Application Specification
Nylon Closed End Splices
NOTE
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All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and
inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2_.
Figures and illustrations are for identification only and are not drawn to scale.
1. INTRODUCTION
This specification covers the requirements for application of nylon closed end splices. The splices consist of
metal inserts insulated with nylon. The splices are available in sizes 22--14 and 22--10. The splices accept a
combination of solid and stranded wires for single and multiple applications. The flared end of the insulation
allows insertion of wires that meet maximum voltage ratings, available in two types: ECN with a rating of 300 V
and EC with ratings of 600 V for building wiring and 1,000 V for fixture and sign wiring. The splices are color
coded to provide a visual reference applicable to the maximum temperature rating the splice can withstand:
transparent is rated at 105_C [221_F] and black is rated at 150_C [302_F]. Each splice is marked on the center
of the splice with listing agencies (UL and CSA), type (EC or ECN), and wire size range suitable for the splice.
The splices are available in loose--piece for terminating with manual and pneumatically--powered hand--held
tools and in tape--mounted form for terminating with semi--automatic hand--held tools and electrically--powered
machines.
When corresponding with personnel, use the terminology provided in this specification to facilitate your
inquiries for information. Basic terms and features of this product are provided in Figure 1.
Wire Barrel
Insulation
Splice Markings
Figure 1
2. REFERENCE MATERIAL
2.1. Revision Summary
Revisions to this application specification include:
S
Updated document to corporate requirements.
2.2. Customer Assistance
Reference Product Base Part Number 328730 and Product Code 3247 are representative of nylon closed end
splices. Use of these numbers will identify the product line and expedite your inquiries through a service
network established to help you obtain product and tooling information. Such information can be obtained
through a local Representative or, after purchase, by calling PRODUCT INFORMATION at the number at the
bottom of page 1.
2.3. Drawings
Customer Drawings for product part numbers are available from the service network. If there is a conflict
between the information contained in the Customer Drawings and this specification or with any other technical
documentation supplied, call PRODUCT INFORMATION at the number at the bottom of this page.
E2011
Tyco Electronics Corporation, a TE Connectivity Ltd. Company
TOOLING ASSISTANCE CENTER 1--800--722--1111
All Rights Reserved
PRODUCT INFORMATION 1--800--522--6752
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks.
*Trademark. Other logos, product and/or Company names may be trademarks of their respective owners.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.te.com
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2.4. Instructional Material
Instruction Sheets (408--series) provide assembly instructions, and Customer Manuals (409--series) provide
machine setup and operation procedures. Documents available which pertain to this product are:
408--9816
408--1003
408--1021
408--1271
408--8806
408--8807
Handling of Reeled Products
Solid and stranded wire sizes 22--10 AWG for EC splices
Solid and stranded wire sizes 22--10 AWG for ECN splices
Solid and stranded wire sizes 22--14 AWG for ECN splices
Solid and stranded wire sizes 22--14 AWG for ECN splices
Solid and stranded wire sizes 22--10 AWG for EC splices
Hand Crimping Tool 46866 (Wire Sizes 22--10 AWG)
Hand Crimping Tools 45216 (Wire Sizes 22--14 AWG) and 45219--2
(Wire Sizes 22--10 AWG)
Crimping Dies 45218 (Wire Sizes 22--14 AWG) and 45221 (Wire Sizes 22--10 AWG)
Hand Crimping Tool 69710--1
Crimping Die Assemblies 69950, 69951, and 69952
Straight--Action Crimper 217200--1
PRO--CRIMPER* III Hand Tool Assembly 217212--1 (with Die Assembly 217212--2)
C--Head Pneumatic Adapter (Crimper) 318161--1
Pneumatic CERTI--CRIMP* (Small) Tool Holder Assembly 356303--1 (Logic)
Checking Crimp Height or Gaging Die Closure
Miniature Quick Change Applicators (Side--Feed Type)
Straight Action Air Tool Die Assembly 47811 (Wire Sizes 22--10 AWG)
626 Pneumatic Head Assembly 354422--1
626 Pneumatic Crimping Head 354422--2
PRO--CRIMPER III Hand Crimping Tool Frame Assembly 354940--1
AMP--TAPETRONIC* Machine 69875
Basic AMP--O--LECTRIC* Model “K” Terminating Modified Machine 471273--[ ]
AMP--O--LECTRIC Model “G” Terminating Machine 354500--[ ]
626 Pneumatic Tooling Assemblies 189721--[ ] and 189722--[ ]
(Use with Small Tool Holder Assembly 189766--1 Non--Logic or
Straight Action Tool Holder Assembly 189928--1 Non--Logic)
A. Wire Combinations
B. Tooling
408--1539
408--1578
408--1634
408--2095
408--2254
408--4105
408--4145
408--4190
408--4303
408--7424
408--8082
408--9641
408--9893
408--9906
408--9930
409--1993
409--5128
409--5842
409--5862
3. REQUIREMENTS
3.1. Material
The splice body is made of copper plated with tin, and the insulation is made of nylon. The insulation is highly
resistant to abrasion.
3.2. Storage
A. Shelf Life
The splices should remain in the shipping containers until ready for use to prevent deformation to the
splices. The splices should be used on a first in, first out basis to avoid storage contamination that could
adversely affect performance.
CAUTION
It is important that the splices remain in the protective poly bags until ready for use; a moist or dry environment may
adversely affect the hygroscopic material used in the splice insulation.
!
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B. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the insulation
material.
C. Reeled Splices
When using tape--mounted reeled splices, care must be taken to prevent stretching, sagging, or other
distortion that would prevent smooth feeding of the tape through automatic machine feed mechanisms.
Store coil wound reels horizontally and traverse wound reels vertically.
3.3. Chemical Exposure
Do not store splices near any chemical listed below as they may cause stress corrosion cracking in the splices.
Alkalies
Amines
Ammonia
Carbonates
Citrates
Nitrites
Phosphates Citrates
Sulfur Nitrites
Sulfur Compounds
Tartrates
3.4. Wire Selection and Preparation
The splices will accept solid and stranded copper wire sizes 22 through 10 AWG (509 through 13,100 circular
mil area). Various combinations of wires for each splice are listed on the applicable wire combination chart
packaged with the splice. The length of the exposed conductors may vary depending upon the number of wires
used in the application. Proper strip length is necessary to properly insert the wire into the splice. The strip
length of the wire is shown in Figure 2.
CAUTION
Reasonable care must be taken not to nick, scrape, or cut any strands during the stripping operation.
!
Single Stranded Wire
Single Solid Wire
Wire Strip Length
(Refer to Table)
Conductor
Insulation
Wire Strip Length
(Refer to Table)
Note:
Not to Scale
Wire Strip Length for
Multiple Wires Must
Be the Same
Wire Strip Length Must
Be Maintained After
Twisting Multiple Wires
SPLICE SIZE
22--14
22--10
Figure 2
WIRE STRIP LENGTH
8.33--9.13 [.328--.359]
10.72--11.51 [.422--.453]
3.5. Wire Placement
Stranded wire conductors must be inside the splice wire barrel. No strands can be folded back over the wire
insulation. Conductor ends must be bottomed in the wire barrel. The wire insulation must be inside the
insulation of the splice, but must not enter the wire barrel, to provide strain relief for the wire.
If local production requirements allow, to prevent the conductors from flaring out, conductors can be twisted
together to form a tight bundle before inserting them into the splice. If conductors are twisted, wire strip length
must be maintained after twisting.
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3.6. Crimp Requirements
The splice must be crimped to the wire according to instructions packaged with applicable tooling.
A. Wire Barrel Crimp
The crimp applied to the wire barrel portion of the splice is the most compressed area and is most critical
in ensuring optimum electrical and mechanical performance of the crimped splice. The crimped area must
be symmetrical on both sides of the wire barrel of the splice. The crimp may be off center on the wire
barrel but not off the end of the wire barrel. See Figure 3.
NOTE
The resilience of the splice insulation prevents accurate direct measurement of crimp height. Crimp height can be
obtained by measuring a crimped solder slug (60% tin and 40% lead) with a diameter comparable to the wire size.
The slug must be measured over the most compressed area of the slug with a standard micrometer or crimp height
comparator (refer to 408--7424 for specific instructions). The solder slug diameter and crimp height must be within the
dimensions provided in Figure 3.
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B. Wire Conductor and Insulation Location
Wire conductor ends must be flush to the end of the wire barrel. All conductors must be held firmly inside
the wire barrel. No strands can be folded back over the wire insulation. The wire insulation must be inside
the insulation of the splice, but must not enter the wire barrel. See Figure 3.
CAUTION
Wire insulation shall NOT be cut or broken during the crimping operation. Reasonable care should be taken to provide
undamaged wire terminations.
!
C. Splice Insulation
The splice insulation must not be deformed, cut, or show uneven stress marks.
D. Flash
There shall be no flash or extruded insulation visible in the crimped area. See Figure 3.
Wire Insulation
Location
Wire Conductor
Location
No Flash in
Crimp Area
Crimp Centered on Wire Barrel (Crimp May Be
Off Center, But Not Off End of Wire Barrel)
SPLICE
SIZE
22--14
22--10
22 10
TYPE
ECN
EC
ECN
Figure 3
DIAMETER
6.35 [.250]
6.35 [ 250]
6 35 [.250]
SOLDER SLUG
CRIMP HEIGHT
2.31--2.46 [.091--.097]
2.92--3.05 [.115--.120]
3.12--3.25 [.123--.128]
NOTE
i
Each crimp height dimension represents the functional range of a wire and splice combination. The developed crimp
configuration is unique for each tool design and is acceptable provided the crimp height is within the functional range.
For crimp height dimensions for a specific tool, refer to instruction sheet packaged with manual tools and applicator log
packaged with power tools.
E. Tensile Strength
Crimped splices must hold the wire firmly and have a crimp pull--out test value meeting that specified in
Figure 4 (the test value is that of the smallest wire size used in the splice).
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NOTE
Adjust tensile testing machine for head travel of 25.4 [1.0] per minute. Directly and gradually apply force for one
minute.
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WIRE SIZE (AWG)V
22
20
18
16
14
12
10
TENSILE FORCE (N [lb]) Min
35 [8]
44 [10]
44 [10]
66 [15]
111 [25]
155 [35]
178 [40]
V
Use the smallest wire size in the splice to determine tensile strength.
Figure 4
3.7. Repair
Damaged splices or splices that do not meet crimp dimension requirements must be removed from wires,
discarded, and replaced with new ones. When removing a splice, cut the wires as close as possible to the end
of the wire barrel.
4. QUALIFICATION
Nylon closed end splices are Listed by Underwriters Laboratories Inc. (UL) in File E13288 and Certified by
CSA International in File LR 7189.
5. TOOLING
Hand tools for manual application of loose piece splices and semi--automatic machines for power assisted
application of tape--mounted splices are available to cover the full wire size range. Tooling part numbers and
instructional material packaged with the tooling are given in Figure 5.
NOTE
Modified designs and additional tooling concepts may be available to meet other application requirements. Machines
have been designed for a variety of application requirements. For assistance in setting up prototype and production
line equipment, contact your local Representative or call the TOOLING ASSISTANCE CENTER at the number at the
bottom of page 1.
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5.1. 626 Pneumatic Tooling System
The pneumatic tooling system consists of a pneumatic power unit, tool holder assembly, and variety of
crimping heads used to crimp splices onto pre--stripped wire. This tooling system was developed to reduce
operator fatigue and provide interchangeability of die assemblies. The system is designed for prototype and
medium--volume application of loose piece splices.
5.2. Semi- Automatic Machines
A. Applicator
The applicator is designed to crimp tape--mounted splices onto pre--stripped wire, and provides for high
volume, heavy duty production requirements. The applicator must be installed onto a power unit. The
applicator used to crimp these splices includes crimping dies.
B. Power Units
Power units provide the force required to drive applicators. These power units are designed to be bench
mounted. The AMP--TAPETRONIC machine consist of a basic AMP--O--LECTRIC Model “K” terminating
machine and applicator (which does not include applicable crimping dies) required to crimp the splices.
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