Wire-to-Wire Splicing
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1 SolderSleeve Wire Splices 8-6 Product Facts Transparent polyvinylidene fluoride or polyolefin sleeve provides encapsulation, inspectability, strain relief, and insulation Prefluxed solder preform provides a controlled soldering process One-piece design makes installation easy and lowers the installed cost With one or two wires per end, the NAS 1744 splices meet 75,000 ft [22,000 m] altitude immersion requirement Thermochromic temperature indicator in the NAS splices facilitates termination and inspection UL and CUL R recognized Available in: Americas Europe Asia Pacific Applications In-line wire splices. Product Options Product Series Minimum Wire Maximum Operating Intended Application Temperature Rating Temperature Environment CWT 85 C [185 F] 125 C [257 F] Splashproof D 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 Tyco Electronics for details. Product Selection Process From the Product Options table above, 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. 3. Select part numbers from the appropriate table: For CWT series (low temperature): Use Table A on page 8-7. For D-110 series (splashproof): Use Table B on page 8-8. For D-1744 series (immersion sealed): Use Table C on page 8-9. 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 CMA or mm 2 sizes): 1. Turn to CMA/mm 2 Calculation on page 8-10 and use the workspace there to calculate the total cross section to be spliced. 2. Use Table E on page 8-11 to select the sleeve recommended for that cross section. Notes: While all combinations listed will provide satisfactory solder joints, the degree of strain relief obtained depends on the outer diameter of the wires being joined. Refer to Table E for the recommended size ranges for the sleeves. Wires (1.21 mm 2 ) and larger, and wires having more than 19 strands, should be pretinned prior to splicing, to obtain the optimum solder joint quality. Part selection for wires (0.15 mm 2 ) and smaller is covered on page 8-8.
2 Table A: CWT Series Selection Side B: Size and Size and 1 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9001 CWT-9002 CWT-9002 CWT CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT CWT-9001 CWT-9002 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9003 CWT CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9003 CWT CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT AWG 1 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 Side B: Size and Size and 10 AWG 1 1 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT CWT-9004 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005 CWT-9005 CWT CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT AWG 1 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT Electrical Interconnect Products 8-7
3 Table B: D-110 Series Selection Side B: Size and Size and 1 D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D AWG 1 D D D D D D D D Side B: Size and Size and 10 AWG 1 1 D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D AWG 1 D D D D D D D D D Fine Wire Splices (0.15 mm 2 ) and Smaller Part Inside Diameter No. As Supplied* Fully Recovered** Length*** D [0.035] 0.6 [0.025] 4.7 [0.185] D [0.035] 0.6 [0.025] 4.2 [0.165] D [0.025] 0.3 [0.013] 6.3 [0.250] D [0.040] 0.6 [0.025) 9.1 [0.360] D [0.025] 0.5 [0.021] 5.1 [0.200] Note: Micro SolderSleeve terminations are used for splicing wires smaller than [0.15 mm 2 ]. *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. 8-8
4 Table C: D-1744 Series Selection Side B: Size and Size and 1 D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D Side B: Size and Size and 1 D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D Electrical Interconnect Products 8-9
5 CMA/mm 2 Calculation To calculate the total circular mil or mm 2 area of the conductors to be terminated in a single splice, follow these steps: 1. Choose either CMA or mm 2 as your unit of measure for selection purposes and continue to use it for all your selection criteria. 2. In the workspace below, list the CMA or mm 2 for each conductor that will go into the same splice. (To assist you, Table D on this page provides the CMA of typical conductors.) 3. Add together the values listed in the workspace below to obtain the total area. 4. From Table E on the next page, select the part number recommended for the total CMA or mm 2 you have calculated. 5. Refer to the examples on this page for further clarification. Wire Number CMA mm Part Number: Total CMA/mm 2 Examples One-to-One Wire Splice Multiwire Splice 1.50 [.060] 2.50 [.100] 1.50 [.060] 3.00 [.120] 2.25 [.090] (CMA 2426) [1.21 mm 2 ] (CMA 754) 1.50 [.060] [0.38 mm 2 ] 2 at (CMA 1508) [0.38 mm 2 ] (CMA 1900) [0.24 mm 2 ] Total CMA = 3180 Total CMA = 3408 Total mm 2 = 1.59 Total mm 2 = 1.71 Correct part number selection from Table E Correct part number selection from Table E (based on CMA/mm 2 and nominal jacket wire OD) (based on CMA/mm 2 and nominal jacket wire OD) = CWT-9002 or D or D = CWT-9003 or D or D Table D. CMA of Typical AWG AWG CMA mm
6 Installation Requirements For proper installation of these devices the correct heating tool and reflector attachment must be used. Any one of the following Raychem heating tools is recommended: HL1802E IR-1759 MiniRay AA-400 Super Heater CV-1981 Refer to Raychem installation procedure RPIP for D-1744 Series and RPIP for CWT Series. You will find ordering information for these tools in Section 10. Table E: Multiwire Splice Selection CMA mm 2 Product Wire Jacket OD Combined Total Combined Total Series Min. Max. Min. Max. Min. Max. CWT [0.015] 1.7 [0.066] CWT [0.05] 2.7 [0.106] CWT [0.07] 4.5 [0.18] CWT [0.11] 6.0 [0.236] CWT [0.125] 7.0 [0.275] D [0.020] 1.90 [0.075] D [0.031] 2.80 [0.110] D [0.050] 4.57 [0.180] D [0.080] 7.11 [0.280] D [0.020] 1.78 [0.070] D [0.050] 2.54 [1.00] D [0.075] 4.5 [0.177] D [0.095] 4.32 [0.17] D [0.140] 7.11 [0.28] D [0.160] 8.76 [0.345] Product Characteristics Material Insulation (D-110, D-1744) Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride Insulation (CWT) 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 (CWT) Solder: Sn50 Pb32 Cd18 Flux: ROM1 per ASNS-J-004 (RA flux) Meltable inserts (CWT, D-1744) Meltable thermoplastic Typical Performance Voltage drop Tensile strength Dielectric strength Temperature rating (CWT) Temperature rating (D-110, D-1744) Insulation resistance 2.0 mv Exceeds strength of conductor 2.0 kv -55 C to +125 C [-67 F to +257 F] -55 C to +150 C [-67 F to +302 F] 1000 megohms 8Electrical Interconnect Products Specifications/Approvals Series Agency Raychem CWT UL E87681 D-5023 D-110 UL E87681 RT-1404 D-1744 NAS-1744 RT
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