specification control drawing te connectivity 305 constitution drive menlo park, ca 94025, usa raychem products title : in-line splice sealing system, multi-wire unless otherwise specified dimensions are in millim eters. inches dimensions are between brackets. document no.: d-436-42/-43 tolerances: 0.00 n/a 0.0 n/a 0 n/a angles: n/a roughness in micron te connectivity reserves the right to amend this drawing at any time. users should evaluate the suitability of the product for their application. date: 15-apr-11 doc issue: 2 drawn by: m. foronda replaces: n/a dcr number: d001303 prod. rev. see table scale: none size: a sheet: 1 of 4 if this document is printed it becomes uncontrolled . check for the latest revision. materials 1. insulation sleeve: heat-shrinkable, transparent blue, radiation cross-linked modified polyvinyliden e flouride. 2. integral multi-wire seal: modified thermoplastic . 3. separate multi-wire seal: modified thermoplastic . 4. crimp splicer: base metal: copper alloy 101 or 1 02 per astm b-75. plating: tin per mil-t-10727, type 1. color code: see table below. dimensions: crimp splice installation data: wire size range of crimp splicer part prod. i.d.0.05 o.d.0.08 color two wires thre e wires name rev. (i.d.0.002) (o.d.0.003) code minimum ma ximum minimum maximum d-436-42 f 1.70 (0.067) 2.62 (0.103) blue 2 x 24 2 x 20 3 x 24 3 x 22 d-436-43 a 2.54 (0.100) 3.81 (0.150) yellow 2 x 22 2 x 16 3 x 22 3 x 18 application 1. these parts are designed to provide an immersion resistant in-line splices of 2 or 3 to 2 or 3 wire s falling within the size range listed above, having insulation s rated for at least 135 ? c. 2. parts are available only as an assembly of one o f each item #1 and item #2. 3. crimp splicer may be installed with raychem ad-1 377 crimp tool or equivalent. 4. inside diameter and outside diameter of splice a re to be measured in crimp area, 2.54 to 5.08 (0.10 0 to 0.200) from ends of part. slight burr permitted on par ted surfaces. 5. acceptance sampling shall be in accordance with paragraph 4.6.1 of mil-t-7928. 6 . packing and packaging shall be in accordance wi th section 5, level c, of mil-t-7928. 7. this document takes precedence over documents re ferenced herein. 1.0 test assemblies
specification control drawing te connectivity 305 constitution drive menlo park, ca 94025, usa raychem products title : in-line splice sealing system, multi-wire unless otherwise specified dimensions are in millim eters. inches dimensions are between brackets. document no.: d-436-42/-43 tolerances: 0.00 n/a 0.0 n/a 0 n/a angles: n/a roughness in micron te connectivity reserves the right to amend this drawing at any time. users should evaluate the suitability of the product for their application. date: 15-apr-11 doc issue: 2 drawn by: m. foronda replaces: n/a dcr number: d001303 prod. rev. see table scale: none size: a sheet: 2 of 4 if this document is printed it becomes uncontrolled . check for the latest revision. the test assemblies for qualification testing shall be 3 to 3 in-line splices made in wire conforming to mil-w-81044/12 or mil-w-16878/4. the assemblies shall be divided equally between the maximum and minimum wire size as shown below: asse mbly minimum maximum d-436-42 24 22 d-436-43 22 18 the qualification sample shall consists of 35 assem blies and 8 uninstalled sleeves. 1.1 acceptance testing: acceptance sampling shall be in accordance with an si/asqc z1.4, inspection level s-4. the acceptable quality level shall be 4.0 for all defec ts. acceptance tests shall consist of visual and dimens ional examination. 2.0 qualification testing: .1 all sleeves shall be tested for compliance with she et 1 in regard to: property test method material and appearance visual examination dimensions mil-i-23053, paragraph 4.6.3 2.2 test group a: ten assemblies shall pass the po st conditioning tests after conditioning in the sequence shown: post conditioning requirement test method insulation resistance 5000 m @500v d-c m il-w-81044, par. 4.7.5.2 altitude immersion 75,000 ft. mil-c-265 00, par. 4.7.21 insulation resistance 5000 m @500v d-c m il-w-81044, par. 4.7.5.2 dielectric withstanding 2.5kv (rms) for 1 min. mil-w-81044, par. 4.7.5.1 conditioning parameters test method altitude immersion 75,000 ft. mil-c-265 00, par. 4.7.21 immersion condition c method 104* temperature cycling -65 ? c to 150 ? c (5 cycles) method 102* moisture resistance step 7b not required method 106* fluid immersion mil-h-5606, mil-l-7808 mil -t-7928, par. 4.8.8 heat aging 96 hours @200 ? c method 108* 2.3 test group b: ten assemblies: test sequence requirement test method
specification control drawing te connectivity 305 constitution drive menlo park, ca 94025, usa raychem products title : in-line splice sealing system, multi-wire unless otherwise specified dimensions are in millim eters. inches dimensions are between brackets. document no.: d-436-42/-43 tolerances: 0.00 n/a 0.0 n/a 0 n/a angles: n/a roughness in micron te connectivity reserves the right to amend this drawing at any time. users should evaluate the suitability of the product for their application. date: 15-apr-11 doc issue: 2 drawn by: m. foronda replaces: n/a dcr number: d001303 prod. rev. see table scale: none size: a sheet: 3 of 4 if this document is printed it becomes uncontrolled . check for the latest revision. insulation resistance 5000 m @500v d-c mil-w-810 44, par. 4.7.5.2 vibration mil-std-202, method 201 mil-t-7928, par . 4.8.6 insulation resistance 5000 m @500v d-c mil-w-8104 4, par. 4.7.5.2 altitude immersion 75,000 ft. (1 cycle) mil-c-265 00, par. 4.7.21 insulation resistance 5000 megaohms mil-w-81044 , par. 4.7.5.2 voltage drop** wire equivalent + 2.0 mil-t-7928, par. 4.8.1 millivolts (maximum) tensile strength table ii mil-t-7928, par. 4.8 .7 * test methods are per mil-std-202. ** test current shall be equal to 3x the rated c urrent fot the smallest gauge wire used. 2.4 test group c: ten assemblies: test sequence requirement test method insulation resistance 5000 m @500v d-c mil-w-810 44, par. 4.7.5.2 salt spray (corrosion)*** mil-t-7928, par. 4.8 .4 insulation resistance 5000 m @500v d-c mil-w-8104 4, par. 4.7.5.2 altitude immersion 75,000 ft. (1 cycle) mil-c-265 00, par. 4.7.21 insulation resistance 5000 m @500v d-c mil-w-8104 4, par. 4.7.5.2 voltage drop** wire equivalent + 2.0 mil-t-7928, par. 4.8.1 millivolts (maximum) tensile strength table ii mil-t-7928, par. 4.8 .7 *** lead ends to be sealed prior to exposure. 2.5 test group d: five assemblies: test requirement test method flammability self extinguishing mil-t-7928, par . 4.8.10 within 15 seconds 2.6 test group e: three sleeves: test requirement test method corrosive effect non-corrosive mil-i-23053, pa r. 4.6.10.2 2.7 test group f: five sleeves: test requirement test method insulation shrinkage sheet 1 mil-i-23053, par. 4.6.3.2.2
specification control drawing te connectivity 305 constitution drive menlo park, ca 94025, usa raychem products title : in-line splice sealing system, multi-wire unless otherwise specified dimensions are in millim eters. inches dimensions are between brackets. document no.: d-436-42/-43 tolerances: 0.00 n/a 0.0 n/a 0 n/a angles: n/a roughness in micron te connectivity reserves the right to amend this drawing at any time. users should evaluate the suitability of the product for their application. date: 15-apr-11 doc issue: 2 drawn by: m. foronda replaces: n/a dcr number: d001303 prod. rev. see table scale: none size: a sheet: 4 of 4 if this document is printed it becomes uncontrolled . check for the latest revision. (5 minutes @ 300 ? c) longitudinal change 10% mil-i-23053, par. 4.6. 5.1 (5 minutes @ 300 ? c) tehrmofit assembly procedure: 1.0 scope this document outlines the procedure to be followed to obtain immersion resistant multiple wire butt s plices using thermofit multi-wire in-line splice sealing system d-436-42/-43. 2.0 procedure a) pass the wires to be attached to one barrel through the separate three wire seal. (item 3) pass the wi res to be attached to the other barrel through the seal ing sleeve from the three hole insert end. b) strip wires 5/16 to 11/32 and crimp into splicer using one of the approved crimping tools (see below). care must be taken that the wires remain un twisted between the splice and the three wire seals or the sealing sleeve cannot be positioned properly. c) position the separate seal as close as possible to the splicer. hold this piece in position by squeezi ng the wires directly behind it, and slide the sealing sleeve over the assembly so that the separate seal is as far inside the sleeve as possible. d) apply heat, using the recommended heat source, firs t to the separate seal end, and then the other. heat should be applied until insert melts and flows axially along the wires. 3.0 recommended tools a. crimp tools manufacturer model number raychem ad-1377 buchanan electric products 614080 daniels manufacturing company ot-609 b. heat tools heater reflector thermogun #500a tg-14 shop air heater #cv-4504 991180 mini-gun #cv-5300 991319 heater should be operated to give an air stream tem perature of at least 550 ? f.
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