46-455 Cover A/W 20/9/02 4:13 pm Page 1 August 2002 Wire and Cable, Harnessing and Protection Products Wire and Cable, Harnessing and Protection Products ©2002 Tyco Electronics Corporation July 2002 Tyco Electronics Corporation Tyco Electronics Corporation Tyco Electronics Corporation Tyco Electronics Corporation 300 Constitution Drive Faraday Road 3816 Noborito, Tama-ku Asia Pacific Headquarters the in Printed Menlo Park, CA 94025-1164 Dorcan, Swindon Kawasaki 26 Ang Mo Kio USA SN3 5HH Kanagawa 214-8533 Industrial Park 2 Tel: (800) 926-2425 Tel: +44 1793 528171 Japan Singapore 569507 (US & Canada) Tel: +81 44 900 5102 Tel: +65 4866 151 USA 1654025 Tel: +1(650) 361-3860 (All other countries) www.tycoelectronics.com Overview etc. 30/9/02 11:35 am Page 3 Contents Application Overview 1 Seal It 1-0 Connect It 1-1 Insulate It 1-2 Protect It 1-3 Wire It 1-4 Hold It 1-5 Join It 1-6 Beautify It 1-7 Reduce It 1-8 Repair It 1-9 Flex It 1-10 All of It 1-11 Electrical Interconnection System Design 2 Harness Design 2-0 Protection of Harness Components 2-4 HarnWare 2-6 Integrated Military Harness Systems for Defense and Allied Industries 2-16 Products Tubing 3 Molded Parts 4 Adhesives 5 Adapters 6 Assemblies 7 Electrical Interconnect Products 8 Wire and Cable 9 Application Equipment 10 Supporting Information 11 Equivalents and Conversions 11-0 Temperature Conversion 11-2 Glossary 11-4 Index 11-22 Overview etc. 30/9/02 11:35 am Page 4 How to use This catalog has four main sections: Application Overview Electrical Interconnection System Design The Product Supporting Information Application Overview (Section 1) presents The product information pages provide some or all general design ideas based on typical uses for of the following information (depending on the Raychem-brand wire and cable, heat-shrinkable tubing product family): and protection products. Application photos depict examples of how customers use our products to Raychem Fax-on-Demand telephone number to enhance the performance and improve the reliability of call to order the product literature. their specific products in one or more of these generic Fax-on-Demand document ID number(s) and applications; Seal It, Connect It , Wire It, Insulate It, description(s). Protect It, Hold It, Join It, Beautify It, Reduce It, Repair It, Typical applications for the product family. Flex It, All of It. Product features/benefits. Abbreviated installation guidelines. Electrical Identification System Design Specifications and agency approvals. (Section 2) describes wire harness components and Part number selection information (not shown in the harness protection issues and provides a step-by-step illustration on the next page). guide to selecting the right Raychem components for a Product data (dimensions, properties, and materials). particular wire harnessing system. Ordering information. Location availability. Products (Sections 3-10) showcases our product groups. Each section provides: Supporting Information (Section 11) provides: Equivalents and conversion tables. An overview of the product group. Temperature conversion table. A table of contents that lets you see at a glance Glossary. the product families in that product group. A selection guide to help you determine which product family will satisfy the requirements of your application. An explanation of the part numbering system for that product group. Information pages on each product family. Overview etc. 30/9/02 11:35 am Page 5 How to use Product Page Guidelines Tyco Electronics Fax-on-Demand telephone number(s), Market icons document ID number(s) and description(s) Typical applications of product literature Operating temperature Website Product dimensions Product features/benefits or characteristics Installation guidelines Location availability Specifications and Ordering information agency approvals Market Icons Use these icons to quickly identify market opportunities at-a-glance. They appear on the product information pages. The icons on each page represent, but are not limited to, the markets that currently exist for that particular product. Medical Marine Automotive Military Commercial Electronics/Communications Rail Industries Industrial Space Aerospace Overview etc. 30/9/02 11:35 am Page 6 Tyco Electronics embraces the most valued brand names worldwide Tyco Electronics Corporation–the largest unit of Tyco International Ltd.– was established in September 1999 when Tyco acquired Elcon Products and Raychem Corporation, and integrated them with AMP, acquired earlier the same year. Since then, the company has rapidly grown and strengthened its competencies as an electrical and electronic component supplier, with product offerings in 25 passive and active product segments. In the passives field, Tyco Electronics is now the world’s largest supplier. The company has facilities located around the globe serving customers in the aerospace, automotive, commercial electronics/communications, industrial/energy, marine, medical, military, and rail industries. Tyco Electronics’ product portfolio continues to grow, encompassing connector systems and application tooling, active and passive fiber optic devices, complete As a truly global player, Tyco Electronics power systems, wireless components (including ICs, Corporation has facilities located radar sensors, and complete communications systems), throughout the world serving customers GPS and integrated antenna systems, heat-shrink in a wide range of applications. products, circuit protection devices, magnetic components, wire and cable systems, touchscreens, PC boards and backplanes, smart cards, relays, sensors, electronic modules, wire harnessing and labeling products, battery packs, terminal blocks and switches. A significant result of this continued growth, and a real benefit to customers, is that Tyco Electronics’ technology leadership becomes even stronger. The synergies of Medical Automotive Commercial Electronics/ Industrial Space Communications expertise in materials science, product design, and process engineering, coupled with knowledgeable application engineers, sales representatives, and customer service personnel enables you to make Aerospace Marine Military Rail Industries your next generation of products successful. Overview etc. 30/9/02 11:35 am Page 7 About Raychem wire and cable, harnessing, and heat-shrinkable products Tyco Electronics, for its Raychem products, pioneered the application of radiation crosslinking and the development of heat-shrinkable polymer tubing. The Tyco Electronics Raychem brand of heat-shrinkable support and a global sales/service organization, polymer products is recognized worldwide. It is backed customers with worldwide operations count on by a history of proven performance, reliability, innovation Tyco Electronics to supply the knowledge and products and superior quality. Tyco Electronics manufactures the they need to solve specific problems and help them world’s largest range of heat-shrinkable tubing – tubing take advantage of opportunity, anywhere it arises. that provides cable protection offering exceptional This philosophy has earned Tyco Electronics a reputation insulation, mechanical protection, and strain relief. for leadership in materials science technologies. We are the recognized world leader in heat-shrinkable Developed from these technologies, Raychem products polymer technology. are sold into many industries including aerospace, automotive, electronics, construction, electrical power, A broad-based product line of Raychem wire and cable utilities, manufacturing, pipeline, process, rail and mass is engineered to meet or exceed the most rigorous transit, and telecommunications. technical specifications. Performing from -100° to +260° Celsius, the product line encompasses fire-resistant cable, small-size controlled electrical cables, multi-conductor cable, high-performance radiation crosslinked ETFE airframe wire, low fire hazard wire, high-performance automotive and commercial wire, and NASA-spec and other space- application types. Additionally, a variety of low-cost, easy-to-install components for wire harnesses and cable assemblies are available including splices, adapters, low-profile rectangular connectors, and contacts. These components are approved to widely recognized standards and specifications that include UL, SAE, MIL, Defense, DNV, Lloyds, and ABS. Tyco Electronics also provides customized harnessing design supported by a pioneering software package, HarnWare, which enables fast, optimum system design with materials and assembly labor estimates. For over forty-five years customers have recognized the global capabilities of Raychem products. Combining these advanced products with superior technical 1-Applications 30/9/02 10:11 am Page A1 1-Applications 30/9/02 10:11 am Page A2 Applications 1-Applications 30/9/02 10:11 am Page A3 Seal It Application Overview Advanced materials and product design have resulted in a complete line of products offering the most effective sealing available today: adhesive-lined tubing, molded parts, and a variety of solder and crimp connection devices. These easy-to-use products provide superior waterproofing, resistance to hydrocarbons and other chemicals, protection against corrosion and oxidation, and a barrier against dust and dirt. Heat-shrinkable, adhesive-lined products— tubings with high shrink ratios, and molded parts—environmentally protect connector-to- cable transitions. Waterblocked and anticapillary wire prevent water and most fluids from wicking between