used. Series Procedure
Any one of the following
TE heating tools B-155 RPIP-824-000
is recommended: CWT RPIP-655-00-D
n HL1920E/HL2020E SO63 RCPS-100-70
n AA-400 Super Heater M83519 (S01/S02) RCPS-100-70
n CV-1981 SO96 RCPS-100-70
n MiniRay S03 RCPS-100-70
n IR-1759 SO175 RCPS-100-70
S200 RCPS-100-71

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Electrical Interconnect Products

Table H. NAS, NAS TE D Series NAS

M83519, and
Part No. Part No. Comment
TE Cross-Reference 1744-1 D-1744-01
1744-2 D-1744-02
1744-3 D-1744-03
1744-4 D-1744-04
1744-5 D-1744-05
1744-6 D-1744-06
1744-7 D-1744-07
1744-8 D-1744-08
1745-1 D-144-25 Inactive, Use SAE-AS83519/1-1 (formerly MIL-S-83519)
1745-2 D-100-00 Inactive, Use SAE-AS83519/1-2 (formerly MIL-S-83519)
1745-3 D-101-00 Inactive, Use SAE-AS83519/1-3 (formerly MIL-S-83519)
1745-4 D-103-00 Inactive, Use SAE-AS83519/1-5 (formerly MIL-S-83519)
1745-5 D-144-26
1745-6 D-100-31
1745-7 D-101-31
1745-8 D-103-31
1745-9 Obsolete - Use NAS1745-13
1745-10 Obsolete - Use NAS1745-14
1745-11 Obsolete - Use NAS1745-15
1745-12 Obsolete - Use NAS1745-16
1745-13 D-142-83 Inactive, Use SAE-AS83519/1-1 (formerly MIL-S-83519)
1745-14 D-142-50 Inactive, Use SAE-AS83519/1-2(formerly MIL-S-83519)
1745-15 D-142-51 Inactive, Use SAE-AS83519/1-3 (formerly MIL-S-83519)
1745-16 D-142-52 Inactive, Use SAE-AS83519/1-5 (formerly MIL-S-83519)
1745-17 D-107-00 Inactive, Use SAE-AS83519/1-4 (formerly MIL-S-83519)
1745-18 D-104-00
1745-19 D-105-00
1745-20 D-107-31
1745-21 D-104-31
1745-22 D-105-31
1745-23 D-142-56 Inactive, Use SAE-AS83519/1-4 (formerly MIL-S-83519)
1745-24 D-142-65
1745-25 D-142-66
1746-1 D-144-25 Inactive, Use SAE-AS83519/1-1 (formerly MIL-S-83519)
1746-2 D-144-00 Inactive, Use SAE-AS83519/1-2 (formerly MIL-S-83519)
1746-3 D-144-01 Inactive, Use SAE-AS83519/1-3 (formerly MIL-S-83519)
1746-4 D-144-02 Inactive, Use SAE-AS83519/1-5 (formerly MIL-S-83519)
1746-5 D-144-26
1746-6 D-144-03
1746-7 D-144-04
1746-8 D-144-05
1746-9 D-144-46 Inactive, Use SAE-AS83519/1-4 (formerly MIL-S-83519)
1746-10 D-144-37
TE TE
Military S01/S02 Series* SO63 Series**
Part No. Part No. Part No.
M83519/1-1 S01-01-R SO63-1-00
M83519/1-2 S01-02-R SO63-2-00
M83519/1-3 S01-03-R SO63-3-00
M83519/1-4 S01-04-R SO63-4-00
M83519/1-5 S01-05-R SO63-5-00
M83519/2-1 S02-01-R SO63-1-55-20-90
M83519/2-2 S02-02-R SO63-2-55-20-90
M83519/2-3 S02-03-R SO63-3-55-20-90
M83519/2-4 S02-04-R SO63-4-55-20-90
M83519/2-5 S02-05-R SO63-5-55-20-90
M83519/2-6 S02-06-R SO63-1-55-22-90
M83519/2-7 S02-07-R SO63-2-55-22-90
M83519/2-8 S02-08-R SO63-3-55-22-90
M83519/2-9 S02-09-R SO63-4-55-22-90
M83519/2-10 S02-10-R SO63-5-55-22-90
M83519/2-11 S02-11-R SO63-1-55-24-90
M83519/2-12 S02-12-R SO63-2-55-24-90
M83519/2-13 S02-13-R SO63-3-55-24-90
M83519/2-14 S02-14-R SO63-4-55-24-90
M83519/2-15 S02-15-R SO63-5-55-24-90
M83519/2-16 S02-16-R SO63-1-55-26-90
M83519/2-17 S02-17-R SO63-2-55-26-90
M83519/2-18 S02-18-R SO63-3-55-26-90
M83519/2-19 S02-19-R SO63-4-55-26-90
M83519/2-20 S02-20-R SO63-5-55-26-90
* QPL listed to SAE-AS83519 (formerly MIL-S-83519)
** Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519)

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 55

 Coaxial Cable
Termination
Introduction
TE 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 150°C
[302°F], the products in this section include:
•S
 olderSleeve coaxial cable terminators, which allow
reliable, economical attachment of coaxial cable to
connector terminals, printed wiring assemblies, or
solderless wrap terminals.
•O
 ne-piece SolderSleeve PCB coaxial cable terminators,
which permit quick, easy, and cost-effective
terminations of coaxial cable to printed circuit boards.
•R
 F 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-C-39012C connectors and are available in 50-ohm
and 75-ohm versions).
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.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 56

 Electrical Interconnect Products

SolderSleeve Coaxial Cable Terminators

Product Selection Process
1. Select product series from the product options table below.
2. Select preinstalled lead type from the table below.
3. Determine cable RG number or dimensions.
4. S
 elect part number from Table A (B-155, CWT series) or
Table B (B-02X/B-04X series) on the next page.

VERSATILE
Product Characteristics
• Transparent polyvinylidene
Material
fluoride or polyolefin insulation
Insulation Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
sleeve provides encapsulation, (B-02X/B-04X, D-181, D-184)
inspectability, strain relief Insulation (B-155, CWT series) Radiation-crosslinked, heat-shrinkable polyolefin
(eliminates center conductor Solder and flux Solder: Sn63 Pb37 Flux: ROL1 per ANSI-J-004 (RMA Flux)
breakage), and insulation. (B-02X/B-04X, D-181)
Solder and flux Solder: Sn50 Pb32 Cd18 Flux: ROM1 per ANSI-J-004 (RA Flux)
• Prefluxed solder preform provides (CWT series, D-184)
a controlled soldering process Solder and flux (B-155) Solder: Sn42Bi58 Flux: ROM1 per ANSI-J-004 (RA Flux)
Typical Performance
EASY TO USE Voltage drop 2.0 mV
Tensile strength Exceeds strength of conductor
• One-piece design means easy
Dielectric strength 2.0 kV
installation and lower installed cost
Temperature rating -55°C to 125°C [-67°F to 257°F]
• Optional preinstalled ground (B-155, CWT, D-184)
leads provide convenience and Temperature rating -55°C to 150°C [-67°F to 302°F]
(B-02X/B-04X, D-181)
ease of installation
Insulation resistance 1000 megohms
APPLICATIONS
• Used for terminating coaxial cable
to component terminals, contacts,
printed circuit boards, and solderless
wrap terminals.

Product Options
Product Series Max. Operating Temp. Use on Cables Rated (Min) Cable Shield Plating Part No. Selection Table Design
B-155, CWT 125°C [257°F] 85°C [185°F] Tin, copper A 2-pc.
B-02X/B-04X 150°C [302°F] 125°C [257°F] Tin, silver B 1-pc.
D-181 150°C [302°F] 125°C [257°F] Tin, silver C 2-pc.
D-184 125°C [257°F] 85°C [185°F] Tin D 2-pc.

Preinstalled Lead Descriptions

Series Lead Type Plating Stranding AWG Length Color
B-155, CWT XL polyethelene Tin Stranded (W1) 22 150 [6.000] White (cntr), green (grnd)
B-021 M81822/13 (solderless wrap) Silver Solid-OFHC 24—30 150 [6.000] White (cntr), blue (grnd)
B-041 M81822/13 (solderless wrap) Silver Solid-OFHC 24—30 150 [6.000] White (cntr), blue (grnd)
B-043 M81822/13 (solderless wrap) Silver Solid-OFHC 24—30 150 [6.000] White (cntr), blue (grnd)
B-020 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), blue (grnd)
B-040 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), blue (grnd)
B-044 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), blue (grnd)
D-181-12XX 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), white w/black stripe (grnd)
D-181-22XX 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), white w/black stripe (grnd)
D-181-32XX 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), white w/black stripe (grnd)
D-181-18XX M81822/13 Silver Solid 26 – 30 150 [6.000] White (cntr), blue (grnd)
D-181-28XX M81822/13 Silver Solid 26 – 30 150 [6.000] White (cntr), blue (grnd)
D-184 55A0111 (MIL-W-22759/32) Tin Stranded 20 – 26 150 [6.000] White (cntr), white w/black stripe (grnd)

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 57

Electrical Interconnect Products

Table A. B-155 Series Dimensions Part No.

Cable RG Number With Preinstalled Lead
Part Numbers Dielectric OD Jacket OD AWG/0.38 mm2 Green/White)
174 0.80–2.30 [.032–.091] 1.30–2.80 [.051–.110] CWT-4174-W122-5/9
58, 122 2.00–2.80 [.079–.110] 2.50–4.40 [.100–.173] CWT-4058-W122-5/9
59 2.80–3.30 [.110–.130] 3.20–6.00 [.125–.235] CWT-4059-W122-5/9

Table B. B-02X/B-04X Part 1: Coaxial Product Group Selection

Series Part Numbers
Typical Compatible
Part No. Dimension Range
TE One-Piece
RG Cable Dielectric Conductor
Number Cable Jacket OD (Max.) Shield OD OD OD Coaxial Product
Description Group
5030A13XX 3.40 1.30–2.30 0.50–1.70 0.30–0.80
RG178, RG404 Group 1
5028A13XX [.134] [.051–.091] [.019–.067] [.011–.032]
5024A13XX
RG179, RG316 7530A13XX 4.40 1.50–2.80 1.20–2.50 0.30–1.60
Group 2
7526A13XX [.173] [.060–.110] [.047–.100] [.011–.063]
9530A13XX
RG180, RG302, 9527A13XX 6.30 2.40–4.60 1.40–4.30 0.30–2.80
Group 3
RG303 9528A13XX [.248] [.094–.181] [.055–.169] [.011–.110]
Part 2: Product Part Number Selection
One-Piece Preinstalled Wire Size
Preinstalled
Coaxial Wire Type 20 22 24 26 28 30
Product Group AWG AWG AWG AWG AWG AWG
Stranded — B-044-22-N B-044-24-N B-044-26-N — —
(M22759)
Group 1
Solid — — B-043-24-N B-043-26-N B-043-28-N B-043-30-N
(M81822)
Stranded B-040-20-N B-040-22-N B-040-24-N B-040-26-N B-040-28-N B-040-30-N
(M22759)
Group 2
Solid — — B-041-24-N B-041-26-N B-041-28-N B-041-30-N
(M81822)
Stranded B-020-20-N B-020-22-N B-020-24-N B-020-26-N — —
(M22759)
Group 3
Solid — — — B-021-26-N — —
(M81822)
1. T
 he B-02X/B-04X series uses a one-piece design to terminate coaxial cables rated at 125°C minimum.
2. U
 sing Part 1 of this table, select the appropriate coaxial product group (1, 2, or 3) based on your RG cable number, TE cable
description, or cable dimensions.
3. U
 sing 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.

Product Dimensions
Table C. D-181 Series Product A B C D E F L1 L2 Wire
Part Numbers Name min. min. min. min. min. min. max. max. AWG
D-181-1220-90/9 20
D-181-1222-90/9 22
D-181-1224-90/9 3.7 3.2 2.7 2.4 0.71 2.3 17 21.5 24
∅E min. D-181-1226-90/9 [0.145] [0.125] [0.105] [0.095] [0.028] [0.09] [0.67] [0.85] 26
∅F min.
L1 max. D-181-1826-6/9 26
L2 max.
D-181-1830-6/9 30
∅A min. ∅D min.
D-181-2220-90/9 20
D-181-2222-90/9 22
D-181-2224-90/9 4.5 4 3.45 2.9 1.1 3 17 22.7 24
∅B min. ∅C min.

D-181-2226-90/9 [0.18] [0.16] [0.135] [0.115] [0.045] [0.12] [0.67] [0.895] 26

D-181-2826-6/9 26
D-181-2830-6/9 30
D-181-3220-90/9 20
D-181-3222-90/9 ] 22
D-181-3224-90/9 5.2 4.7 4.45 3.95 1.3 4 17 21.5 24
D-181-3226-90/9 [0.205] [0.185] [0.175] [0.155] [0.055] [0.16] [0.67] [0.85] 26
D-181-3826-6/9 26
D-181-3830-6/9 30

Table D. D-184 Series Product Dimensions

Part Numbers Product ∅A ∅B ∅C ∅D ∅E ∅F L1 L2 Wire
Name min. min. min. min. min. min. max. max. AWG
D-184-1220-90/9 20
∅E min.
D-184-1222-90/9 3.7 3.2 2.7 2.4 0.71 2.3 17 21.5 22
∅F min.
L1 max. D-184-1224-90/9 [0.145] [0.125] [0.105] [0.095] [0.028] [0.09] [0.67] [0.85] 24
L2 max. D-184-1226-90/9 26
∅A min. ∅D min.
D-184-2220-90/9 20
D-184-2222-90/9 4.5 4 3.45 2.9 1.1 3 17 22.7 22
∅B min. ∅C min.
D-184-2224-90/9 [0.18] [0.16] [0.135] [0.115] [0.045] [0.12] [0.67] [0.895] 24
D-184-2226-90/9 26

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 58

Electrical Interconnect Products

SolderSleeve PCB/Coaxial Cable Terminators

Installation Requirements
For proper installation of these devices, the correct heating
tool and reflector attachment must be used. Any one of the
following TE heating tools is recommended:
• HL1920E/HL2020E
• AA-400 Super Heater
• IR-1759 MiniRay
VERSATILE • CV-1981
• Transparent polyvinylidene Refer to TE installation procedure ES-61139 for detailed
fluoride or polyolefin insulation
sleeve provides encapsulation,
instructions and recommended reflector attachments.
inspectability, strain relief
(eliminates center conductor Product Selection Process
breakage), and insulation. 1. Select product series from the Product Options table below.
• Prefluxed solder preform provides 2. Determine cable RG number or outside diameter dimensions.
a controlled soldering process
3. Select the appropriate part number from Table A
EASY TO USE (D-607 series) or Table B (B-046 series).
• One-piece design means easy
•F
 or D-607 (matched impedance) series, determine straight
installation and lower installed cost
or right-angle entry to PCB and grid pattern, then select the
• Optional preinstalled ground appropriate part number from Table A on the next page.
leads provide convenience and
ease of installation •F
 or B-046 (PinPak, or pin to ground) series, determine hole
spacing and diameter. Refer to Table B for product selection
APPLICATIONS (see illustration below for cable dimensions).
• Used for terminating coaxial cable
to component terminals, contacts,
printed circuit boards, and solderless
wrap terminals.

A B C D

Product Options
Product Series Typical Application Performance Shield Method Part No. Selection Table
D-607 Matched impedance up to 2.3 GHz Metal body A
B-046 Effective transmission up to 100 MHz Pin to ground B

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 59

Electrical Interconnect Products

Specifications/Approvals

Series TE
D-607 RT-1404
B-046 RT-1404

Table A. D-607 Series

Part Numbers

Cable Dimensions (mm/in) Part No.

Max. Outside Diameter Entry to PCB
RG Cable No.
Jacket Shield Dielectric Straight Right-Angle Straight
grid 5.08 [.200] Grid 5.08 [.200] Grid 2.54 [.100]
174, 178, 179, 1.5–3.55 1.1–3.15 0.60–2.25
316, 404 [.060–.140] [.045–.125] [.025–.090] D-607-09 D-607-10 D-607-40*

Table B. B-046 Series

Part Numbers

Cable Dimensions Part No.

RG Cable No. D Pin Diameter Spacing Between Pins
A B C 5.08 [.200] 6.35 [.250]
Max. 2.54 [.100]
0.30–0.80 0.5–1.7 1.3–2.3 3.4 0.6 [.023] B-046-10-N B-046-12-N
178, 404 B-046-14-N
[.011–.032] [.019–.067] [.050–.091] [.134] 0.8 [.031] B-046-11-N B-046-13-N
0.3–1.6 1.2–2.5 .1.5–2.8 4.4 0.6 [.023] B-046-66-N B-046-16-N
179, 316 B-046-15-N
[.011–.063] [.047–.100] [.060–.110] [.173] 0.8 [.031] B-046-68-N B-046-18-N

Product Characteristics

Material
Insulation Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Solder and flux Solder: Sn63 Pb37 Flux: ROL1 per ANSI - J - 004 (RMA flux)
Termination body/pin Copper alloy, solder-plated
Typical Performance
Voltage drop 2.0 mV
Tensile strength Exceeds strength of conductor
Dielectric strength 2.0 kV
Temperature rating -55°C to 150°C [-67°F to 302°F]
Insulation resistance 1000 megohms
Electrical Performance (typical) D-607 Series
Only Frequency VSWR (D-607-09, -40) VSWR (D-607-10)
350 MHz 1.04 max. 1.04 max.
700 MHz 1.05 max. 1.09 max.
2.3 GHz 1.09 max. 1.12 max.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 60

 RF One Step BNC/TNC
Connectors
DURABLE Applications
One-Step BNC/TNC connectors are single-piece
• Outstanding cable-retention force
assemblies for terminating the center conductor and the
• Exceptional cable retention force braid of a broad range of coaxial cables.
to withstand high vibration and The connectors are fully intermateable with
frequent mates and unmates MIL-C-39012 connectors and are available in 50-ohm
and 75-ohm versions.
• Excellent built-in strain relief against
vibration and excessive handling

CAPABLE

• Long-term reliability

• Meets performance requirements of

MIL-C-39012 up to 2.8 GHz

• Solder-solder connection type

(center conductor and braid)

• Fully soldered center conductor

and braid

VERSATILE

• Three product sizes to accommodate

a wide range of cables

• Use with standard RG/U cables and

TE Cheminax cables

EASY TO USE

• One-step termination for easy, quick

installation and lower installed cost

Specifications Installation
For proper installation of these devices,
the correct heating tool and reflector
attachment must be used. Refer to TE installation procedure
TE
RB-115 Any one of the following TE RPIP-683-00 for detailed instructions.
heating tools is recommended:
• Steinel ® Model HL-2010E-230V
• CV-1981

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 61

Electrical Interconnect Products

Product Options and

Part Numbering System

Connector Style
Dash No. Style Connector Type
RXX - XX - X - XX -XX TNC BNC

24.5 Max. 24.5 max.

[.965] [.965]

-00 Straight plug

33.5 Max. 31.5 max.

[1.32] [1.23]

Male
-01 Right-angle plug 28 [1.09] Male
28 [1.09]

25.4 max. 25.4 Max.

[1.0] [1.0]

-02 Straight bulkhead jack

25.4 max. 25.4 Max.

[1.0] [1.0]

-03 Straight jack

Female
Female
25.4 Max. 25.4 Max.
[1.0] [1.0]

-04 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.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 62

Electrical Interconnect Products

Product Characteristics
Solder Transition Center Dielectric Connector
Contact Insulator Body

Insulation Insulation Sleeve

Sleeve Shield and Solder

Material
Gold-plated beryllium copper (female)
Center contact
Gold-plated brass (male)
Dielectric insulator PTFE
Transition Silver-plated brass
Connector body Nickel-plated brass
Solder and flux Sn63Pb37, RMA flux
Braided shield Tin-plated copper wire per ASTM B3
Insulation sleeve Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride, transparent blue
Strain relief/sealing sleeve Radiation-crosslinked, heat-shrinkable modified polyolefin with adhesive, black
Typical Performance
Dielectric withstand voltage 1500 V
Insulation resistance 5000 megohms
Temperature rating -55˚C to 150˚C [-67˚F to 302˚F]
Contact resistance-straight Inner = 1.5 milliohms, outer = 1.0 milliohm
Contact resistance — right-angle Inner = 2.5 milliohms, outer = 1.5 milliohms
Cable retention force 295N (66 lb) to 822N (196 lb)
Voltage rating 500 V RMS
Connector durability 500 mating cycles minimum
Electrical Performance
Nominal impedance 50 and 75 ohms
Frequency range Up to 2.8 GHz­

Part Selection Process

1. From Product Options and Part Numbering System, 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
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

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 63

Electrical Interconnect Products

Cable Type Cable Dimensions

Part
Impedance D E F G
RG Cables Cables No.
(ohms) (Min.–Max.) (Min.–Max.) (Max.) (Max.)
BNC Straight Plugs, Male Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RBD-50-S-00
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RBD-50-M-00
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RBD-50-L-00
75 RG-179, RG-187 7530A1317 1.50–5.00 5 0.90-3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RBD-75-S-00
75 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
— [.138–.276] [.083–.197] [.126] [.050] RBD-75-M-00
75 RG-6, RG-11, RG-12, RG-59 5.00–.12.50 4.10–9.50 7.3 2.45
RG-144, RG-216 — [.197–.500] [.161–.375] [.287] [.100] RBD-75-L-00

BNC Right-Angle Plugs, Male Contacts

50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RBD-50-S-01
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RBD-50-M-01
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.1–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RBD-50-L-01
75 RG-179, RG-187 7530A1317 1.50–5.50 0.9-3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RBD-75-S-01
75 — 524A1311, 7528A1317 3.50–7.00 2.1–5.00 3.70 1.25
[.138–.276] [.083–.197] [.146] [.050] RBD-75-M-01
75 RG-6, RG-11, RG-12, RG-59 — 5.00–12.50 4.1–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RBD-75-L-01

BNC Straight Bulkhead Jacks, Female Contacts

50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RBD-50-S-02
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RBD-50-M-02
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RBD-50-L-02
75 RG-179, RG-187 7530A1317 1.50–5.00 5 0.90-3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RBD-75-S-02
75 75 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
— [.138–.276] [.083–.197] [.146] [.050] RBD-75-M-02
75 RG-6, RG-11, RG-12, RG-59 — 5.00-12.50 4.10–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RBD-75-L-02

BNC Straight Jacks, Female Contacts

50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RBD-50-S-03
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RBD-50-M-03
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RBD-50-L-03
75 RG-179, RG-187 7530A1317 1.50–5.50 0.90–3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RBD-75-S-03
75 — 75 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
[.138–.276] [.083–.197] [.146] [.050] RBD-75-M-03
75 RG-6, RG-11, RG-12, RG-59 — 5.00–12.50 4.10–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RBD-75-L-03

BNC Straight Panel Jacks, Female Contacts

50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RBD-50-S-04
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RBD-50-M-04
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RBD-50-L-04
75 RG-179, RG-187 7530A1317 1.50–5.50 0.90–3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RBD-75-S-04
75 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
— [.138–.276] [.083–.197] [.146] [.050] RBD-75-M-04
75 RG-6, RG-11, RG-12, RG-59 5.00–12.50 4.10–9.5o 7.30 2.45
RG-144, RG-216 — [.197–.500] [.161–.375] [.287] [.100] RBD-75-L-04­

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 64

Electrical Interconnect Products

TNC Coaxial Connectors

Cable Type Cable Dimensions
Part
Impedance D E F G
RG Cables Cables No.
(ohms) (Min.–Max.) (Min.–Max.) (Max.) (Max.)
TNC Straight Plugs, Male Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RTD-50-S-00
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RTD-50-M-00
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RTD-50-L-00
75 RG-179, RG-187 7530A1317 1.50–5.50 0.90-3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RTD-75-S-00
75 — 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
[.138–.276] [.083–.197] [.146] [.050] RTD-75-M-00
75 RG-6, RG-11, RG-12, RG-59 — 5.00–12.50 4.10–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RTD-75-L-00

TNC Straight Jacks, Female Contacts

50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.5–5.5 0.9–3.0 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RTD-50-S-03
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.5–7.0 2.1–5.0 3.0 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RTD-50-M-03
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.0–12.5 4.1–9.5 7.3 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RTD-50-L-03
75 RG-179, RG-187 7530A1317 1.5–5.5 0.9–3.0 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RTD-75-S-03
75 — 7524A1311, 7528A1317 3.5–7.0 2.1–5.0 3.7 1.25
[.138–.276] [.083–.197] [.146] [.050] RTD-75-M-03
75 RG-6, RG-11, RG-12, RG-59 — 5.0–12.5 4.1–9.5 7.3 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RTD-75-L-03

TNC Straight Panel Jacks, Female Contacts

50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.5–5.5 0.9–3.0 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RTD-50-S-04
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.5–7.0 2.1–5.0 3.0 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RTD-50-M-04
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.0–12.5 4.1–9.5 7.3 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RTD-50-L-04
75 RG-179, RG-187 7530A1317 1.5–5.5 0.9–3.0 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RTD-75-S-04
75 — 7524A1311, 7528A1317 3.5–7.0 2.1–5.0 3.7 1.25
[.138–.276] [.083–.197] [.146] [.050] RTD-75-M-04
75 RG-6, RG-11, RG-12, RG-59 — 5.0–12.5 4.1–9.5 7.3 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RTD-75-L-04

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 65

Electrical Interconnect Products

TNC Coaxial
Connectors Panel thickness: 3.2 [.125] max.
RBD-XX-X-04 RBD-XX-X -02
RTD-XX-X-04 RTD-XX-X -02
12.7 [.5] 20.5 [.8] min.
= =
12 [.47]
12.7 = ∅11.2 [.44]
[.5] = ∅3 [.12]

18 [.7] min. ∅12.9 [.51]

Cable Type Cable Dimensions

Part
Impedance D E F G
RG Cables Cables No.
(ohms) (Min.–Max.) (Min.–Max.) (Max.) (Max.)
TNC Straight Bulkhead Jacks, Female Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RTD-50-S-02
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.5–7.0 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RTD-50-M-02
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.0–12.5 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RTD-50-L-02
75 RG-179, RG-187 7530A1317 1.5–5.5 0.90–3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RTD-75-S-02
75 — 7524A1311, 7528A1317 3.5–7.0 2.10–5.00 3.70 1.25
[.138–.276] [.083–.197] [.146] [.050] RTD-75-M-02
75 RG-6, RG-11, RG-12, RG-59 — 5.0–12.5 4.10–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RTD-75-L-02

TNC Right-Angle Plugs, Male Contacts

50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RTD-50-S-01
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RTD-50-M-01
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RTD-50-L-01
75 RG-179, RG-187 7530A1317 1.50–5.50 0.90–3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RTD-75-S-01
75 — 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
[.138–.276] [.083–.197] [.146] [.050] RTD-75-M-01
75 RG-6, RG-11, RG-12, RG-59 — 5.0–12.5 4.10–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RTD-75-L-01

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 66

 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 TE SolderShield
cable splices. SolderShield devices are one-piece
products consisting of a flux-coated, solder-impregnated
copper shield braid encased in a heat-shrinkable
insulation sleeve.
SolderShield cable-to-cable splice kits, designed for
single-conductor or 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.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 67

Electrical Interconnect Products

SolderSleeve Shielded and Coaxial

Cable Splices
Product Selection Process
1. Select product series from the Product Options table below.
2. Determine cable RG number or outside diameter dimensions.
3. Select the appropriate part number from Table A (D-607
series) or Table B (B-046 series).
•F
 or D-607 (matched impedance) series, determine straight
VERSATILE or right-angle entry to PCB and grid pattern, then select the
• Flux-coated, solder-impregnated
appropriate part number from Table A on the next page.
copper shield braid encased in •F
 or B-046 (PinPak, or pin to ground) series, determine hole
a transparent heat-shrinkable spacing and diameter. Refer to Table B for product selection
insulation sleeve provides a (see illustration below for cable dimensions).
controlled soldering process,
Installation Requirements
encapsulation, inspectability, strain
relief, and insulation
For proper installation of these devices, the correct heating
tool and reflector attachment must be used. Any one of the
EASY TO USE following TE heating tools is recommended:
• One-piece design means easy • HL1920E/HL2020E
installation and lower installed cost • IR-1759 MiniRay
CAPABLE • CV-1981
• Circumferential (360°) shielding Refer to TE installation procedure RCPS-150-02 (D-150 series)
results in EMI protection and shield and RPIP-699-00 (B-202 series) for detailed instructions and
continuity equal to or better than the recommended reflector attachment.
original cable
Applications
• Conductor splices are made using
Used for splicing a wide range of cables, including coaxial and
MiniSeal crimp products, which are
multiconductor cables.
recognized by MIL-S-81824 and
MIL-W-5088
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, solder-impregnated copper shield encased
in a heat-shrinkable sealing sleeve, for splicing the shields.
SolderShield kits terminate single- or multiple-conductor cables,
eliminate EMI problems at the splice, and provide strain relief
for the cable.

Specifications/Approvals
Series Military TE
US: M81824 (conductor splice only)
D-150 RT-1404
UK: RAF AP 1130-2008-1

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 68

Electrical Interconnect Products L1

L3 L2

Table A. Multiconductor SolderShield Splice Crimp Splice

Cable Splices L1
Each SolderShield part L3 L2
consists of a SolderShield
splice and one or more I.D.
conductor splices. Refer
to information below for
description and numbers of
conductor splices.

SolderShield Product Dimensions

Conductor Splice
Part No. Dimensions
Size Range Color Quantity
Tin Plated Nickel Plated L1 L2 L3 ID CMA [mm2] Code Per Kit
Max. Nom. Min. Min. Min.–Max.
D-150-0168 D-150-0228 80.50 50.00 10.20 3.00 304–1510 Red 1
[3.17] [1.97] [.400] [.118] [0.15–0.75]
D-150-0169 D-150-0229 80.50 50.00 10.20 4.00 779–2680 Blue 1
[3.17] [1.97] [.400] [.157] [0.39–1.34]
D-150-0170 D-150-0230 80.50 50.00 10.20 5.00 1900–6755 Yellow 1
[3.17] [1.97] [.400] [.197] [0.95–3.37]
D-150-0174 D-150-0231 10.60 75.00 10.20 4.00 304–1510 Red 2
[4.17] [2.95] [.400] [.157] [0.15–0.75]
D-150-0175 D-150-0232 10.60 75.00 10.20 5.00 779–2680 Blue 2
[4.17] [2.95] [.400] [.197] [0.39–1.34]
D-150-0176 D-150-0233 10.60 75.00 10.20 6.00 1900–6755 Yellow 2
[4.17] [2.95] [.400] [.236] [0.95–3.37]
D-150-0177 D-150-0234 10.60 75.00 10.20 9.00 304–1510 Yellow 2
[4.17] [2.95] [.400] [.356] [0.15–0.75]
D-150-0178 D-150-0235 10.60 75.00 10.20 4.00 304–1510 Red 4
[4.17] [2.95] [.400] [.157 ] [0.15–0.75]
D-150-0179 D-150-0236 10.60 75.00 10.20 5.00 779–2680 Red 4
[4.17] [2.95] [.400] [.197] [0.39–1.34]
D-150-0180 D-150-0237 10.60 75.00 10.20 6.00 1900–6755 Blue 4
[4.17] [2.95] [.400] [.236] [0.95–3.37]
D-150-0181 D-150-0238 10.60 75.00 10.20 9.00 1900–6755 Yellow 4
[4.17] [2.95] [.400] [.353] [0.95–3.37]
Note: The SolderShield splice kits listed in this table are for 1:1 cable splices. The kits can be used on cables with tin-, silver-, and nickel-plated copper conduc-
tors. All the kits have environmental-sealing capability. The cable temperature rating must be 125°C minimum.
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.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 69

Electrical Interconnect Products
L1

L3 L2
Table B. Coaxial
SolderShield Splice Crimp Splice
Cable Splices
Each SolderShield part consists of a L1
SolderShield splice and one or more L3 L2
conductor splices. Refer to information
below for description and numbers I.D.
of conductor splices.

Conductor Part SolderShield Dimensions

RG Cable No.
Cable Description Splice Qty/Kit No. L1 Max L2 Min ID Min
8A, 9B, 11 5012A3311
13, 26, 31 5012E1339
115, 144, 149 7518A1311 80.50 50.00 12.00
1 D-150-0214
165, 213, 214 — [3.170] [1.970] [.472]
216, 235, 391 —
393, 397 —
178, 196, 5028A1317
179, 187, 188, 7528A1317 80.50 50.00 3.00
1 D-150-0094 [3.170] [1.970] [.118]
316, 404, M17/138-00001, 5030A1317
M17/136-00001 7530A1317
180, 195 5024A1311
M17/137-00001 7526A1311 80.50 50.00 4.00
1 D-150-0095 [3.170] [1.970] [.157]
M17/139-00001 9527A1318
— 9530E1014
124, 140, 141 5020A1311
159, 302, 303 5022A1311
80.50 50.00 5.00
— 1 D-150-0096
7522A1311 [3.170 ] [1.970] [.236]
— 7523D1331
— 7524A1311
29, 30, 55B 5019D3318
56.00 23.00 7.00
58, 223 5021D1331
1 B-202-81* [2.200] [.900] [.275]
— 5022A1311
59, 62, 71 7523D1331
56.00 23.00 7.00
— 7524A1311
1 B-202-82* [2.200 ] [.900] [.275]
— 9524A1311
*These kits use solder to terminate the center conductors. All other kits use crimp.
All kits are for one-to-one coaxial cable splices, and all kits have environmental sealing capability. Each kit contains products to splice conductors, build up
dielectric, splice the shield, and provide insulation.

Product Characteristics
Materials
Insulation sleeve Radiation-crosslinked polyvinylidene fluoride
Meltable inserts Fluorocarbon-based thermoplastic
MiniSeal crimp splice Base metal: Copper alloy C10200 per ASTM B75
Plating: Tin per MIL-T-10727 or nickel per QQ-N-290
SolderShield shield splice Base metal: Tin-plated copper wire braid per ASTM B3
Solder and flux coating: Type Sn63 Pb37. Flux: ROM1 per ANSI - J - STD - 004 (RA flux)
Parameter Test Method Requirement
Electromechanical Performance
Dielectric strength (shield connection) — No breakdown or arcing at 1000 Vac (RMS)
Dielectric strength (conductor connection) — 2.5 kV
Voltage drop MIL-S-81824 Less than 2.0-millivolt increase
Insulation resistance (shield connection) — 1000 megohms minimum at 500 Vdc
Insulation resistance (conductor connection) — 5000 megohms
Tensile strength for MiniSeal MIL-S-81824 Exceed yield strength (pounds) of wire.
Tensile strength for SolderShield MIL-S-81824 75% of strength (pounds) of unspliced cable
Temperature rating — -55°C to 150°C [-67°F to 302°F]
Environmental Resistance
Salt spray MIL-STD-202 M101 Meet voltage drop requirement.
Heat aging 750 hours at 150°C [302°F] Meet all electromechanical requirements.
Temperature cycling MIL-STD-202 M107C Meet all electromechanical requirements.
Altitude immersion Immersion at 22,860m [75,000 ft] Meet insulation-resistance requirement.
Corrosion resistance — No evidence of corrosion after testing in accordance
with MIL-STD-202, Method 101, Test Condition A

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 70

Electrical Interconnect Products

Raychem C-Wrap Side Entry Repair Sleeve

TE Connectivity’s (TE) C-Wrap repair sleeve is a side-entry
sleeve designed to repair and seal a damaged wire jacket that is
either chafed or has a radial crack or cut on the insulation.
It consists of two pieces: the outer tubing and an adhesive
inner layer.

MECHANICAL/ENVIRONMENTAL
• Environmental resistant
• Ideal for use on insulations rated at 135˚C or higher
EASY INSTALLATION • Temperature range: -65˚C to +150˚C
• Easy to install: saves time,
MATERIALS
manpower, and cost
• Meltable Adhesive: Modified thermoplastic fluoroelastomer
• Color-coded to ensure proper sizing • Insulation Sleeve: Radiation cross-linked modified fluoropolymer
for each application
STANDARDS
• Low profile (small diameter and
short length) • SAE AS81824 (fluid and sealing requirements)
• TE Performance Specification: D-6201
• Side entry for easy access to
• TE Application Specification: RPIP-1101
damaged wire
• TE Qualification Test Reports: ISTR-1134 and ISTR-1206

MECHANICALLY ROBUST APPLICATION TOOLING

• 150˚C rated • General Purpose Heat Gun: Steinel HL19XX or HL20XX
• SolderSleeve Reflector: Steinel HL1802E-074616
• Long-term performance provides a
•M
 il Spec installation tools:
permanent repair
D-150-C-11: M81969/8-08
D-150-C-12: M81969/8-08
• Wrap-around design eliminates
D-150-C-13: M81969/8-10
de-pinning of connector for repair D-150-C-14: M81969/8-10
Contact TE for details on installation tooling

APPLICATIONS
• Used as a side-entry repair kit
•R
 epair of nicks, chafed and radial cracks on the wire in most Aerospace,
Defense and Marine applications
• Prevents galvanic corrosion on center conductor
• RoHS compliant

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 71

Electrical Interconnect Products

ORDERING INFORMATION

Product Dimension Conductor

Part Color I.D. (A) Cut Length (B)
Description Code Wire OD
Adhesive Sleeve Adhesive Sleeve AWG (Note*)
±.05 (.002) ±.05 (.002) ±.5 (.02) ±.5 (.02)
1.11 2.29 21.59 0.80 - 1.10
D-150-C-11 Green 19.05 (.75) 26 - 24
(.044) (.090) (.85) (.031 - .043)
1.68 2.74 21.59 1.10 - 1.50
D-150-C-12 Red 19.05 (.75) 22 - 20
(.066) (.108) (.85) (.043 - .029)
2.13 3.43 21.59 1.50 - 2.30
D-150-C-13 Blue 19.05 (.75) 18 - 16
(.084) (.135) (.85) (.059 - .090)
3.34 4.80 21.59 2.30 - 2.80
D-150-C-14 Yellow 19.05 (.75) 14 - 12
(.133) (.189) (.85) (.090 - .110)

MATERIALS • Install using TE approved convection or infrared

heating tools in accordance with TE. When installed
• Meltable Adhesives: Environment-resistant modified
with approved convection or infrared heating tools,
thermoplastic fluoroelastomer. Color coded.
assemblies will meet the performance requirements
• Insulation Sleeve: Heat-shrinkable, transparent, radiation of TE D-6201 specification. Infrared tools are not
cross-linked modified fluoropolymer. Color coded. recommended for use with black cable jackets.
•T
 emperature range: -65°C to +150°C.
APPLICATION Note*: If the O.D. of the wire is out of the range that is specified in
• Parts are designed to provide an environment-resistant the Table, use the next size of C-Wrap up or down

repair to damaged primary wire that has a radial crack up

to 360°, nicks/scrapes not longer than 1/4” on insulations
rated for 135°C minimum with no damage to the wire
conductor. For insulation procedures, refer to RPIP 1101.

D-150-C-11 D-150-C-12 D-150-C-13 D-150-C-14

(Part No. CX2001-000) (Part No. CX2096-000) (Part No. CX2097-000) (Part No. CX2098-000)
NSN 5970-01-611-8609 NSN 5970-01-611-8596 NSN 5970-01-611-8600 NSN 5970-01-611-8586

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 72

Electrical Interconnect Products

Rayseal High-Performance, Large-Gauge

Cable Repair
The Rayseal large gauge cable repair sleeve is a high-performance
side-entry repair product for large gauge and power feeder cables
(8 AWG to 4/0 AWG) with chafed or cracked insulation.
Its tough fluoropolymer material has been specially formulated by
TE to give greater resistance to mechanical abrasion and common
aerospace fuels and fluids. The high-temperature adhesive lining,
by sealing around the underlying damage to the cable jacket,
maintains the cable jacket properties as close as possible to its
RUGGED PERFORMANCE
original specification.
• Designed for 8 AWG to
4/0 AWG cable The operating temperature range from -65°C to +260°C helps
• Abrasion-resistant fluoropolymer ensure excellent high-temperature performance.
• Resists aerospace fuels and fluids
ENVIRONMENTAL/MECHANICAL
COST SAVINGS • Operating temperatures: -65°C to +260°C
• Easy to install: helps save manpower
• Durability: Adheres and seals for permanent repair
and cost
• Fluid resistance: Resists aggressive fluids used in military and aerospace platforms
• Permanent, tough and robust repair
• Side entry helps reduce repair times
MATERIALS
VERSATILE • Sleeve: Fluoropolymer, black
• Make permanent repairs to chafed • Adhesive: Fluoropolymer
and cracked cable insulation
• High-temperature adhesive lining TOOLING
seals around repair
•H
 eat gun: CV2014-JETS-120V460W-UL (US plug)
• -65°C to +260°C temperature range
CV2014-JETS-230V460W-EU (European plug)
CV2014-JETS-230V460W-UK (UK plug)
APPLICATIONS
PR-38-B-REFLECTOR
• Military Aerospace and Defense
• Commercial Air EACH KIT ALSO CONTAINS:
• Military Ground Systems
• Abrasive Cleaning Pad, 2” x 2”
• Wet/Dry Cleaning Wipes, 2-Package Kit
• PTFE Tape, 2 Mils Thick, 1” Wide, 30” Long

Cable Sleeve Dimensions Part Kit Part No.

Description
Wire Size (AWG) Cable OD L L1
10, 8 .137-203 [3.48-5.16] 1.40 [35.6] 1.00 [24.5] D-260-C-A EF7428-000
6, 4 .225-.308 [5.72-7.82] 1.70 [43.2] 1.25 [31.8] D-260-C-B EF7429-000
2, 1/0 .356-.465 [9.04-11.81] 2.20 [55.9] 1.75 [44.5] D-260-C-C EF7430-000
2/0, 3/0 .485-.590 [14.99-12.32] 2.67 [67.8] 2.10 [53.3] D-260-C-D EF7431-000
4/0 .590-.640 [14.99-16.26] 3.10 [78.8] 2.50 [63.5] D-260-C-E EF7432-000

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 73

Electrical Interconnect Products

Raychem D-200 Flexible Splice Kit

Our D-200 flexible splice kit features environmentally resistant,
high-temperature splices with EMI protection and flexibility.

In-Line Splicing for Harsh Aerospace and

Defense Applications
An important extension of the Raychem family of termination
devices, the D-200 splice kit is specially designed for
use in demanding high temperature aerospace and defense
applications.
DURABLE SPLICING
• Resistant to most common Fast Installation and Lower Costs
aerospace fluids
Make in-line splices fast and easy with the D-200 flexible splice
• Flexible splice for long-term kit. Whether splicing shielded single, twisted pair, or trio cables,
performance
the D-200 splice kit creates a permanent, flexible, immersion-
• Immersion resistant, sealed cable
resistant splice for long-term reliable performance in the
splice with 360° shielding
harshest environments. Easy installation with existing crimp and
HIGH PERFORMANCE heating tools results in a lower total installed cost.
• Rated for 200°C continuous
operating temperature
• Resists vibration and mechanical
shock without loss of signal
• Splice allows bending without
insulation cracking

VERSATILE
• Cables can be spliced with existing
heating and crimping tools
• Additional sealing rings allow
splicing 1 to 1, 2 to 1, and 2 to 2
constructions
• Works with shielded single, paired,
and triple cables
• 26 AWG to 10 AWG wire range

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 74

Electrical Interconnect Products

D-200-0232-RT D-200-0233-RT D-200-0237-RT

STANDARDS AND TEST REPORT PHYSICAL PROPERTIES

• SAE AMS-DTL-23053/13 (applies to insulation sleeve only) •T  ensile Strength: 75% min. of an unspliced cable
• SAE AS81824/11 • Vibration and Mechanical Shock: Resistant without
• TE Performance Specification: D-6203 loss of signal
• TE Qualification Test Report: ISTR-1404 • Temperature Range: -55°C to 200°C

MATERIALS CHEMICAL PROPERTIES

• Cable Sealing Sleeve • I mmersion Resistance: Resists most common aerospace
Insulation Sleeve: Heat-shrinkable fluoropolymer, black fluids (e.g., fuels, oils, MPK, etc.)
Meltable Inserts: Environment-resistant thermoplastic • Immersion Resistance Altitude: 75,000 feet
fluoroelastomer, light blue
• SolderSleeve Device ELECTRICAL PROPERTIES
Insulation Sleeve: Heat-shrinkable fluoropolymer,
•V oltage Drop: Voltage drop across spliced conductors and
transparent blue
shield do not exceed equivalent length of unspliced cable
Solder Preform with Flux: 96% tin per ANSI/J-STD-006.
• Dielectric Strength: 2500 V
ROM1 per ANSI/J-STD-004
• Insulation Resistance: 100 V
Meltable Insert: Thermoplastic, blue
• Crimp Splice: Nickel-plated copper alloy
TOOLING
• Sealing Splice Sleeve: Heat-shrinkable fluoropolymer,
containing two environment-resistant sealing rings, • Steinel HL20XXE heat gun • TE AD-1377 crimp tool
transparent blue • TE IR-550 infrared tool • TE 46447 crimp tool
• Meltable Insert: Environment-resistant thermoplastic
fluoroelastomer, light blue

Number of Conductors Wire Range (AWG) Color Code Part Description Part Number
26 – 20 Red D-200-0228-RT CV7712-000
20 – 16 Blue D-200-0230-RT EG4031-000
1
16 – 12 Yellow D-200-0232-RT EG4032-000
12 – 10 None D-200-0242-RT EG3869-000
26 – 20 Red D-200-0233-RT EG3678-000
20 – 16 Blue D-200-0234-RT CU1642-000
2
16 – 12 Yellow D-200-0235-RT EG3865-000
12 – 10 None D-200-0249-RT CW7956-000
20 – 16 Blue D-200-0237-RT EG3867-000
3 16 – 12 Yellow D-200-0238-RT EG3868-000
12 – 10 None D-200-0243-RT CW7949-000

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 75

 Shielded
Contacts
Introduction
TE 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 TE’s 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.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 76

Electrical Interconnect Products

SolderTacts Shielded One-Piece

Solder Contacts
One-piece controlled-reflow-solder SolderTacts contacts are
designed to terminate coaxial cables, shielded wires and twisted
pairs faster and more reliably than other methods. SolderTacts
contacts help eliminate the variables of crimping. The one-step
installation process helps cut down on production time while
reducing handling and installed costs.

Controlled Soldering and Strain Relief

ECONOMICAL SolderTacts contacts provide the optimum amount and type
• One-piece contact design with of solder and flux in a prefluxed solder preform that controls
integrated soldering technology soldering and reduces operator sensitivity. The geometry of
the coaxial cable is carried through the connector to eliminate
• One-step installation process
separate pins, help reduce crosstalk, and supports improved
• One contact fits multiple cable sizes shielding effectiveness and signal transmission.
• No special tools required
These contacts contain two SolderSleeve terminations.
RELIABLE One terminator connects the cable’s signal conductor to the
contact’s inner pin. The other terminator connects the shield or
• 360° shielding reduces crosstalk
ground lead to the contact body. When the contact is heated, the
and improves signal transmission
solder melts to provide a precise solder connection. SolderTacts
• Reflow solder joints are strong contacts provide a simultaneous electrical connection and strain
and reliable relief. Heat shrinkable tubing insulations help eliminate stress
• Controlled reflow soldering concentration on the wire within the contact.
process yields reliable,
consistent terminations Improved Signal Integrity
For digital and RF signals, SolderTacts contacts offer better
• Terminations are fully inspectable
signal transmission than obtained with crimp contacts. They
VERSATILE reduce crosstalk, signal attenuation, and reflections, while
providing excellent protection against outside noise.
• Compatible with a variety of
commercial and military connectors Compatibility
• Termination available for coax SolderTacts contacts are compatible with a wide range of circular
cables, shielded pairs, twisted pairs, and rectangular military and commercial connectors, including
and triaxial cables MIL-DTL-38999, MIL-DTL-83723 and MIL-DTL-28748. Compatible
• 150°C temperature rating with most standard connector cavities, SolderTacts contacts are
intermateable and intermountable with contacts qualified to the
above connector specifications. They use standard insertion and
extraction tools.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 77

Electrical Interconnect Products

APPLICATION TOOLING
• Steinel HL1920E or HL2020E
• Steinel HL1802E-074616
• Raychem CV-1981
• Raychem CV-1983
• Raychem AA-400
For more details, please see TE Application Tooling
brochure 1-1773872-1

SPECIFICATION
• D-6002: SolderTacts Military-Grade Electrical Contacts for
Solder Termination

APPLICATIONS
• Commercial Aerospace
• Military Aerospace
• C4ISR
• Ground Defense
• Military Marine
• Missile Defense
• Offshore/Civil Marine
• Space

The outer SolderSleeve termination is a The inner SolderSleeve The precision outer body meets
cross-linked heat-shrinkable insulating termination is a heat-shrinkable electrical engagement and
sleeve supplied in the expanded state. sleeve with a precisely contact retention requirements of
Cables insert easily, with no spacers or prefluxed solder preform individual connector systems.
other parts required. conforming to QQ-S-571.

The outer solder preform Inner pin and socket contacts

contains precise amounts of are permanently fixed within
solder and flux conforming the assembly to provide proper
to QQ-S-571. setback and concentricity.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 78

Electrical Interconnect Products

SolderTact Part No. Engineering Standard Repair Wand

Series (D-602-) (Termination Instructions) Part No. Part Description
0218, 0219 ES-61170
Submin 959014-000 AD-1481-SUBMN-SLDTK-HOLDR
0238, 0239 ES-61169
44, 45 ES-61133
0172, 0173 ES-61240
748 994040-000 AD-1480
54, 55 ES-61132
0126, 0127 ES-61199
D-610-09, -10 ES-61187 551737-000 AD-1571-1-POWERTACT-HOLDR
0094, 0095 ES-61128
723 0106, 0107 ES-61134 994057-000 AD-14940723-SLTC-HLD-ASY
0104, 0105 ES-61129
No. 12 16, 17 ES-61161 966800-000 AD-1508-REP-FOR-12-CONT
46, 47 ES-61137
482 181779-000 AD-1565-1-SLDTCT-HLDR-ASY
56, 57 ES-61138
0140, 0141 ES-61226
999 0142, 0143 ES-61224
859747-000 AD-1572-1-SOLD-HOLDER-ASY
Size 16 0171 ES-61226
0174 ES-61124
0144, 0145 ES-61206
999
0146, 0147 ES-61218 122917-000 AD-1566-1-HOLDER-ASSEMBLY
Size 12
0159/0151 ES-61223
1108/1109
ES-61172
1110/1111
999
1112/1113 ES-61184 635308-000 AD-1568-1-SOLDERTACT-HLDR
Size 8
0156/0157-X ES-61231
0169/0170-X ES-61235

In the terminated signal lead, the

heat-shrink tubing shrinks tightly around
the termination to insulate and strain
relieve the connection. The tensile
strength of the soldered terminations
exceeds that of the cable itself.

The dielectric between inner and outer The shield termination

contacts provides concentricity, electrical can be inspected through
integrity, precise mating dimensions, and the viewing port.
closed entry at the inner socket.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 79

Electrical Interconnect Products

Table I: SolderTacts Contacts-to-Cable Cross Reference

Submin 723 Series 723 Series 748 Series 748 Series 847 Series 748 Series
Series Size 12 Size 12 Size 16 Size 16 Size 16 Size 16
D-602-0278 D-602-0094 D-602-0106 D-602-44 D-602-0172 D-602-72 D-602-76
D-602-0279 D-602-0095 D-602-0107 D-602-45 D-602-0173 D-602-73 D-602-77
Cheminax Coaxial Cables

5021K1X1X

5022A1X1X

5024A1X1X 4 4
5026A1X1X 4 4 4 4
5026D1X2X 4 4 4 4
5028A1X1X 4
5028A1X2X 4
5030A1X1X 4 4 4
4 4 4
7522A1X1X

7524A1X1X

7528A1X1X 4 4 4 4
4 4 4
7530A1X1X 4 4 4
4 4 4
7530D1X2X

9526A1X1X

9528A1X1X 4
9528D1X2X 4
9530A1X1X 4
9530H1X1X 4 4
9532A1X1X 4 4 4 4
4 4 4
RG/U Coaxial Cables

RG-58

RG-174 4 4 4 4 4
RG-178 4 4 4 1
4 4 1
4 1

RG-179 4 4 4 4 4 4
RG-180 4
RG-195 4
RG-316 4 4 4 4 4
Twisted Pair Cables
Submin 723 Series 723 Series 748 Series 748 Series 847 Series 748 Series
Series Size 12 Size 12 Size 16 Size 16 Size 16 Size 16
D-602-0288 D-602-0104 D-602-54 D-602-0126 D-602-74
— —
D-602-0289 D-602-0105 D-602-55 D-602-0127 D-602-75
22-26 4
24-26 4
24-303 4 2
4 4
26-303

1. Requires use of barrier.

2. .048” maximum insulation diameter.
3. Smaller cables can be accommodated. Consult product management.
4. These cables can be accommodated by D-602-44 and D-602-45. However, the D-602-0172 and the D-602-0173 are preferred for these cables.
The cross reference list above is not intended to be exhaustive. Please consult TE.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 80

Electrical Interconnect Products

Table I: SolderTacts Contacts-to-Cable Cross Reference

482 Series No. 12 999 Series 999 Series 999 Series 999 Series
Size 16 Size 12 Size 8 Size 12 Size 12 Size 16
D-602-0140
D-602-46 D-602-16 D-602-0122 D-602-0144 D-602-0150
D-602-0141
D-602-47 D-602-17 D-602-0123 D-602-0145 D-602-0151
D-602-0171
Cheminax Coaxial Cables

5021K1X1X 4
5022A1X1X 4 4
5024A1X1X 4 4
5026A1X1X 4 4 4 4
5026D1X2X 4 4 4
5028A1X1X 4
5028A1X2X 4
5030A1X1X 4 4 4
7522A1X1X 4
7524A1X1X 4
7528A1X1X 4 4 4 4
7530A1X1X 4 4 4 4
7530D1X2X 4
9526A1X1X 4
9528A1X1X 4 4
9528D1X2X 4 4
9530A1X1X 4
9530H1X1X 4 4
9532A1X1X 4 4 4
RG/U Coaxial Cables

RG-58 4
RG-174 4 4 4
RG-178 4 4
RG-179 4 1
4 4 4
RG-180 4 4
RG-195 4
RG-316 4 4 4 4
Twisted Pair Cables
482 Series No. 12 999 Series 999 Series 999 Series 999 Series
Size 16 Size 12 Size 8 Size 12 Size 12 Size 16
D-602-56 D-602-0146
— — — —
D-602-57 D-602-0147
22-26 AWG 4
24-26

24-303 4
26-303 4
1. Requires use of barrier.
2. .048” maximum insulation diameter.
3. Smaller cables can be accommodated. Consult product management.
4. These cables can be accommodated by D-602-44 and D-602-45. However, the D-602-0172 and the D-602-0173 are preferred for these cables.
The cross reference list above is not intended to be exhaustive. Please consult TE.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 81

Electrical Interconnect Products

Table II: Connector Accommodation: SolderTacts Shielded Contacts

Military SolderTacts Contacts Contact
Specification Cable Type Part No.
Specification Series/Contact Size Type
NAS 1599 AS39029/74 Small Coaxial Pin D-602-0094
MIL-DTL-26482 AS39029/73 Small Coaxial Socket D-602-0095
Series II
SAE-AS81703 723 Series AS39029/74 Large Coaxial Pin D-602-0106
Series III Size 12 Contact AS39029/73 Large Coaxial Socket D-602-0107
MIL-DTL-83723 AS39029/74 Twisted Pair Pin D-602-0104
Series I & III
MIL-DTL-83733 AS39029/73 Twisted Pair Socket D-602-0105
No. 12 Series MIS-20067 Coaxial Pin D-602-17
MiL-DTL-26482 Size 12 Contact (Army) Coaxial Socket D-602-16
Series I Coaxial Pin D-602-46
MIL-DTL-26500
MIL-PRF-81733 482 Series Coaxial Socket D-602-47
Series II Size 16 Contact Twisted Pair Pin D-602-56
Twisted Pair Socket D-602-57
Coaxial Pin D-602-44
Coaxial Socket D-602-45
Twisted Pair Pin D-602-54
Twisted Pair Socket D-602-55
MIL-DTL- Power Pin D-610-09
748 Series MIS20067
28748/3,4,9,10
Size 16 Contact (Army) Power Socket D-610-10
MIS-20065 (Army)
Coaxial Pin D-602-0173
Coaxial Socket D-602-0172
Twisted Pair (MIL-STD-1553) Pin D-602-0126
Twisted Pair Socket D-602-0127
AS39029/76 Coaxial Pin D-602-0140
AS39029/77 Coaxial Socket D-602-0141
999 Series AS39029/77 Coaxial* Socket D-602-0171
Size 16 Contact AS39029/76 Twisted Pair Pin D-602-0142
AS39029/77 Twisted Pair Socket D-602-0143
AS39029/77 Twisted Pair* Socket D-602-0174
AS39029/28 Coaxial Pin D-602-0144
AS39029/75 Coaxial Socket D-602-0145
999 Series AS39029/28 Twisted Pair Pin D-602-0146
MIL-DTL-38999 Size 12 Contact AS39029/75 Twisted Pair Socket D-602-0147
Series I, ll*, III, IV AS39029/28 Large Coaxial Pin D-602-0150
AS39029/75 Large Coaxial Socket D-602-0151
AS39029/60 Coaxial Pin D-602-0122
AS39029/59 Coaxial Socket D-602-0123
USAF8340712-1^ Shielded Twisted Pair (MIL-STD-1553) Socket D-602-1108
999 Series USAF8340713-1^ Shielded Twisted Pair (MIL-STD-1553) Pin D-602-1109
Size 8 Contact USAF8340712-2^ Shielded Twisted Pair (MIL-STD-1553) Socket D-602-1112
Shielded Twisted Pair (MIL-STD-1553) Pin D-602-1113
USAF8340713-2^ Triaxial Socket D-602-1110
Triaxial Pin D-602-1111
Coaxial Pin D-602-0278
Submin Series Coaxial Socket D-602-0279
—
Size 16 Twisted Pair Pin D-602-0288
Twisted Pair Socket D-602-0289
* Size 16 contacts only for use with MTCP and MIL-DTL-38999 Series II connectors only.
^ Intermountable and intermatable, replaces crimp style termination.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 82

Electrical Interconnect Products

Table III: SolderTacts Contact Compatibility

TE
Contact Military SolderTacts - Compatible SolderTact
Equivalent* Nature of Compatibility
Specification Connector Specifications Series
Part Numbers
M39029/73-396 D-602-0107
M39029/73-397 D-602-0095 MIL-DTL-26482 Series II
M39029/73-398 D-602-0105 MIL-DTL-81703 Series III
M39029/73-555 D-602-0093 Equivalent product. 723
MIL-DTL-83723 Series I, III
TE is a qualified vendor. Series
M39029/74-399 D-602-0106 MIL-DTL-83733
M39029/74-400 D-602-0094 NAS-1599
M39029/74-401 D-602-0104
D-602-0144
M39029/28 D-602-0146
D-602-0150
M39029/59 D-602-0123
M39029/60 D-602-0122
D-602-0145
M39029/75 D-602-0147 Intermountable and intermatable.
D-602-0151 Replaces crimp-style termination.
D-602-0140
M39029/76
D-602-0142
D-602-0141 MIL-DTL-38999 Series I, II*, III, IV 999
D-602-0143 *Size 16 only Series
M39029/77
D-602-0171
D-602-0174
DK-602-0156-N-X
M39029/90
DK-602-0169-N-X Intermountable and intermatable.
DK-602-0157-N-X Replaces crimp-style termination.
M39029/91
DK-602-0170-N-X
USAF8340712-1 D-602-1108
USAF8340712-2 D-602-1112 Equivalent product.
USAF8340713-1 D-602-1109 TE is a qualified vendor.
USAF8340713-2 D-602-1113
M39029/25 D-602-17 Intermountable and intermatable.
M39029/26 D-602-16 Replaces crimp-style termination. MIL-DTL-26482 Series I
No. 12
MIL-DTL-26500
MIS20067/5 D-602-16 Equivalent product. Series
MIL-DTL-81703 Series II
MIS20067/6 D-602-17 TE is a qualified vendor.
M39029/40 D-602-76
M39029/41 D-602-77 Intermountable and intermatable. 748
MIL-DTL-28748/3, /4, /9, /10
M39029/42 D-602-77 Replaces crimp-style termination. Series
M39029/43 D-602-76
D-602-72
M39029/79
D-602-74 Intermountable and intermatable. 847
D-602-73 Replaces crimp-style termination. Series
M39029/80
D-602-75
MIS20067/1 D-602-45
MIS20067/2 D-602-44
MIS20067/3 D-602-55 Equivalent products. MIS-20065 (Army) 748
MIS20067/4 D-602-54 TE is a qualified vendor. Series
MIS20067/7 D-610-10
MIS20067/8 D-610-09
D-602-77
D-602-76 Intermountable and intermatable. 748
D-602-76 Replaces crimp-style termination. Series
D-602-77
D-602-0278
D-602-0279 Intermountable and intermatable. Submin
Souriau Trim Trio Connector Family
D-602-0288 Replaces crimp-style termination. Series
D-602-0289
* SolderTacts contacts are intermatable and interchangeable with existing MIL-spec contacts.

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 83

 Additional Repair
Products
Raychem Matched Impedance Splices
With the matched impedance splice, TE Connectivity (TE)
solves the problem of costly removal and replacement of
damaged coaxial cable. Not only does the new splice allow fast,
easy repair of the cable in situ, it maintains the characteristic
impedance and other electrical properties. System performance
is not affected by the repair.

Save Time and Money

Removing and replacing a damaged coaxial cable can be
MATCHED IMPEDANCE time consuming and expensive. The matched impedance
•M  aintains cable’s electrical splice’s ability to be applied without removing the cable can
properties significantly speed the repair, saving time and cost.
• Meets MIL-PRF-32517 performance
requirements Simple and Effective
• Matches cable’s impedance The splice contains three components: a hexagonal crimp
+10%/-3%
barrel for the center conductors, a dielectric shell that helps
TIME AND COST SAVING maintain cable geometry for impedance control, and a
• Repairs made in situ SolderShield splice that both terminates the cable’s shield and
• No need to remove or replace cable provides sealing to protect the splice environmentally.

SEALED The SolderShield splice uses a flux-coated, solder-impregnated

•H
 eat-shrinkable outer layer plus
copper shield inside an adhesive-lined, heat-shrinkable sleeve.
thermoplastic adhesive for sealing The completed assembly provides an environmentally sealed
and strain relief termination and strain relief.
ROBUST Part Numbers
• Withstands high vibration
• Corrosion resistant Cable Type Part Number
• Wide temperature range RG-393 D-150-Z393
• Excellent fluid resistance
• Suitable for high EMI environments

APPLICATIONS
• Military Aerospace Hexagonal Crimp Barrel

• Commercial Aerospace
Dielectric Shell

SolderShield Splice

Specifications

Electrical Cable Compatibility

Impedance: MIL-PRF-32517 Cable Types: RG-393
Insertion Loss: MIL-PRF-32517
Return Loss: MIL-PRF-32517
Insulation Resistance: 5000 MΩ

Environmental/Mechanical TE Specifications
Altitude Immersion: 75,000 ft Application Specification: D-6204
Heat Aging: 750 hr. at +165°C Product Specification: D-6204
Temperature Range: -55° C to 150°C Qualification Test Reports: HT4203 (for D-150-Z393)
Installation Instructions: RPIP-1108

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 84

 Raychem Application Tooling
Lit #1-1773872-1

Raychem
Application Tooling
The Tools to Make Every Connection Count

AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 85

Electrical Interconnect Products

Notes

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 86

Electrical Interconnect Products

Notes

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS PAGE 87

LET’S CONNECT
We make it easy to connect with our experts and are ready to
provide all the support you need. Just call your local support number or visit
www.te.com/industrial to chat with a Product Information Specialist.

Technical Support
te.com/support-center

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te.com/devices

AMP, AGASTAT, CII, DEUTSCH, DuraSeal, HARTMAN, KILOVAC, MICRODOT, MiniSeal, NANONICS, POLAMCO,
Raychem, Rayseal, SEACON, SolderGrip, SolderSleeve, SolderTacts, TE, TE Connectivity and the TE connectivity
(logo) are trademarks owned or licensed by TE Connectivity. Other products, logos, and company names
mentioned herein may be trademarks of their respective owners.
While TE Connectivity (TE) has made every reasonable effort to ensure the accuracy of the information herein,
nothing herein constitutes any guarantee that such information is error-free, or any other representation, warranty
or guarantee that the information is accurate, correct, reliable or current. The TE entity issuing this publication
reserves the right to make any adjustments to the information contained herein at any time without notice. All
implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of
merchantability or fitness for a particular purpose are expressly disclaimed. The dimensions herein are for reference
purposes only and are subject to change without notice. Specifications are subject to change without notice.
Consult TE for the latest dimensions and design specifications.
© 2019 TE Connectivity All Rights Reserved.

2347480-1  01-19   

AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS