Wire-to-Wire Splicing

MiniSeal High-Performance, Immersion-Resistant Crimp Splices Product Facts

Immersion-resistant crimp splices are on QPL for MIL-S-81824 I MIL-Spec approval I Small size I Light weight I Insulation and strain relief I Easy installation

Applications MiniSeal wire-to-wire splicing products offer solutions for hundreds of aerospace and defense applications. These environment-resistant splices provide excellent reliability, long term performance, MIL-S-81824/1 qualification, and a low installed cost. MiniSeal crimp splices consist of a plated copper crimp barrel and a separate, heat-shrinkable, transparent sealing sleeve. They can be used on a combination of wires, from 1:1 to 10:10. MiniSeal splices are one of the smallest, lightest, and most environmentresistant splices available. They preserve the electrical integrity of the splice by preventing the penetration of liquids and the resulting chemical and galvanic corrosion.

Product Selection Process 1. Determine the type of splice required.

Stub (parallel) splice: Butt (in-line) splice:

2. Determine which crimp barrel plating is required:

Table A provides the CMA of typical conductors. (Both CMA and mm give the same results, so choose either CMA or mm as your unit of measure for selection purposes and continue to use it for all your selection criteria.)
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Tin plating, recommended for tin or silverplated wire Nickel plating, recommended for nickel-plated wire, or silver-plated wire in applications above 150C [302F].

4. Select the color code for the size crimp barrel required. Using Table B (page 8-23), select the crimp barrelcolorcoded red, blue, or yellowfor the CMA or mm you calculated.
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5. Determine the type of sealing sleeve required. Some wire insulations will not fit in the holes of the sealing sleeve inserts, so be sure to compare the internal diameter of each hole with the outer diameter of the wire(s) you intend to insert in that hole. To create a reliable seal, place a maximum of two wires in any hole of the sealing sleeve. 6. Select the part number. Turn to the MiniSeal part number selection tables (Tables C and D, page 8-23 and 8-24) and find the table for the type of splice (stub or butt) required. Using the appropriate table, find the crimp barrel size range and the size and number of wires for your application. Then select the part number for the type of plating required. The color code accompanying that part number should match the color code you arrived at in Table B, confirming that the part number you have selected is correct.

3. Calculate the size of crimp barrel required. Using the CMA/mm2 worksheet on the next page, calculate the total cross section to be spliced by adding the circular mil area (CMA) or square millimeters (mm ) of each wire.
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Stub splice: Select the barrel that will accommodate the total cross section. Butt splice: Select the smallest barrel that will accommodate the largest CMA/mm2 required. (Refer to the example in the worksheet for a more specific description.) If the CMA/mm2 of the smaller side of a butt splice is too small for the size barrel required to fit the larger side, increase the CMA/mm2 either by doubling back one wire (stripping the conductor twice the length you would ordinarily strip it and then folding it back) or by adding a filler wire.

Stub splice: Add the CMA or mm of all wires together.

Butt splice: Calculate each side separately (see example on the worksheet).
Available in: Americas Europe Asia Pacific
I I I

8-22
Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171

Wire-to-Wire Splicing
MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued)
Table A. CMA of Typical Conductors
Strands AWG CMA mm2 7 28 177 0.09 19 26 304 0.15 19 24 475 0.24 19 22 754 0.38 19 20 1216 0.61 19 18 1900 0.95 19 16 2426 1.21 19 14 3831 1.92 37 12 5874 2.94

Table B. Crimp Barrel Color Code Selection

CMA Range 3041510 7792680 19006755

mm2 Range 0.150.75 0.391.34 0.953.37

1:1 Splice (AWG Size) 2620 2016 1812

Color Code Red Blue Yellow

CMA/mm2 Worksheet

Example: Application: A butt splice with three AWG 22 wires in one side and one AWG 18 wire in the other side: The CMA for AWG 22 wire in Table A is 754 (0.38 mm2). Side one is therefore calculated as follows: CMA = 3 x 754 = 2262 (mm2 = 3 x 0.38 = 1.14)
Wire Number CMA

The other side, where the CMA for AWG 18 is 1900, is calculated as: CMA = 1 x 1900 = 1900 (mm2 = 1 x 0.95 = 0.95) Using Table B to select the smallest crimp barrel that will easily fit 2262 CMA (0.95 mm2), the blue barrel is the correct choice.

mm2

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

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Electrical Interconnect Products
Crimp Barrel Size Range CMA [mm2] Min.Max. 3041510 [0.150.75] 7792680 [0.391.34] 19006755 [0.953.37] 7792680 [0.391.34] 19006755 [0.953.37] I.D.dimensions Side 1 Sealing Insert
2.16 [.085]

Table C. Stub (Parallel) Splices

Part No. Illustration Tin Plated D-436-0128 Red D-436-58 Blue D-436-59 Yellow D-436-60 Blue D-436-61 Yellow Nickel Plated D-436-0119 Red D-436-75 Blue D-436-76 Yellow D-436-77 Blue D-436-78 Yellow

Side 2 Max. No. of Wires 2 Sealing Insert

Max. No. of Wires 2

4.56 [.180]

2.28 [.090]

4.56 [.180]

2
2.28 [.090]

2.03 [.080]

10 (2 per hole) 10 (2 per hole)

2
6.35 [.250]

2.03 [.080]

2
6.35 [.250]

8-23
Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171

Wire-to-Wire Splicing
MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued)
Table D. Butt (in-line) splices

Part No. Illustration Tin Plated D-436-36* Red D-436-37* Blue D-436-38* Yellow D-436-0110 Red D-436-52 Blue D-436-53 Yellow D-436-0115 Red D-436-42 Blue D-436-43 Yellow *Qualified to MIL-S-81824/1. Nickel Plated D-436-82 Red D-436-83 Blue D-436-84 Yellow D-436-85 Red D-436-86 Blue D-436-87 Yellow D-436-88 Red D-436-89 Blue D-436-90 Yellow

Crimp Barrel Size Range CMA [mm2] Min.Max. 3041510 [0.150.75] 7792680 [0.391.34] 19006755 [0.953.37] 3041510 [0.150.75] 7792680 [0.391.34] 19006755 [0.953.37] 3041510 [0.150.75] 7792680 [0.391.34] 19006755 [0.953.37]

I.D.dimensions Side 1 Sealing Insert Max. No. of Wires 2 Sealing Insert Side 2 Max. No. of Wires 2

2.16 [.085]

2.16 [.085]

2.79 [.110]

2.79 [.110]

2
4.32 [.170] 4.32 [.170]

2.36 [.093]

6
4.06 [.160]

2.36 [.093]

6 (2 per hole) 6 (2 per hole) 6 (2 per hole) 6 (2 per hole) 6 (2 per hole)

2
4.06 [.160]

2.36 [.093]

2
4.06 [.160]

2.36 [.093]

2.36 [.093]

6 (2 per hole) 6 (2 per hole) 6 (2 per hole)

2.36 [.093]

2.36 [.093]

2.36 [.093]

2.36 [.093]

Table E. Crimp Barrel Only

Type Butt (in-line) Butt (in-line) Butt (in-line) Stub (Parrel) Stub (Parrel) Stub (Parrel)

Color Code Red Blue Yellow Red Blue Yellow

Tin-Plated D-609-06 D-609-07 D-609-08 D-609-03 D-609-04 D-609-05

Nickel Plated D-609-09 D-609-10 D-609-11 D-609-12 D-609-13 D-609-14

Crimp Barrel Size Range CMA [mm2] Min. - Max. 304-1510 [0.15-0.75] 779-2680 [0.39-1.34] 1900-6755 [0.95-3.37] 304-1510 [0.15-0.75] 779-2680 [0.39-1.34] 1900-6755 [0.95-3.37]

Table F. Sealing Sleeve Only

A min.

Part No. D-436-0096 D-436-0097 D-436-0098

Color Code Red Blue Yellow

L Max. 29.2 [1.15] 29.2 [1.15] 29.2 [1.15]

A Min. 2.16 [0.085] 2.8 [0.110] 4.32 [0.170]

8-24
Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171

Wire-to-Wire Splicing
MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued)
Product Characteristics
Material Insulation Crimp barrel Meltable inserts Typical Performance Voltage drop Tensile strength Dielectric strength Temperature rating Insulation resistance

Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride Tin- or nickel-plated copper Meltable thermoplastic 6.9 mV at 4.5 A vs 8.1 mV for an equal length of wire Exceeds strength of conductor 2.5 kV -55C to 150C [-67F to 302F] 5000 megohms

Specifications/Approvals

Series D-436

Military MIL-S-81824/1 for D-436-36/37/38

Installation

For proper installation of these devices, the correct crimp tool (Raychem part number AD-1377) and a heating tool and reflector attachment must be used.

Any one of the following Raychem heating tools is recommended:

You will find ordering information for these tools in Section 10.

HL1802E AA-400 Super Heater

Refer to Raychem installation procedure RCPS 20020 for detailed instructions and recommended reflector attachments.

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Electrical Interconnect Products
8-25
Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171