Wire-to-Wire Splicing MiniSeal High-Performance, Immersion-Resistant Crimp Splices Product Facts Immersion-resistant crimp splices are on QPL for SAE-AS-81824 MIL-Spec approval Small size Light weight Insulation and strain relief Easy installation Applications Product Selection Process Table A provides the 5. Determine the type of CMA of typical conduc- sealing sleeve required. MiniSeal wire-to-wire splic- 1. Determine the type of 2 tors. (Both CMA and mm Some wire insulations will ing products offer solutions splice required. give the same results, so not fit in the holes of the for hundreds of aerospace Stub (parallel) splice: choose either CMA or sealing sleeve inserts, so and defense applications. 2 mm as your unit of be sure to compare the These environment-resistant measure for selection internal diameter of each splices provide excellent Butt (in-line) splice: purposes and continue hole with the outer reliability, long term per- to use it for all your diameter of the wire(s) formance, MIL-S-81824/1 selection criteria.) you intend to insert in qualification, and a low 2. Determine which crimp that hole. To create a installed cost. barrel plating is required: 4. Select the color code for reliable seal, place a the size crimp barrel MiniSeal crimp splices con- Tin plating, maximum of two wires required. Using Table B sist of a plated copper recommended for tin in any hole of the sealing (page 8-23), select the crimp barrel and a sepa- or silverplated wire sleeve. crimp barrelcolor- rate, heat-shrinkable, trans- Nickel plating, coded red, blue, or 6. Select the part number. parent sealing sleeve. They recommended for yellowfor the CMA or Turn to the MiniSeal part can be used on a combina- nickel-plated wire, or 2 mm you calculated. number selection tables tion of wires, from 1:1 to silver-plated wire in (Tables C and D, page 10:10. MiniSeal splices are Stub splice: Select the applications above 8-23 and 8-24) and find one of the smallest, lightest, barrel that will accommo- 150C 302F . the table for the type of and most environment- date the total cross splice (stub or butt) 3. Calculate the size of resistant splices available. section. required. crimp barrel required. They preserve the electrical Butt splice: Select the 2 integrity of the splice by Using the appropriate Using the CMA/mm smallest barrel that will preventing the penetration table, find the crimp worksheet on the next accommodate the of liquids and the resulting barrel size range and 2 page, calculate the total largest CMA/mm chemical and galvanic the size and number of cross section to be required. (Refer to the corrosion. wires for your applica- spliced by adding the example in the work- tion. Then select the circular mil area (CMA) sheet for a more specific part number for the type or square millimeters description.) If the 2 of plating required. The 2 (mm ) of each wire. CMA/mm of the smaller color code accompany- side of a butt splice is Stub splice: Add the ing that part number 2 too small for the size CMA or mm of all wires should match the color barrel required to fit the together. code you arrived at in larger side, increase the Butt splice: Calculate Table B, confirming that 2 CMA/mm either by each side separately the part number you doubling back one wire (see example on the have selected is correct. (stripping the conductor worksheet). twice the length you Available in: would ordinarily strip it Americas and then folding it back) Europe or by adding a filler wire. Asia Pacific 8-24 Catalog 1654025 Dimensions are shown for Dimensions are in millimeters Canada: +1 (905) 475-6222 UK: +44 (0) 800-267666 Revised 5-12 reference purposes only. unless otherwise specified. Mexico/C. Am.: +52 (0) 55-1106-0800 France: +33 (0) 1-3420-8686 Specifications subject Latin/S. Am.: +54 (0) 11-4733-2200 Netherlands: +31 (0) 73-6246-999 www.te.com to change. USA: +1 (800) 522-6752 Germany: +49 (0) 6251-133-1999 China: +86 (0) 400-820-6015Electrical Interconnect Products Wire-to-Wire Splicing MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued) Table A. CMA of Typical Strands 7 19 19 19 19 19 19 19 37 Conductors AWG 28 26 24 22 20 18 16 14 12 CMA 177 304 475 754 1216 1900 2426 3831 5874 2 mm 0.09 0.15 0.24 0.38 0.61 0.95 1.21 1.92 2.94 Table B. Crimp Barrel Color CMA Range 1:1 Splice (AWG Size) Color Code Code Selection 3041510 2620 Red 10582680 2016 Blue 23756755 1612 Yellow 2 CMA/mm 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 calcu- will easily fit 2262 CMA, the lated as follows: blue barrel is the correct choice. CMA = 3 x 754 = 2262 2 Wire Number CMA mm 1 2 3 4 5 6 7 8 8 9 10 Part Number: Total Table C. Stub (Parallel) Splices I.D.dimensions Crimp Barrel Part No. Size Range Side 1 Side 2 Illustration CMA Sealing Max. No. Sealing Max. No. Tin Plated Nickel Plated Min.Max. Insert of Wires Insert of Wires D-436-0128 D-436-0119 3041510 22 Red Red 2.16 .085 1.01 .040 D-436-58 D-436-75 10582680 22 Blue Blue 4.56 .180 2.28 .090 D-436-59 D-436-76 23756755 22 Yellow Yellow 4.56 .180 2.28 .090 D-436-60 D-436-77 10 10582680 2 2.03 Blue Blue (2 per hole) .080 6.35 .250 D-436-61 D-436-78 10 23756755 2 2.03 Yellow Yellow (2 per hole) .080 6.35 .250 8-25 Catalog 1654025 Dimensions are shown for Dimensions are in millimeters Canada: +1 (905) 475-6222 UK: +44 (0) 800-267666 Revised 5-12 reference purposes only. unless otherwise specified. Mexico/C. Am.: +52 (0) 55-1106-0800 France: +33 (0) 1-3420-8686 Specifications subject Latin/S. Am.: +54 (0) 11-4733-2200 Netherlands: +31 (0) 73-6246-999 www.te.com to change. USA: +1 (800) 522-6752 Germany: +49 (0) 6251-133-1999 China: +86 (0) 400-820-6015