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Raychem Devices 

No:    RCPS-200-20 
Rev:   E1 
Date:  August 10, 2016 

Installation Procedures for D-436-XX and D-200-XX 

(Miniseal™) Sealed Crimp Splices

 

 

_________________________________________ 
Unless otherwise specified dimensions are in millimeters.  [Inches dimensions are in between brackets] 
© 2007-2016 TE Connectivity Corporation.  All rights reserved.  

If this document is printed it becomes uncontrolled.  Check for the latest revision.

 

 

 
1. 

Scope: 
This document covers the installation procedures and inspection requirements for D-436-
XX and D-200-XX devices for making immersion-resistant crimped splices. 

 
2. 

References: 

 

(1) MiniSeal™ Wire Splices Selection Guide (H50279 6/79).

 

 

(2) Tyco Electronics Customer Drawings (CD), D-436-XX. 

                  (3) Tyco Electronics Customer Drawings (CD), D-200-XX 
 

 

3. 

Application Equipment and Tools: 

3.1 

Crimp Tools 
(1) AD-1377 Crimp Tool. 
(2) Manufacturer's recommended crimp tool for splices other than Tyco Electronics/ 

Raychem crimp splices. 

 
3.2 

Heating Tools 

 

Products 

Heating Tool 

Reflector 

Setting 

D-436-XX 

AA-400 Superheater 

Solder Sleeve 

700°F (370°C) 

HL1910E 

PR-25D-
REFLECTOR 
with HL-1802E-
ADAPT-PR or 
HL1802E-07616 
REFLECTOR 

6 on dial 

(1)

 

HL2010E 

700°F (370°C) on LCD 

(1)

 

D-200-XX 

AA-400 Superheater 

Solder Sleeve 

750°F (400°C) 

HL1910E 

PR-25D-
REFLECTOR 
with HL-1802E-
ADAPT-PR or 
HL1802E-07616 
REFLECTOR

 

7 on dial 

(1)

 

HL2010E 

750°F (400°C) on LCD 

(1)

 

D-436-XX, 
D-200-XX 

IR-500 or IR-550 
Infrared Heater 

RG-2  
RG-6 

N/A 

 

Note: CV-1981 Heating Tools are suitable alternatives. See product brochure for additional details. 

 

4. 

General Information: 

4.1 

Description 

 

The parts covered by this document are designed for making immersion resistant crimped  

 

splices in wires rated for at least 135

C. This procedure covers crimp splices for making  

Summary of Contents for RAYCHEM D-436 Series

Page 1: ...3 Application Equipment and Tools 3 1 Crimp Tools 1 AD 1377 Crimp Tool 2 Manufacturer s recommended crimp tool for splices other than Tyco Electronics Raychem crimp splices 3 2 Heating Tools Products...

Page 2: ...upplied in three basic configurations according to the number of wires that can be spliced together These part and splice configurations are as follows 4 1 1 One Wire to One Wire In Line Splices or Tw...

Page 3: ...he D 436 XX and D 200 XX series Separate procedures are provided for parts conforming to paragraphs 4 1 1 4 1 2 and 4 1 3 WARNING Follow installation instructions carefully Use adequate ventilation an...

Page 4: ...n the splicing tables to fold any conductors back fold the appropriate conductor s as shown below 5 3 One to one In line Splices and Two wire Stub Splices 5 3 1 Select proper slice components and prep...

Page 5: ...lows a Use one of the heating tools listed in section 3 b Heat from one end toward the other For stub splices start at the end from which the wires exit c Continue heating until the seals melt and flo...

Page 6: ...All rights reserved If this document is printed it becomes uncontrolled Check for the latest revision 5 4 2 Splicing Procedure 1 Insert one of the multiple wires through each hole of the multiple hole...

Page 7: ...the multiple wire seal melts and flows around and along the wire insulation c Move the heat toward the single wire or open end shrinking the sleeve along the way d Heat the second end until the seal m...

Page 8: ...ltiple wires coming from the other direction through the separate seal one wire per hole as shown 3 Crimp the wires in the crimp splice as shown below Make sure that the multiple wires do not become c...

Page 9: ...sturbed WARNING The heating tool and the assembly become hot during the installation of the Sealing Sleeve To prevent burns allow tool and the assembly to cool down before handling 7 Inspect the compl...

Page 10: ...r the latest revision 3 The sealing sleeve must not be discolored to the point where it prevents visual inspection of the splice overheated condition 6 3 Inspection for Damage 1 The sealing sleeve mus...

Page 11: ...tears melting charring 1 These values are for reference only and may change based on other variables i e reflector type sleeve s relative distance to the reflector etc DISCLAIMER All of the above inf...

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