TE Connectivity D-150-Z Series Reference guide

Installation Procedure for Cable Splice shield Kits for RG-Cables

RPIP-1108

Revision A

April, 2016

Devices Installation Procedure

TUS-24-4006 rev E, 2 Aug 12 If this document is printed, it becomes uncontrolled. Check for latest revision. Page 1 of 6

1.0 Scope

This standard contains the procedures for making environment resistant 1 to 1 in-line splices in

shielded and jacketed cables listed in Table I using TE Connectivity D-150-ZXXX Series

shielded cable splice kits.

2.0 References

TE Connectivity Customer Drawing (TECD) D-150-ZXXX. Connectivity parts.

3.0 Application Equipment

3.1 Wire Handling Tools

a. Wire stripper for primary.

b. Wire stripper for cable jacket.

c. Small sharp scissors or diagonal cutters for braid.

d. Ruler readable to 0.50 (0.025).

e. DMC crimp tool HX4 (M22520/5-01).

f. Die set Y1535 for D-150-Z393

3.2 Heating Tools

Use one of the following, or TE Connectivity approved alternative.

a. CV1981 AT Digital with p/n reflector PR13C. Temperature setting 750-800°F

b. CV2014 HOT JET S with wrap-around reflector PR-38-REFLECTOR

4.0 General Information

4.1 Splice Kit Description

The TE Connectivity D-150-ZXXX Series shielded cable splice kits consists of:

a. SolderSleeve.

b. Crimp barrels for splicing the primary conductors.

c. Sealing insert for encapsulating the primary conductor splices.

4.2 Consumable Materials

a. PTFE tape P-422 (A-A-59474, Type 1, Class 4)

Installation Procedure for Cable Splice shield Kits for RG-Cables

RPIP-1108

Revision A

April, 2016

Devices Installation Procedure

TUS-24-4006 rev E, 2 Aug 12 If this document is printed, it becomes uncontrolled. Check for latest revision. Page 2 of 6

5.0 Installation Procedure

•Overheating the product to charring or burning may produce vapors that may cause

eyes, skin, nose, or throat irritation. Persons with pre-existing eye, skin or respiratory

disorders (e.g., asthma conditions) may be more susceptible to the effects of these

vapors.

•Shrink products in a well-ventilated area.

•Wear eye protection.

5.1 Part Selection

Table I

Parts Description

RG Cables

D-150-Z393

RG-393

5.2 Cable Preparation

5.2.1 Single Conductor Shielded Cable

Tolerances: All lengths ± 0.50 mm (0.025”)

a. Remove cable jacket: 15 mm (0.600’’)

b. Fold back the braid.

Installation Procedure for Cable Splice shield Kits for RG-Cables

RPIP-1108

Revision A

April, 2016

Devices Installation Procedure

TUS-24-4006 rev E, 2 Aug 12 If this document is printed, it becomes uncontrolled. Check for latest revision. Page 3 of 6

c. Remove cable dielectric leaving 2.5 mm (0.100’’) exposed dielectric.

d. Ensure exposed center conductor is 6.35 mm (0.250’’). Trim excess.

e. Place the SolderSleeve onto the left cable end, with the small opening to

the left.

f. Slide crimp barrel onto exposed center conductor. Ensure it is flush

against the cable dielectric. Crimp the metal barrel using the HX4

(M22520/5-01) crimp frame with the Y1535 crimp die.

Installation Procedure for Cable Splice shield Kits for RG-Cables

RPIP-1108

Revision A

April, 2016

Devices Installation Procedure

TUS-24-4006 rev E, 2 Aug 12 If this document is printed, it becomes uncontrolled. Check for latest revision. Page 4 of 6

g. Perform steps a thru d above to the right end of the cable to be spliced.

h. Insert exposed center conductor into the crimp barrel. Ensure it is fully

inserted and flush with the cable dielectric. Trim excess conductor as

needed.

i. Crimp the center and then the right side of the crimp barrel so that it has a

continuous, hexagonal appearance.

j. Insert the dielectric insert over the crimp barrel. If needed, trim the

minimum amount form the length of the insert for a snug fit. Limiting air

gaps improves splice performance.

k. Apply pressure on the two halves of the dielectric insert and apply one

revolution and one quarter of PTFE tape P-422 (A-A-59474, Type 1, Class

4) over the insert to hold in place. Smooth out edges to remove any air

voids.

Installation Procedure for Cable Splice shield Kits for RG-Cables

RPIP-1108

Revision A

April, 2016

Devices Installation Procedure

TUS-24-4006 rev E, 2 Aug 12 If this document is printed, it becomes uncontrolled. Check for latest revision. Page 5 of 6

l. Fold back the right side of the cable braid first, then the left side over it. .

m. Slide the SolderSleeve and center where the cable shields overlap.

n. Use approved heating tools, reflectors, and setting. The air gun is shown

with the wrap-around reflector (PR-38-REFLECTOR).

o. Apply heat to the Solder Sleeve until the solder melts and the heat shrink

tubing recovers. SolderSleeve is recovered when the solder ring has fully

melted and the blue thermoplastic seals melt and seep past the edge of

the sleeve. Note that slight flux residue may be visible after the solder

melts.

Installation Procedure for Cable Splice shield Kits for RG-Cables

RPIP-1108

Revision A

April, 2016

Devices Installation Procedure

TUS-24-4006 rev E, 2 Aug 12 If this document is printed, it becomes uncontrolled. Check for latest revision. Page 6 of 6

6.0 Recommendation

To confirm the cable performance after installation of the splice the characteristic impedance

shall be tested as per MIL-PRF-32517. The specimen shall be prepared for testing by

assembling appropriate connections to the cable ends. The rise time of Time Domain

Reflectometer (TDR) shall be 150 picoseconds or less, and the vertical sensitivity of the system

shall provide for minimum resolution of one major scale division. The measurement shall be

taken by gating within 1 nanosecond on each side of the matched impedance splice.

The characteristic impedance shall not exceed the impedance limits shown in Table I.

Table II. Characteristic Impedance limits

Matched impedance splice

part number

Impedance

(Ohms)

D-150-Z393

46 –57.5

IMPORTANT

The information contained in these installation instructions is for use only by installers trained to make electrical power

installations and is intended to describe the correct method of installation for this product. However, TE Connectivity

has no control over the field conditions which influence product installation. All information, including illustrations, is

believed to be reliable. Users, however, should independently evaluate the suitability of each product for their

application. TE Connectivity makes no warranties as to the accuracy or completeness of information, and disclaims

any liability regarding its use. TE Connectivity only obligations are those in the TE Connectivity Standard Terms and

Conditions of Sale for this product, and in no case will TE Connectivity or its distributors be liable for any incidental,

direct, or indirect, or consequential damages arising from the sale, use, or misuse of the product. Specifications are

subject to change without notice. In addition, TE Connectivity reserves the right to make changes without notification

to the Buyer to materials or processing that do not affect compliance with any applicable specification.

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