Section 16.3 provides criteria for shrink sleeving.
Target – Class 1,2,3
Wire insulation is flush against end of barrel splice (A).
Bare wire ends are flush with barrel splice, bellmouth is evident (B).
Crimp is centered and properly formed to retain wires (C).
Barrel splice is not cracked.
Sleeving, if required, is centered on the barrel splice and overlaps wire insulation on both sides of the spliced area at least a distance of 1 wire/bundle diameter.
If applicable, meltable sealing rings have flowed.
Acceptable – Class 1,2,3
Wire insulation gap is within 2 wire diameters (A).
Bare wire end is less than flush, but is visible and included in crimp indentation (B).
Crimp slightly offset but properly formed, bellmouth is evident (C).
Barrel splice is not cracked.
Sleeving, if required, overlaps the wire insulation at least 1 wire/bundle diameter on both sides of the barrel splice (not shown).
Does not violate minimum electrical clearance.
Acceptable – Class 1,2<Sep2010>
Wire insulation gap is within 2 wire diameters (A).
Conductor ends extend no more than 2 wire diameters beyond crimp barrel.
Figure 8-31 620A Fig 08-31
Figure 8-32 620A Fig 08-32
Figure 8-33 620A Fig 08-33
A-620B Final Draft for Industry Review – February 2012
8- 11 Process Indicator – Class 3
Wire insulation gap is more than 1 but less than two wire diameters (A).
Conductor ends extend more than 1 but less than 2 wire diameters beyond crimp
barrel.<Sep2010>
Acceptable – Class 1
Process Indicator – Class 2,3
Heat shrinkable sleeve is not centered yet sleeve ends fit snugly to the wire insulation.
Acceptable – Class 1,2 Process Indicator – Class 3
Crimp not centered but bellmouth is evident and ends of all conductors are visible. .<Sep2010>.
Defect – Class 2,3
Heat shrinkable sleeve does not overlap wire insulation on both ends at least 1 wire/bundle diameter (not shown).
Defect – Class 1,2,3
Insulation gap exceeds 2 wire diameters (not shown).
Conductors extend greater than 2 wire diameters beyond crimp barrel.
Wire insulation extends into barrel splice crimp.
(not shown).
Barrel splice is cracked (Figure 8-36 arrow).
Crimp indentation is off the end of the barrel splice, bellmouth is not evident.
Wires are not contained in the crimp.
Conductors twisted together before insertion into the contact.
Ends of all conductors are not visible.
.<Sep2010>
Figure 8-34 620A Fig 08-34
Figure 8-35 620A Fig 08-35
Figure 8-36 620A Fig 08-36
A-620B Final Draft for Industry Review – February 2012
8- 12 8.2.2 Crimped Splices – Double Sided
Target – Class 1,2,3
Ends of wires are visible through the inspection window and are flush to the wire stop (Figure 8-37 (A)).
Bellmouth is evident (Figure 8-37, B).
Wire insulation is flush with ends of splice.
Crimp is centered and properly formed to retain wires.
Sleeving, if required, is centered on ferrule and overlaps wire insulation a minimum of 1 wire diameter (Figure 8-38).
If present, the color-code on heat shrinkable sleeve matches color code on contact, Figure 8-38 (A).
Meltable sealing rings when present .<Sep2010>have flowed.
Acceptable – Class 1,2
Wire insulation gap is less than 2 wire diameters at both ends .<Sep2010>.
Figure 8-37 620A Fig 08-37
Figure 8-38 620A Fig 08-38
A-620B Final Draft for Industry Review – February 2012
8- 13 Acceptable – Class 1,2,3
Ends of wires are visible through the inspection window and are flush to the wire stop (Figure 8-39, arrows).<Sep2010>
Wire insulation gap is less than 2 wire diameters including insulation.
Bellmouth is evident.
Wire insulation gap is within 2 wire diameters including insulation on both ends, (not shown).
Heat shrinkable sleeve ends are sealed to the wire insulation (no wire strands are exposed).
when heat shrinkable sleeving has sealing rings.
.<Sep2010>.
Crimp indents on seamless splices are rotated (Figure 8-41) (seamless splices only).
Acceptable – Class 1
Process Indicator – Class 2,3
Heat shrinkable sleeve with sealing rings is not centered yet sleeve ends are sealed to the wire insulation.<Sep2010>
Process Indicator – Class 3
Wire insulation gap is greater than 1 but less than 2 wire diameters at either ends .<Sep2010>.
Figure 8-39 620A Fig 08-39
Figure 8-40 620A Fig 08-40
Figure 8-41 620A Fig 08-41
Figure 8-42 620A Fig 08-42
A-620B Final Draft for Industry Review – February 2012
8- 14 Defect – Class 1,2,3
Wire insulation extends into the wire crimp barrel (Figure 8-43, A).
Crimp indent is off the end of the splice (Figure 8-43, B).
Wire end(s) are not visible through the inspection window(s) (Figure 8-43, C).
Wire insulation gap is greater than 2 wire diameters including insulation (Figure 8-43, D).
Sleeving, if required, does not overlap wire insulation at least 1 wire diameter on both ends (not shown).
Wire strands extend out of inspection window (Figure 8-44).
Wire strands have pierced the heat shrinkable sleeve (Figure 8-45).
Multiple conductors twisted together before insertion into the contactcrimp barrel.<Sep2010>
8.2.3 Wire In-Line Junction Devices (Jiffy Junctions) Wire in-line junction devices, sometime referred to as “Jiffy Junctions,” are essentially feed through environmentally resistant disconnect components for joining wires. Crimp contacts are terminated onto conductors (Figure 8-46) and then inserted into the in-line junction device as it would be with a rear-entry machined contact connector (Figure 8-47, shown in cross-section).
The tooling, tooling verification, crimping processes, and completed terminations shall [?1?2?3] comply with the
requirements for tool control and machined contact crimped terminations in Chapters 1 (general), 5 (crimp) and 19 (testing) of this addendum.
When the circular mil area of the conductor needs to be built up so that it falls within the minimum and maximum CMA range of the contact, CMA buildup shall [?1?2?3] be in accordance with 5.3.5.
As an exception to 9.5.2, when a sealing plug is required it shall [?1?2?3] be inserted shaft first.
Figure 8-43 620A Fig 08-43
Figure 8-44 620A Fig 08-44
Figure 8-45 620A Fig 08-45
A-620B Final Draft for Industry Review – February 2012
8- 15 Defect
Multiple wire attachments, when used, do not meet the requirements of 5.3.
Insulation clearance does not meet the requirements of 5.3.1.
The conductor location does not meet the requirements of 5.3.3.
Crimping does not meet the requirements of 5.3.4.
Circular mil area (CMA) buildup, when used, does not meet the requirements of 5.3.5.
Contact installation does not meet the requirements of 9.5.
Qualification of crimped connection fails Pull Force/Tensile Test per 19.7.2.
Mated assembly fails Pull Test Contact Retention Verification Test per 19.7.5.2.