SPECIFICATION CONTROL DRAWING
Product Rev
Product
Name
D-300-01
D-300-02
D-300-03
A±2.54
(A±0.100)
25.40
(1.000)
27.90
(1.100)
33.02
(1.300)
Product Dimensions
As Received
After Free Recovery
øB
min
4.45
(0.175)
6.35
(0.250)
9.14
(0.360)
W
min
0.25
(0.010)
0.38
(0.015)
0.38
(0.015)
øB
max
2.03
(0.080)
3.05
(0.120)
4.57
(0.180)
W
min
0.76
(0.030)
1.02
(0.040)
1.27
(0.050)
Maximum
Weight
Pounds/mpc
1.15
2.55
4.50
E
E
E
MATERIALS
1. MOLDED CAP: Heat-shrinkable, cross-linked, flame-retarded modified polyolefin.
2. MELTABLE RING: Modified thermoplastic.
APPLICATION
1. These parts are designed to meet the requirements as shown in the Requirements Section when tested as listed.
2. Parts to be assembled as outlined herein.
3. “B” recovered is the maximum inside diameter of the heat-shrinkable cap.
4. “W” is the wall thickness of the heat-shrinkable cap only, and is measured along the vertical wall.
5. “A” is the average length of the cap and is equal to (A min + A max)/2.
1.0
SCOPE
This document covers the requirements and test procedures applicable to heat shrinkable, stub-splice
encapsulation cap (caps) and the molded component thereof.
2.0
APPLICABLE DOCUMENTS
The specifications and standards referenced herein shall form part of this specification to the extent
specified.
307 Constitution Drive Menlo Park, CA 94025, USA
Wire and
Harnessing
Products
TITLE :
CAP, SPLICE ENCAPSULATION
DOCUMENT NO.:
DCR NUMBER:
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS.
INCHES DIMENSIONS ARE BETWEEN BRACKETS.
Tyco Electronics reserves the right to amend
ANGLES: N/A
TOLERANCES:
this drawing at any time. Users should
0.00 N/A
evaluate the suitability of the product for
ROUGHNESS IN
0.0 N/A
their application.
MICRON
0 N/A
D-300-01/-03
REPLACES:
D010043
SCALE:
None
SIZE:
A
N/A
SHEET:
1 of 7
DRAWN BY:
DATE:
PROD. REV.
DOC ISSUE:
M. FORONDA
15-Feb.-01
SEE TABLE
1
If this document is printed it becomes uncontrolled. Check for the latest revision.
SPECIFICATION CONTROL DRAWING
3.0
3.1
REQUIREMENTS
Material: The splice encapsulation caps shall be fabricated from the materials specified on sheet 1 of this
specification. The materials shall be homogenous and essentially free from flaws, defects, pinholes, seams,
cracks and inclusions.
Color: The caps shall be black.
Properties of Molded Component: The molded component and the material from which it is fabricated
shall meet the requirements in Table 1.
Properties of Finished Caps: The finished caps shall meet the requirements of Table 2.
QUALITY ASSURANCE PROVISIONS
3.1.1
3.1.2
3.1.3
4.0
4.1
4.1.1
4.1.2
Classification of Tests:
Qualification of Tests: Qualification testing shall consist of all test listed in this specification.
Acceptance tests: Acceptance tests shall consist of those tests applicable to Qualification Test Groups A
and F.
4.2
Sampling Instructions:
4.2.1
Qualification Test Samples: Qualification test samples shall consist of six molded slabs, 6 x 6 x 0.075±
.010 inches and 62 caps of the size for which qualification is desired. The molded slabs shall be fabricated
from the same lot of material and shall be subjected to the same degree of cross-linking as the molded
components.
4.2.2
Acceptance Test Samples: Acceptance test samples shall consist of finished caps selected at random in
accordance with ANSI/ASQC Z1.4, Inspection Level S-2, AQL 6.5%. A lot of finished caps shall consist
of all caps fabricated from the same lot of molded components, from the same production run, and offered
for inspection at the same time.
4.3
Test Procedures – Molded Slabs
4.3.1
Tensile Strength And Ultimate Elongation: Three specimens cut from a molded slab, using die D of
ASTM D 412, shall be tested for tensile strength and ultimate elongation in accordance with ASTM D 412.
4.3.2
Low-Temperature Flexibility: A 6- x ¼ inch specimen cut from a molded slab shall be mounted in a loop
position between movable, parallel, sets of jaws 2 ½ inches apart, mounted on a test fixture. Each end of
the specimen shall extend at least ¾ inch into a set of jaws and shall be firmly fastened. The specimen and
the test fixture shall be conditioned for four hours at –55 ± 2°C (-67 ± 4°F). While at this temperature, the
sets of jaws shall be moved rapidly from a 2 ½ inch to a 1 inch separation.
4.3.3
Heat Shock: Three 6 x ¼ inch specimens, cut from a molded slab, shall be conditioned for four hours in a
225 ± 5°C (437 ± 9°F) mechanical-convection oven in which air passes the specimens at a velocity of
100 to 200 feet per minute. After conditioning, the specimens shall be removed from the oven, cooled to
room temperature, and visually examined for evidence of dripping, flowing, or cracking.
4.3.4
Heat Aging:
4.3.4.1 Procedure A: Three specimens, prepared and measured in accordance with 4.3.1, shall be conditioned for
168 hours in a 175 ± 5°C (347 ±9°F) mechanical-convection oven in which air passes the specimens at a
velocity of 100 to 200 feet per minute. After conditioning, the specimens shall be removed from the oven,
cooled to room temperature, and tested for tensile strength and ultimate elongation in accordance with
4.3.1.
307 Constitution Drive Menlo Park, CA 94025, USA
Wire and
Harnessing
Products
TITLE :
CAP, SPLICE ENCAPSULATION
DOCUMENT NO.:
DCR NUMBER:
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS.
INCHES DIMENSIONS ARE BETWEEN BRACKETS.
Tyco Electronics reserves the right to amend
ANGLES: N/A
TOLERANCES:
this drawing at any time. Users should
0.00 N/A
evaluate the suitability of the product for
ROUGHNESS IN
0.0 N/A
their application.
MICRON
0 N/A
D-300-01/-03
REPLACES:
D010043
SCALE:
None
SIZE:
A
N/A
SHEET:
2 of 7
DRAWN BY:
DATE:
PROD. REV.
DOC ISSUE:
M. FORONDA
15-Feb.-01
SEE TABLE
1
If this document is printed it becomes uncontrolled. Check for the latest revision.
SPECIFICATION CONTROL DRAWING
4.3.4.2. Procedure B: Three specimens, prepared and measured in accordance with 4.3.1, shall be conditioned for
1000 hours in a 150 ± 3°C (302 ± 5°F) mechanical-convection oven in which air passes the specimens at a
velocity of 100 to 200 feet per minute. After conditioning, the specimens shall be removed from the oven,
cooled to room temperature, and tested for tensile strength and ultimate elongation in accordance with
4.3.1.
4.2.1
Solvent Resistance: Three specimens, prepared and measured in accordance with 4.3.1, shall be
completely immersed in each of the solvents listed in the applicable section of Table 1 for 24 hours at 25 ±
3°C (77 ± 5°F). The volume of the fluid shall be not less than 20 times that of the specimens. After
conditioning, the specimens shall be lightly wiped, and then air-dried for 30 to 60 minutes at room
temperature. The specimens shall then be tested for tensile strength and ultimate elongation in accordance
with 4.3.1.
4.3
Test Procedures – Finished Caps
4.3.1
Test Assembles: The test assembles shall consist of fifty-five crimped stub splices made in wire
confirming to MIL-W-81044/12 or MIL- 16878/4. Leads shall be 10 ± 1 inches long, and shall be of the
gauge listed below for the cap for which qualification is desired. Caps shall be installed in accordance with
Thermofit Assembly Procedure (see sheet 6).
Cap Size
D-300-01
D-300-02
D-300-03
4.2.1
Number of Wires/Splice
2
2
3
Wire Gauge (AWG)
18
14
12
4.2.2
4.2.3
4.2.4
Dimensions And Dimensional Recovery: Five specimens, as supplied, shall be measured for dimensions in
accordance with ASTM D 876. The specimens shall then be conditioned for ten minutes in a 200 ± 5°C
(392 ± 9°F) oven, quenched in water in less than 35°C (95°F) for at least 30 seconds, wiped dry, and the
appropriate measurements taken.
Insulation Resistance: The specimen shall be immersed to within 3 inches of the lead ends in a water bath
containing 5% by weight of NaCl for a minimum of 30 minutes after which time the insulation resistance
shall be measured between the salt solution and the test leads. The test potential shall be 500 volts D.C.
The readings shall be taken after an electrification time of one minute.
Dielectric Withstanding Voltage: The specimen shall be immersed to within 3 inches of the lead ends in a
water bath containing 5% by weight of NaCl for a minimum of 30 minutes after which time the potential
between the salt water and the test leads shall be raised from 0 to the specified voltage at a rate of 500 volts
per second. This potential shall be maintained for one minute and the voltage reduced to 0.
Temperature Cycling: Fifteen assemblies shall be subjected to 200 cycles. Each cycle shall consist of 20
minutes at 135°C (275°F) and 5 minutes at 240°C (400°F) in mechanical-convection ovens with an air
velocity of 100 to 200 feet per minute past the specimens. The specimens shall be subjected to 20 cycles
per day and shall be maintained at 25
±
5°C (77 ± 9°F) between test days. After the last cycle, the
specimen shall be cooled to 25
±
5°C (77 ± 9°F) within one hour and tested for insulation resistance (4.4.3)
and dielectric withstanding voltage (4.4.4).
307 Constitution Drive Menlo Park, CA 94025, USA
Wire and
Harnessing
Products
TITLE :
CAP, SPLICE ENCAPSULATION
DOCUMENT NO.:
DCR NUMBER:
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS.
INCHES DIMENSIONS ARE BETWEEN BRACKETS.
Tyco Electronics reserves the right to amend
ANGLES: N/A
TOLERANCES:
this drawing at any time. Users should
0.00 N/A
evaluate the suitability of the product for
ROUGHNESS IN
0.0 N/A
their application.
MICRON
0 N/A
D-300-01/-03
REPLACES:
D010043
SCALE:
None
SIZE:
A
N/A
SHEET:
3 of 7
DRAWN BY:
DATE:
PROD. REV.
DOC ISSUE:
M. FORONDA
15-Feb.-01
SEE TABLE
1
If this document is printed it becomes uncontrolled. Check for the latest revision.
SPECIFICATION CONTROL DRAWING
4.2.1
Heat Aging: Fifteen assemblies shall be conditioned for 1000 hours at 150
±
3°C (302
±
5°F) in a
mechanical-convection oven with an air velocity of 100 to 200 feet per minute past the specimens. After
conditioning, the specimen shall be cooled to 25
±
5°C (77
±
9°F) within one hour and tested for insulation
resistance (4.4.3) and dielectric withstanding voltage (4.4.4).
Altitude Immersion: Fifteen assemblies shall be immersed in a water bath containing 5% by weight of
NaCl and placed in a chamber. Wire ends, opposite the cap, shall be within the chamber, but not
submerged. The exposed wire ends shall not be sealed. The chamber pressure shall be reduced to
approximately 1 inch of mercury and maintained for 30 minutes. The chamber pressure shall then be
returned to atmospheric pressure. The insulation assistance shall be measured in accordance with 4.4.3.
This shall constitute one cycle. Two additional environment cycles shall be run. At the end of the third
cycle, the insulation resistance (4.4.3) shall be re-measured, and the dielectric withstanding voltage test
(4.4.4) shall be performed.
Corrosive effect: Two caps, as supplied, shall be placed in the bottoms of two clean ½ x 12 inches test
tubes (one cap per tube). A third tube shall be used for control. A copper-glass mirror, about 1 x ¼ inches
shall be suspended from 6 to 7 inches above the bottom of each tube by a fine copper wire attached to a
cork wrapped in aluminum foil. The corks shall tightly seal the test tubes. The lower 2 inches of each tube
then shall be placed in an oven or oil bath at 175
±
3°C for 16 hours. After cooling, the mirrors shall be
examined in a good light against a white background. Evidence of corrosion shall be areas of transparency
larger than pinholes in a mirror. Discoloration of the copper film or reduction of its thickness shall not be
considered corrosion. The mirrors shall be vacuum- deposited copper with thickness equal to 10
±
5%
transmission of normal incident light of 5000 angstroms. They shall be stored in a vacuum and shall be
used for test only if no oxide film is present and the copper is not visibly damaged.
Flammability: Specimens shall be mounted horizontally in a draft-free chamber. A standard 1/8” Bunsen
burner shall be adjusted to produce a blue flame approximately 1” high. This flame shall be applied at a
distance of 1” to the closed end of the test specimen for 10 seconds. The flame shall then be removed and
the specimen shall remain undisturbed until burning ceases. Failure of more than one specimen to
extinguish itself with 30 seconds shall be cause for rejection.
4.2.1
4.2.1
4.2.1
TABLE 1
REQUIREMENTS FOR MOLDED COMPONENT
Property
Tensile Strength
Ultimate Elongation
Stiffness
Specific Gravity
Unit
psi
percent
psi
Requirement
1500 minimum
250 minimum
10,000 minimum
25,000 maximum
1.40 maximum
Method of Test
Section 4.3.1
(ASTM D 412)
ASTM D 747
ASTM D 792
307 Constitution Drive Menlo Park, CA 94025, USA
Wire and
Harnessing
Products
TITLE :
CAP, SPLICE ENCAPSULATION
DOCUMENT NO.:
DCR NUMBER:
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS.
INCHES DIMENSIONS ARE BETWEEN BRACKETS.
Tyco Electronics reserves the right to amend
ANGLES: N/A
TOLERANCES:
this drawing at any time. Users should
0.00 N/A
evaluate the suitability of the product for
ROUGHNESS IN
0.0 N/A
their application.
MICRON
0 N/A
D-300-01/-03
REPLACES:
D010043
SCALE:
None
SIZE:
A
N/A
SHEET:
4 of 7
DRAWN BY:
DATE:
PROD. REV.
DOC ISSUE:
M. FORONDA
15-Feb.-01
SEE TABLE
1
If this document is printed it becomes uncontrolled. Check for the latest revision.
SPECIFICATION CONTROL DRAWING
TABLE 1
REQUIREMENTS FOR MOLDED COMPONENT
(continued)
Property
Hardness
Low Temperature Flexibility
4 hours @ -55°C (-67°F)
Heat Shock
4 hours @ 225°C (437°F)
Heat Aging
Followed by test for:
Tensile Strength
Ultimate Elongation
Flammability
Fungus Resistance
Water Absorption
24 hours @ 25°C (77°F)
Solvent Resistance
24 hours @ 25°C (77°F) in
JP-4 Fuel
Skydrol* 500
Hydraulic Fluid (MIL-H-5606)
Aviation Gasoline (100/130)
Water
Followed by test for:
Tensile Strength
Ultimate Elongation
Unit
Shoe D
Requirement
50±10
No cracking
No Dripping, flowing or
cracking
Method of Test
ASTM D 2240
Section 4.3.2
Section 4.3.3
Section 4.3.4
Procedures A and B
psi
percent
1200 minimum
200 minimum
Non-burning
Rating of 1 or less
0.2 maximum
Section 4.3.1
(ASTM D 412)
ASTM D 635
ASTM D 876
ASTM D 570
Procedure A
Section 4.3.5
percent
psi
percent
1200 minimum
200 minimum
Section 4.3.1
(ASTM D 412)
307 Constitution Drive Menlo Park, CA 94025, USA
Wire and
Harnessing
Products
TITLE :
CAP, SPLICE ENCAPSULATION
DOCUMENT NO.:
DCR NUMBER:
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS.
INCHES DIMENSIONS ARE BETWEEN BRACKETS.
Tyco Electronics reserves the right to amend
ANGLES: N/A
TOLERANCES:
this drawing at any time. Users should
0.00 N/A
evaluate the suitability of the product for
ROUGHNESS IN
0.0 N/A
their application.
MICRON
0 N/A
D-300-01/-03
REPLACES:
D010043
SCALE:
None
SIZE:
A
N/A
SHEET:
5 of 7
DRAWN BY:
DATE:
PROD. REV.
DOC ISSUE:
M. FORONDA
15-Feb.-01
SEE TABLE
1
If this document is printed it becomes uncontrolled. Check for the latest revision.
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