TE CONNECTIVITY AD-1386-CALIBRATION-GAUGE

Raychem Application Tooling The Tools to Make Every Connection Count AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING Raychem Application Tooling The Tools to Make Every Connection Count TE Connectivity (TE) offers a variety of dependable HIGH QUALITY hand and bench-mount tools for crimping Raychem devices and heating heat-shrinkable products. The • Manufactured to TE Connectivity’s strict quality standards tools help give you more accuracy in terminations— increasing productivity, reducing rework, and taking • Tools are designed to make every job easy and trouble-free the guesswork out of procedures. With easy-to-use controls and ergonomic design, Raychem tools help • Made from the highest quality materials for low cost of ownership make the job go faster and easier. EASY TO USE HAND CRIMPING TOOLS AD-1377 Hand Crimping Tool 3 • Designed and developed with the operator in mind AD-1522-1 Hand Crimping Tool 4 AD-1381 Hand Crimping Tool 5 • Convenient, easy to use features make installations faster and easier INFRARED HEATING TOOLS • More choice in tooling, from IR-550 Infrared Heating Tools 6 simple hand tools to advanced, automatic operation IR-550/ED-7 Heating Tool and Controller Kit 8 Mini-Ray MK5 Infrared Heating Tool 10 APPLICATION SPECIFIC Mini-Ray MK4 Heating Tool Systems 12 • Tools offered by TE are designed to aid in the installation of HOT AIR HEATING TOOLS TE wire and cable products CV2014 Series ThermoGun Heating Tool 15 • Decades of experience are CV1981 and CV1983 Series ThermoGun Heating Tools 17 applied to the development of all HG Series ThermoGun Heavy-Duty Heating Tools 20 TE installation tools HL1920E and HL2020E Heat Guns 22 • Choose from a wide range of tools for any cable management task COMPRESSED AIR HEATING TOOLS AA-400 Super Heater Compressed Air Heating Tool 24 HT-900B Compressed Air Nitrogen Heater Tools 26 HEATING TOOLS FOR TINEL-LOCK RING SCREENED TERMINATIONS AD-5000 Installation Tool 28 AD-5020 Installation Tool 30 RH-396X Tinel-Lock Installation Tool 32 UNDERWATER SPLICE KIT Underwater Cable Splice (UWCS) Kit 34 ACCESSORIES AD-1319-9 Holding Fixture for Heat-Shrinkable Devices 36 PRODUCTS AND RECOMMENDED TOOLING 38 TE Components . . . TE Technology . . . TE Know-how . . . AMP | AGASTAT | CII | HARTMAN | KILOVAC | MICRODOT | NANONICS | POLAMCO | Raychem | Rochester | DEUTSCH SEACON Phoenix | LL ROWE | Phoenix Optix | AFP | SEACON Get your product to market faster with a smarter, better solution. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 2 Raychem AD-1377 Hand Crimping Tool VERSATILE • Crimps MiniSeal splices, covering a wire range from 26 to 12 AWG • Ratchet-controlled release handle • Pre-set crimp depth that provides the optimum combination of tensile strength and insulation integrity in the finished splice HIGH PERFORMANCE • Built-in ratchet system ensures AD-1377 Hand Crimping Tool full cycling of the tool and prevents Tool is used for crimping wire terminations with MiniSeal splices. early release AD-1377-CRIMP-TOOL-3-CVTY • Designed for an easy and smooth MIL-DTL-22520/37-01 effort to achieve the crimp The Raychem AD-1377 crimp tool from TE is designed for MiniSeal • Inside cavities are polished to splices. It has a pre-set crimp depth that provides the optimum bring maximum reliability to the combination of tensile strength and insulation integrity in the finished crimping operation splice. The ratcheted release ensures full closure of the tool to help prevent undercrimping. QUALIFICATIONS The tool is calibrated with standard gauge pins or with TE calibration • Tool: MIL-DTL-22520/37-01 gauge AD-1386. The drawing supplied with the tool defines appropriate cavity dimensions as diameters for the “Go” and “No Go” conditions. • Calibration Gauge: MIL-DTL-22520/39-01 Specifications DIMENSION • Overall Length: 230 mm (9”) approx. WEIGHT • 350 g (12.3 oz.) Ordering Information AD-1377 Crimp Tool for MiniSeal Splices Model Description Part No. Mil Spec MiniSeal Splice Crimp Tool AD-1377 AD-1377-CRIMP-TOOL-3-CVTY 992008-000 MiniSeal Splice Crimp Tool AD-1377-S-SPEC-CRIMP-TOOL 959025-000 Calibration Gauge AD-1386-CALIBRATION-GAUGE 992013-000 Accessories and Replacement Parts Parts Description Part No. Crimp Locator AD-1377-103-CRIMP-LOCATOR 994855-000 Spring AD-1377-P-E118-TOR-SPRNG 994123-000 ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/ This product must not be disposed of as municipal waste. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 3 Raychem AD-1522-1 Hand Crimping Tool VERSATILE • Crimps DuraSeal crimp splices, covering a range from 22 to 10 AWG EASY TO USE • Ratchet-controlled release handle • Pre-set crimp depth that provides the optimum combination of tensile strength and insulation integrity in the finished splice HIGH PERFORMANCE • Built-in ratchet system ensures full cycling of the tool and prevents early release AD-1522-1 Hand Crimping Tool • Designed for an easy and smooth Tool is used for completing wire terminations using effort to achieve the crimp DuraSeal splices. • Inside cavities are polished to The Raychem AD-1522-1 crimp tool from TE can be used on all bring maximum reliability to the DuraSeal splices. It has a pre-set crimp depth that provides the crimping operation optimum combination of tensile strength and insulation integrity in the finished splice. The ratcheted release ensures full closure of the tool to help prevent undercrimping. The tool is calibrated with standard gauge pins or with TE calibration gauge AE-2245. The drawing supplied with the tool defines appropriate cavity dimensions as diameters for the “Go” and “No Go” conditions. Specifications DIMENSION • Overall Length: 230 mm (9”) approx. WEIGHT • 350 g (12.3 oz.) PRODUCT RANGE • DuraSeal Crimp Splices and Terminals Ordering Information AD-1522-1 Crimp Tool for DuraSeal Splices Product Description Part No. Crimp Tool AD-1522-1 047011-000 Calibration Gauge AE-2245 020435-000 ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/ This product must not be disposed of as municipal waste. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 4 Raychem AD-1381 Hand Crimping Tool VERSATILE • Crimps cold-applied gel-filled splices, covering a wire range from 26 to 12 AWG EASY TO USE • Ratchet-controlled release handle • Pre-set crimp depth that provides the optimum combination of tensile strength and insulation integrity in AD-1381 Hand Crimping Tool the finished splice Tool is used to crimp cold-applied gel-filled splices with wires ranging from 26 to 12 AWG. HIGH PERFORMANCE The Raychem AD-1381 crimping tool from TE terminates • Built-in ratchet system ensures cold-applied splices, which are TE’s in-line, sealed, crimp splices full cycling of the tool and prevents designed for 150°C applications. early release The tool has a pre-set crimp depth that provides the optimum • Designed for an easy and smooth combination of tensile strength and insulation integrity in the finished effort to achieve the crimp splice. The ratcheted release ensures full closure of the tool to help prevent undercrimping. QUALIFICATIONS The tool is calibrated with standard gauge pins or with the TE • Tool: MIL-DTL-22520/44-01 calibration gauge AD-1382. The drawing supplied with the tool defines appropriate cavity dimensions as diameters for the • Calibration Gauge: “Go” and “No Go” conditions. MIL-DTL-22520/39-03 Specifications DIMENSION • Overall Length: 230 mm (9”) approx. WEIGHT • 350 g (12.3 oz.) COLD-APPLIED SPLICE PRODUCT RANGE • D-436-36-COLD: 26 to 20 AWG wire range • D-436-37-COLD: 18 to 16 AWG wire range • D-436-38-COLD: 14 to 12 AWG wire range Ordering Information AD-1381 Hand Crimping Tool Model Description Part No. AD-1381 Hand Crimping Tool AD-1381 CS1660-000 Calibration Gauge AD-1382 992013-000 ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/ This product must not be disposed of as municipal waste. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 5 Raychem IR-550 Infrared Heating Tools CAPABLE • Designed for fast installation of SolderSleeve terminations, MiniSeal terminations, SolderTacts contacts, and heat-shrinkable tubing • Controls include a power switch, foot switch, and a handle-mounted switch • The IR-550-300-MARKIII-CE unit is CE approved IR-550-50-MARKII-HT-TOOL - 120 V SAFE OPERATION • Fan keeps external surfaces cool and allows for long-duration heating • Thermostatic switch helps protect from overheating • Optical filter helps reduce glare from the lamp for safer observation • A 30-degree base reduces eye strain and glare to others working nearby CONVENIENT IR-550-300-MARKIII-CE - 230 V • Viewing window enables viewing of the heating process IR-550-50-MARKII-HT-TOOL (120 V) • Foot switch or handle switch IR-550-300-MARKIII-CE (230 V) operation The Raychem IR-550 heating tool from TE is a portable electric • Designed primarily as a benchtop infrared heating tool designed for fast, reliable installation of heating tool Raychem SolderSleeve terminations, MiniSeal terminations, SolderTacts contacts, and heat-shrinkable tubing. The IR-550 heating tool can be used as a hand tool, but is primarily designed as a bench-top heating tool. As a hand tool, it is operated using a switch on the handle. As a bench-top heating tool, it can be operated by either a foot switch or handle switch. A halogen lamp provides the radiant heat source, and reflectors focus the heat from the lamp to concentrate it within the work area of the front reflector. Interchangeable front reflectors are designed for specific product applications. An optical filter between the lamp and the work area reduces the glare from the lamp, allowing the operator to observe the heating process. The tool also has a viewing window to further reduce glare. The 30-degree base has been designed to further reduce eye strain and glare to others working nearby. The IR-550-50 is a single unit containing both controls and infrared tool. For the IR-550-300, the control box and infrared tool are separate units. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 6 Application Tooling Specifications IR-550-50 IR-550-300 Input Power 120 V, 50-60 Hz, 4.5 A 230 V, 50–60 Hz, 3 A Weight 2.5 kg (5.5 lb.) 4.8 kg (10 lb.) approx. 113 x 120 x 249 mm Control Box: 152 x 120 x 19.mm (6” x 4.7” x .75”) Dimensions (4.46” x 4.7” x 9.8”) Tool: 114 x 209 x 249 mm (4.5” x 8.2” x 9.8”) Duty Cycle 80%, 90-second max. heating times Lamp Life 1000+ hours of intermittent use Ordering Information IR-550 Infrared Heating Tools Model Description Part No. IR-550-50 Heating Tool IR-550-50-MARKII-HT-TOOL 994350-000 IR-550-300 Heating Tool IR-550-300-MARKIII-CE C66438-000 Reflectors Parts Description Part No. RG-2 Reflector for SolderSleeve Terminations IR-500-24-RG-2-REFLECTOR 993770-000 19.0 mm (.75”) Wide Aperture RG-6 Reflector For Large-Diameter SolderSleeve Terminations IR-550-19-RG-6-NOSECONE 994590-000 25.4 mm (1.0”) Wide Aperture RG-9 Reflector IR-550-39-RG-9-REFLECTOR 993693-000 9.525 mm (.375”) Wide Aperture RG-11 Reflector; IR-550-41-RG-11-REFLECTOR 993695-000 12.7 mm (9.5”) Wide Aperture Accessories and Replacement Parts Parts Common to Both IR-550-50 and -300 Description Part No. Upgrade Kit: Filter, Viewing Window, IR-550-240-Refurb-KIT 529600-000 Inner Reflector-Outer Reflector Filter IR-550-237-FLTR-DUAL-COAT 118902-000 Button, Large, Black AES-IR550-C23-BUTTON C33802-000 Viewing Window (Frame Not Included) IR-550-238-VIEWING-WINDOW 007510-000 Parts for IR-550-50 Only Lamp (120 V) IR-1000-P-N-13-LAMP 993020-000 Foot Switch Assembly IR-550-216-FOOT-SWITCH-ASSY 994375-000 Parts for IR-550-300 Only Lamp (220-230 V), 500 W IR-550-303-CE-LAMP F95965-000 Foot Switch Assembly IR-550-301-CE-FOOT-SW-ASSY F91912-000 PC Board AES-IR550-63-PC-BRD 576297-000 ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/ This product must not be disposed of as municipal waste. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 7 Raychem IR-550/ED-7 Heating Tool and Controller Kit COMPREHENSIVE • Controller and foot-pedal-operated portable infrared heating tool • Controller keypad enables the selection of the operation mode up to 20 stored programmed sequences EASY TO USE • Provides reliable installation of SolderSleeve and MiniSeal devices, SolderTacts contacts, and TE heat-shrinkable products • Controller can be used in a manual or automatic mode FLEXIBLE OPERATION IR-550/ED-7 Heating Tool and Controller Kit Kit is used to install SolderSleeve and MiniSeal devices, • Manual Mode: Applies full power SolderTacts contacts, and TE heat-shrinkable products. when foot pedal is depressed, and removed power when the pedal is The Raychem IR-550/ED-7 from TE provides a convenient released portable electric infrared heating tool and controller. This system gives fast, reliable installations of SolderSleeve devices, MiniSeal • Automatic Mode: Controls duration devices, SolderTacts contacts, and TE heat-shrinkable products. and level of power according to a preset sequence stored in The foot-pedal-operated, benchtop tool allows both manual memory when foot pedal is pressed and automatic control of the heating tool. In the manual mode, the operator uses the foot pedal to start and stop the heating and released sequence. In the automatic mode, the power and duration of heating—including varying levels and times in the sequence— allow consistent and precise application of heat. The controller can store up to 20 sequences in memory. Specifications INPUT POWER • IR-550/ED-7-KIT: 220 V, 50 Hz, 7.3 A • ED-7-001-550 Controller: 220 V, 50 Hz, 2.8 A • IR-550-MK3-CE-MINUS Heating Tool: 220 V, 50 Hz, 4.5 A DIMENSIONS • ED-7-001-550: 160 mm x 120 mm x 250 mm (6.29” x 4.7” x 9.8”) • IR-550-MK3-CE-MINUS: 113.2 mm x 119.3 mm x 250 mm (4.46” x 4.7” x 9.8”) WEIGHT • IR-550/ED-7-KIT: 8.7 kg (19.1 lb.) • ED-7-001-550: 6.2 kg (13.6 lb.) • IR-550-MK3-CE-MINUS: 2.5 kg (5.5 lb.) AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 8 Application Tooling Ordering Information IR-550/ED-7 Heating Tool and Controller Kit Model Description Part No. IR-550/ED-7 Heating Tool and Controller IR-550/ED-7-KIT CV1032-000 Accessories and Replacement Parts Parts Description Part No. Infrared Heating Tool IR-550-MK3-CE-MINUS-00 CY8483-000 Controller* ED-7-001-550 CV2777-000 Lamp 220/230 500 W Lamp IR-550-303-CE-LAMP F95965-000 Foot Switch Assembly IR-550-301-CE-FOOT-SW-ASSY F91912-000 Viewing Window (frame not included) IR-550-238-VIEWING-WINDOW 007510-000 RG-2 Reflector, SolderSleeve Reflector, 19 mm (.75”) IR-500-24-RG-2-SLD-SL-REF 993770-000 RG-6 Reflector, Large-Diameter Solder Sleeve IR-550-19-RG-6-NOSECONE 994590-000 Terminations. Aperture is 25, 4 mm (1.0”) wide Holding Fixture ED-7-001-550-HOLD-FIX CV4406-000 PCB for Controller ED-7-001-550-PCB CV4408-000 Filter IR-550-237-FLTR-DUAL-COAT 118902-000 *Controller can be purchased separately. ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/ This product must not be disposed of as municipal waste. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 9 Raychem Mini-Ray MK5 Infrared Heating Tool CONVENIENT • Portable, lightweight and convenient for use where workspace is constrained • Product being installed is visible during the heating cycle • Available as a complete kit, comprised of manual control box, hand tool, AT3130 reflector and spare bulb SAFE AND EFFICIENT • Heat energy is derived from a tungsten halogen lamp and focused onto the product with a reflector Mini-Ray MK5 Infrared Heating Tool • Optical filter eliminates unwanted UV Tool is designed for installing SolderSleeve termination products emissions and excess visible light, up to 9 mm diameter. reducing glare for the operator • UL Approved IR1759-MK5-AT3130-ED-CONT The Raychem Mini-Ray MK5 tool from TE is a hand-held infrared EASY TO USE heating tool designed for use in installing TE’s SolderSleeve • Hand-held unit with simple termination products. The tool is portable, lightweight and convenient for use where workspace is constrained. trigger operation The hand tool is fan cooled and has low heat emission, as the • Options available for products up to lamp is only energized on demand. The heat energy is derived 9 mm diameter from a halogen lamp and is focused onto the product by means of the reflector design. • Tool can be used with either 230 V or 110 V (nom.) power supply The IR1759-MK5 standard aperture is recommended for products up to 6 mm diameter, and the IR-3104-MK4/A large aperture for installing products up to 9 mm diameter. This version of the tool will accept larger diameter components, but uniform heating cannot be assured. The Raychem ED-7 controller is a simple unit, with no variable ROHS Information can be found at the following time or variable power memory functions. It maintains power website: http://www.te.com/customersupport/ to the lamp for as long as the tool’s trigger switch remains productcompliance/ depressed. The controller can be used with either 230 V or 110 V This product must not be disposed of as supply voltage. municipal waste. NOTE: Control unit ED-7-CONT-230/110V-MK5 is used with the IR-1759-MK5-GUN and cannot be used with or fitted to other existing Mini-Ray systems (such as 1759-MK4/A and IR-3104-Mk4/A hand tool). AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 10 Application Tooling Specifications HEATING TOOL CONTROLLER • Supply Voltage: 24.0 VAC Nom. • Supply Voltage: 230 V, 50 Hz or 110 V, 50-60 Hz • Typical Operating Temperature: 600°C @ 10-second operation • Input Current: 6.3 A • Typical Heating Time: 15 to >70 seconds • Output Voltage: 24.0 VAX • Lamp: 250 W tungsten halogen, 800 cycles • Weight: 8.0 kg (17.6 lb.) • Noise: 51 dB (A) • Dimension: 160 x 120 x 250 mm • Weight: 1.1 kg (2.4 lb.) • Power Cord Length: 3.1 m Ordering Information IR-1759 Infrared Heating Tools Model Description Part No. Mini-Ray Infrared Heating Tool IR1759-MK5-AT3130-EDCont CV3948-000 (With manual control box, hand tool, AT3130 reflector IR-1759-MK5-GUN* CV4411-000 and spare bulb) ED-7-CONT-230/110V-MK5* CV4409-000 *Note: Heating tool and controller not sold separately. Accessories and Replacement Parts Part Description Part No. Reflectors for Standard Aperture Reflector With Vee Block AT-3130 988299-000 Reflector for SolderTacts Contacts AT-3131 988300-000 Reflector With Clamps AT-3132 988301-000 Reflector With Clamps and 5 mm Mask AT-3132 -MK31 879865-000 Reflector With Special Vee Block AT-3191 588701-000 Linear Reflector AE-205 988596-000 Reflectors For Large Aperture (Requires Conversion Kit AE-897) Conversion Kit From Standard To Large Aperture AE-897 966953-000 Reflector With Clamps AT-3134 988303-000 Reflector With Clamps AT-3147 988328-000 Linear Reflector AE-206 988314-000 Inner Reflectors For Standard Aperture AE-424 Standard IR-1759 547918-000 For Large Aperture AE-153 3104 988285-000 Replacement Parts PCB For Trigger/Handle IR-1759-MK5-TRIGGER-PCB CV4416-000 Thermal Switch With Plate/Tubing IR-1759-MK5-THRMSW-PLT CV4418-000 Dual Filter AES-IR1759-100- FILTER-DUL 431468-000 Main PCB ED-7-CONT-MK5-PCB CV4414-000 Filter Spring IE-1759 AE-900 277774-000 Bulb, 250 W, 24 V IR1759/3104 NAE-143-3 988208-000 Replacement Connector, De-Pin Tool, and Instructions IR1759-MK5-REPCON-DEPINTL EG2846-000 Cable, Trigger PCB, Lamp Holder, and Thermal Switch IR-1759-MK5-CABLE-ASY CV4412-000 AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 11 Raychem Mini-Ray MK4 Heating Tool Systems SAFE AND EFFICIENT • Product being installed is visible during the heating cycle • Optical filter eliminates unwanted UV emissions and excess visible light, reducing glare for the operator • Heat energy from a tungsten halogen lamp is focused onto the product with a reflector VERSATILE • Controller can be used in a manual mode with the trigger switch or by pre-set time and power • Up to 20 memory locations are Mini-Ray MK4 Infrared Heating Tool available for the storage of time/ Designed for installing SolderSleeve termination products power values up to 9 mm diameter. COMPONENTS IR-1759-MK4/A, IR-3104-MK4/A • The ED-7-Cont-230 V/110 V ED-7-001/002, ED-7-CONT-230 V/110 V controller is a simple unit, with no ED-7-BATTERYBOX-230 V/110 V variable time or variable power The Raychem Mini-Ray MK4 tool from TE is a hand held memory functions infrared heating tool designed for use in installing SolderSleeve termination products. The tool is portable, lightweight and • The ED-7-001/002 control units convenient for use where workspace is restricted. provide controls for both power and time, and are suitable where the The hand tool is fan cooled and has low heat emission as the lamp is only energized on demand. A duty cycle up to 50% is use of pre-set installation conditions permissible with a maximum heating time of 50 seconds. With is required the ED-7-Cont and ED-7-Batterybox, this duty cycle is fixed • The ED-7-Batterybox controller is within the controller software. designed for remote areas, and can The controllers have a new software feature that improves install approximately 50 30-second filter and bulb life. The heat energy is derived from a halogen installations before recharging lamp and is focused onto the product by means of the reflector design. The IR-1759-MK4/A standard aperture is recommended COMPLETE for products up to 6 mm diameter and the IR-3104-MK4/A large aperture for products up to 9 mm diameter. This version of • A kit product is available, comprising the tool will accept larger diameter components, but uniform manual control box, hand tool, heating is not then assured. AT3130 reflector and bulb Note: Current optical filters still fit the older MK III tools. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 12 Application Tooling Specifications Mini-Ray MK4 Heating Tool System Hand Tool Control Units IR-1759/IR-3104 ED-7-001/002 ED-7-Cont ED-7-Batterybox 230 VAC, NP7-12FR 230 VAC, 50 Hz or Supply Voltage 21.5 VAC nom. 50 Hz and Yuasa 12 V 7 Ah 110 V, 50-60 Hz 110 V, 50-60 Hz 2 x 12 V Input Current — 4 A/10 A 6.3 A batteries, not supplied 16-22 VAC Output Voltage — (dependent on 21.5 VAC 22 VDC nominal program) 6.2 kg 8.5 kg, 160 Weight 1.1 kg (2.4 lb.) 8.0 kg (17.6 lb.) (13.6 lb.) (18.7 lb.) Typical Operating 500°C @ 10 second operation — — — Temperature Typical Heating Time 15 seconds — — — Halogen Lamp. Power/ 250 W x 24 V average life 10,000 — — — Live, Typical Values cycles @ 50% duty cycle Noise 41 dB (A) — — — Power Cord Length 3.1 m — — — Dimensions — 6.3” x 4.7”x 9.8” Timer A 1-250 secs Memory Locations — — — 20 Memory (001 and 002 only) *Note: Current optical filters still fit the older MK III tools. Ordering Information IR-1759 Infrared Heating Tools Model Description Part No. IR1759-MK4-AT3130-EDCont Mini-Ray MK4 Heating Tool System CF0024-000 Hand tool/Reflector/Control Box (1)* IR-1759-MK4/A Hand tool, standard aperture (2)* CF0025-000 IR-3104-MK4/A Hand tool large aperture (2)* CF5497-000 Hand tool/standard aperture/Timed 230 V IR1759-MK4AT3130-ED-7-001 EG3472-000 control Box (1)* (3)* ED-7-001-MK4-230V-50HZ Control Box with time control-230 V (3)* CF0199-000 ED-7-002-MK4-110V-60HZ Control Box with time control-110 V (3)* CF0201-000 ED-7-CONT-230/11OV-MK4 Control Box manual control 110/230 (4)* CF0026-000 ED-7-BATTBOX-MK4-230/110V Battery Box† CF0200-000 *Note: Heating tool and controller not sold separately. †Battery box takes 2X12V batteries, type NP7-12FR. Please note that TE does not supply replacement batteries. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 13 Application Tooling Ordering Information (continued) Accessories and Replacement Parts Model Description Part No. AE-153 Inner reflector for large aperture (3104)* 988285-000 AE-424 Inner reflector for standard aperture* 547918-000 AES-IR1759-100- FILTER-DUL Standard filter* 431468-000 AES-IR1759-300-FLT-LRG Large filter F52511-000 ED-7-CONT-PCB PCB* CA3022-000 AE-900 Filter spring IR-1759* 277774-000 AE-897 Conversion kit for standard to Large aperture* 966953-000 AT-3130 Reflector to fit standard aperture standard Vee block* 988299-000 AT-3131 Reflector to fit standard aperture for SolderTacts contacts* 988300-000 AT-3132 Reflector to fit standard aperture* 988301-000 AT-3132-MK31/1 Reflector to fit standard aperture with clamps* 879865-000 AT-3134 Reflector to fit large aperture with standard Vee block* 988303-000 AT-3147 Reflector to fit large aperture with clamps* 988328-000 AT-3191 Reflector to fit standard aperture special Vee block* 588701-000 ED-7-CONT-TRANSFORMER Transformer 139128-000 ED-7-BATT-FRONT-PANEL Comes complete with PCB 132692-000 IR-1759/3104-CABLE-ASSY Trigger PCB/cable/fan/lamp holder* 585643-000 NAE-143-3 Bulb 250 W, 24 V IR1759/3104* 988208-000 AE-205 Linear reflector for standard aperture 988596-000 AE-226 Linear reflector for large aperture 988314-000 AT-3134/AE-897 Reflector and conversion kit (see above) 934630-000 NAE-109-02 Lamp support 988382-000 NAE-152-1 Fan 988204-000 MINIRAY-GUN-CASE Mini-Ray heat gun case CM8837-000 *Items marked with an asterisk are compatible and can be used with MK2/MK3 IR1759. ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/ This product must not be disposed of as municipal waste. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 14 Raychem CV2014 Series ThermoGun Heating Tool SPACE AND WEIGHT EFFICIENT • Ultra compact design • Lightweight: 600 g (1.32 lb.) POWERFUL • Produces temperatures to 650°C • Electronic steplessly controlled temperature • Electronic steplessly controlled airflow • Electronic heating element protection SAFE CV2014 Series ThermoGun Heating Tool • Low noise Tool is used for installing TE heat-shrink tubing and SolderSleeve terminations, and for making cable repairs. • Built in stand • UL Approved CV2014-JETS-120V460W-UL CV2014-JETS-230V460W-EU CV2014-JETS-230V460W-UK The small, but powerful Raychem CV2014 hot air gun is capable of producing temperatures of up to 600°C. It can be used for installing heat-shrink tubing, SolderSleeve devices, and cable repair products. PR Reflectors as shown below can be used with a reflector adapter. Specifications POWER • Voltage: 120 V (US models) or 230 V (UK/EU models) • Power Consumption: 460 W AIR • Air Flow (@ 20°C): 20 to 80 l/min TEMPERATURE • Temperature Range: 40°C to 650°C DIMENSIONS • Size (L x ø): 235 mm L × 70 mm dia., 9.25” L x 2.75 dia. Handle is 40 mm (1.6”) dia. WEIGHT • 0.6 kg (1.3 lb.) (with 3 m cord) AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 15 Application Tooling Ordering Information CV2014 Series ThermoGun Heating Tools Model Plug Description Part No. Hot Jet S 120 V/460 W UL (US) CV2014-JETS-120V460W-UL EG2900-000 Hot Jet S 230 V/460 W Schuko (EU) CV2014-JETS-230V460W-EU EG2902-000 Reflectors Reflector/Application Description Part No. PR Reflector adaptor CV2014-PR-ADAPTOR EG3417-000 PR-38: Large cable repair PR-38-REFLECTOR EG2498-000 PR-13: Tubing up to 6 mm dia. PR-13-REFLECTOR 991963-000 PR-13-C: Tubing 6 to 12 mm dia. PR-13C-REFLECTOR 991974-000 PR-25: SolderSleeve products up to 6 mm dia. PR-25-REFLECTOR 991965-000 PR-25-D: SolderSleeve products 6 to 12 mm dia. PR-25D-REFLECTOR 989523-000 PR-26: Miniature SolderSleeve products and small products PR-26-REFLECTOR 991967-000 PR-33: For SolderSleeve products 20 to 27 mm dia. PR-33-REFLECTOR 997768-000 ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/ This product must not be disposed of as municipal waste. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 16 Raychem CV1981 and CV1983 Series ThermoGun Heating Tools VERSATILE • Heavy-duty bench or hand held hot air tool • Intelligent e-Drive operating unit • Digital temperature indicator (AT models) for easy adjustment to product requirements CAPABLE • Wide temperature range: 40°C to +650°C • Precise temperature control on AT models allows tool temperature to be matched to the heat-shrink product’s requirements • Closed-loop controlled temperature • Open-loop controlled air volume CV1981 and CV1983 Series ThermoGun Heating Tools ThermoGun heating tools are used for installation of TE heat- shrink products, molded parts, and SolderSleeve terminations. SAFE • Ergonomic handling CV1981 Series ThermoGun Heating Tool • Modern design CV1983 Series ThermoGun Heating Tool • Safety guard Raychem CV1981 and CV1983 Series ThermoGun heating tools from TE are intelligent, robust, double insulated heavy-duty tools. The tools use an internal thermocouple to ensure accurate output temperature. CV1981 AT model use closed-loop control to ensure that the set value is achieved even while supply voltage varies slightly. The digital display shows set temperature and measured temperature simultaneously. AT models also feature adjustable airflow. A motor-driven fan forces air through the heating element, which is enclosed in a stainless steel barrel and safety guard. The tool is fitted with power control, to allow for adjustment of output temperature. An integral stand allows the tool to be used as a bench tool. The heating tool is available in a variety of models and is suited to a wide range of heat-shrink applications. The various PR Series push-on reflectors are easily and quickly attached to the gun. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 17 Application Tooling Specifications CV1981 CV1983 Power Consumption 1600 W 2300 W/2400 W/3400 W Voltage 120 V or 230 V Temperatures 40°C to 650°C Air Flow (20°C) 240 l/min max. Tool: 338 mm L x 90 mm dia. (13.3” L x 3.5” dia.) Dimensions Handle: 56 mm (2.2” dia.) Weight 990 g (2 lb.) 1.3 kg (2.9 lb.) Ordering Information Heating Tools Model Description Part No. CV1981 AT Series (with Controlled Temperature, Adjustable Air Volume, and Digital Display) 230 V, 1600 W, EU Plug CV1981-ATPID-230V1600W-EU EG1106-000 230 V, 1600 W, UK Plug CV1981-ATPID-230V1600W-UK EG1108-000 120 V, 1600 W, US Plug CV1981-ATPID-120V1600W-US EG1110-000 120 V, 1600 W, CEE Plug CV1981-ATPID120V1600W-CEE EG1112-000 CV1981 ST Series† 230 V, 1600 W, EU Plug CV1981-ST-230V1600W-EU EG1114-000 230 V, 1600 W, Swiss Plug CV1981-ST-230V1600W-CH* EG1115-000 230 V, 1600 W, UK Plug CV1981-ST-230V1600W-UK* EG1116-000 120 V, 1600 W, US Plug CV1981-ST-120V1600W-US* EG1118-000 120 V, 1600 W, CEE Plug CV1981-ST-120V1600W-CEE* EG1120-000 CV1983 ST Series† 230 V, 3400 W, EU Plug CV1983-ST-230V3400W-EU EG0998-000 230 V, 2300 W, EU Plug CV1983-ST-230V2300W-EU EG1100-000 120 V, 2400 W, CEE Plug CV1983-ST-120V2400W-CEE EG1102-000 230 V, 3400 W, CEE Plug CV1983-ST-230V3400W-CEE EG1104-000 *Note: Refer to TE installation guides and Codes of Practice for appropriate temperature settings. † ST tooling does not feature digital display. Accessories and Replacement Parts Spare/replacement elements for CV1981 and CV1983 Description Part No. CV1981-ATSTELEM-230V1600W EG8165-000 CV1981-ATSTELEM-120V1600W EG8166-000 CV1983-STELEM-230V3400W EG8167-000 CV1983-STELEM-230V3400W EG8168-000 CV1983-STELEM-120V2400W EG8169-000 AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 18 Application Tooling Accessories and Replacement Parts (continued) Spares for CV1981MK2-PID, CV1983M2 Description Part No. CV-1981-PID-ELEM-120V 179178-000 CV-1981-PID-ELEM-230V 091282-000 CV-1983-M2-230V-2200W-ELE D40442-000 CV-1983-M2-230V-3060W-ELE 123906-000 Reflectors Part Description Part No. AD-1962-CV1648-PR.RFL-ADP Adaptor to CV1983 for PR Series Reflectors 989172-000 AD-1999-Temp-Meas-Rflt Temperature Measurement Reflector 932525-000 PR-12-REFLECTOR For Tubing 6 to 25 mm Dia. 991973-000 PR-13-REFLECTOR For Tubing up to 6 mm Dia. 991963-000 PR-13C-REFLECTOR For Tubing 6 - 12 mm Dia. 991974-000 PR-21-REFLECTOR For Tubing 6 - 25 mm Dia. 991984-000 PR-24-REFLECTOR For Small Molded Parts and Tubing 25 to 35 mm Dia. 991964-000 PR-24-A-REFLECTOR For Small Molded Parts and Tubing 35 to 60 mm Dia. 991989-000 PR-25-REFLECTOR For SolderSleeve Products up to 6 mm Dia. 991965-000 PR-25-D-REFLECTOR For SolderSleeve Products 6 to 12 mm Dia. 989523-000 PR-26-REFLECTOR For Miniature SolderSleeve Products and Small Products 991967-000 PR-27-REFLECTOR Special 997858-000 PR-33-REFLECTOR For SolderSleeve Products 20 to 27 mm Dia. 997768-000 PR-34-REFLECTOR For SolderSleeve Products 12 to 20 mm Dia. 989111-000 PR-ATUM-HTAT-16/4-32/8 For HTAT 16/4 - 32/8 463664-000 AD-7-025 Unicure Heat Shield (HS1) 121629-000 ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/ This product must not be disposed of as municipal waste. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 19 Raychem HG Series ThermoGun Heavy-Duty Heating Tools RUGGED • Stand-mounted or handheld, rugged unit for heavy-duty use • Built-in stand and turbo-fan driven blower ADJUSTABLE • Adjustable temperature, 1680 to 2160 watts • Adjustable side vents CAPABLE • High heat output for fast installation of a broad range of products • Large reflector size HG Series ThermoGun Heavy-Duty Heating Tools Tools are used for installing molded parts onto adapters or harnesses. HG-501A, HG-502A, HG-715B-C, HG-752A The HG Series ThermoGun heating tool is used for installing molded parts onto adapters or harnesses and installing a broad range of heat shrinkable products, including boots and tubing up to 75 mm (3”) in diameter. The tools have a fan speed of 1700 rpm and produce an airflow of 23 cfm. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 20 Application Tooling Specifications Model Power Power Requirements Input Watts Temperature Range HG-501A 120 V, 60 Hz, 14 A 1680 260°C to 400°C HG-502A 230 V, 50 Hz, 7 A 1680 260°C to 400°C HG-751B-C 120 V, 60 Hz, 18 A 2160 400°C to 540°C HG-752A 220 V, 50Hz, 9 A 1740 400°C to 540°C Ordering Information HG Series ThermoGun Medium-Duty Heating Tools Model (Includes Stand) Description Part No. HG-501A HG-501A-THERMOGUN-120V 462047-000 HG-502A HG-502A-THERMOGUN-230V 389363-000 HG-751B-C HG-751B-C-THERMOGUN-120V CY4287-000 HG-752A HG-752A-THERMOGUN-220V EG4976-000 Accessories and Replacement Parts Reflectors Applications Description Part No. A-160-HG Up to 19 mm (0.75") Dia. Tubing TG-12/A-160-HG-RFL-SMALL 991017-000 A-170-HG 19 to 51 mm (0.75" to 2") Dia. Tubing A-170-HG 991018-000 TG-23 44 to 51 mm (1.75") Dia. Tubing TG-23/A-205-HG 991026-000 TG-24 Molded Parts TG-24-RFL-LGE-BOOT 991027-000 A-160-HG Reflector A-170-HG Reflector TG-23 Reflector ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/ This product must not be disposed of as municipal waste. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 21 Heat Guns for Raychem Products HL1920E CONVENIENT • Electronic temperature control • Hand-held and self-resting • Industrial grade rubber power cord RELIABLE • Thermal fuse • Dual air vents • Ergonomic soft grip handle HL2020E ADVANCED Raychem Heat Guns Tools are designed for installation of TE heat-shrink products • Electronically controlled hot air tool and SolderSleeve devices. with LCD display • Adjustable by joystick from 80°C to HL1920E 630°C in 10°C steps HL2020E • Current working temperature and HL1920E airflow rate is indicated on the display The HL1920E heat gun is a powerful, electronically controlled hot air gun with temperature control and cool air stage. SAFE, COMFORTABLE The switch, located on the grip handle, is used for setting temperature and airflow. The heat gun can be conveniently • Residual heat indicator to operated using one hand. prevent burns Temperature range 50°C to 600°C @150/300/500 l/min. • Ergonomic soft grip handle Both tools are suited for heat-shrink products and SolderSleeve devices. HL2020E The HL2020E heat gun from TE is a microprocessor-controlled, ROHS Information can be found at the following high-end heat gun with temperature control, LCD display, and website: http://www.te.com/customersupport/ cold air stage. The heat gun features a joystick for making productcompliance/ temperature adjustments, and the current working temperature This product must not be disposed of as is identified on an LCD display. municipal waste. Temperature range: 80°C to 630°C in 10°C steps @150/300/ 500 l/min. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 22 Application Tooling Specifications TEMPERATURE HEATER ELEMENT POWER • HL2020E: 80°C to 630°C • 120 V, 2000 W • HL1920E: 50°C to 600°C • 230 V, 2000 W POWER WEIGHT • 120 V - 60 Hz, 12.5 A • 900 g (2.0 lb.) • 230 V - 50 Hz, 8.7 A CORD LENGTH • 2.2 m (7.2’) approx. Ordering Information Heat Guns Models Description Part No. HL1920E Tools 230 V, UK Plug HL1920E-230V-UK EG8160-000 230 V, EU Plug HL1920E-230V-EURO EG8162-000 Kit, 230 V, EU Plug HL1920E-KIT-230V-EURO EG8164-000 Kit, 120 V, US Plug HL1910E-KIT-120V CJ2086-000 HL2020E Tools 230 V, UK Plug HL2020E-230V-UK EG6424-000 230 V, EU Plug HL2020E-230V-EURO EG6422-000 Kit, 230 V, EU Plug HL2020E-KIT-230V-EURO EG6426-000 Kit, 120 V, US Plug HL2010E-KIT-120V CJ2087-000 Note: Kit contains heating tool plus SolderSleeve reflector EH0600-000. Accessories and Replacement Parts Part/Application Description Part No. Reflectors Adaptor for PR Series Reflectors *HL-ADPT-PR-REFLECTORS EH0598-000 Reflector For Tubing HL-GEN-TUBE-REFLECTOR EH0599-000 Reflector for SolderSleeve Products HL-SOLDER-SLV-REFLECTOR EH0600-000 Reduction Nozzles 9 mm Nozzle For Small-to-Medium Tubing HL-9MM-REDUCTION-NOZ EH0601-000 14 mm Medium Nozzle HL-14MM-REDUCTION-NOZ EH0602-000 20 mm Medium-to-Large Nozzle *PR-12-REFLECTOR 991973-000 Stands Bench Stand for Fixed Position Environments HL-BENCH-STAND EH0603-000 Note - Reflector: SolderSleeve reflector comes with the kit only. *HL-ADPT-PR-REFLECTORS required for use with PR-12-REFLECTOR. SolderSleeve Reflector 20 mm Reduction Nozzle Small to Medium Tubing Reflector Tubing AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 23 Raychem AA-400 Super Heater Compressed-Air Heating Tool APPLICATIONS • For installing heat-shrinkable tubing in confined spaces • Small SolderSleeve devices • Devices (wire-to-pin applications) • SolderTacts contacts VERSATILE • Very focused heat • Wide variety of reflectors available • Excellent tool for small items and confined areas EASY TO USE AA-400 Super Heater Compressed-Air Heating Tool • Automatic power cut-off switch to Tool is used for installing heat-shrinkable tubing and devices. protect heating element if air flow is interrupted AA-400-32-Mk3 (120V) • Pressure regulator and gauge for AA-400-200-CE-SUPERHTR (230V) CE adjusting air flow and temperature Specifications • Indicator light to show when power is applied to heating element POWER • 120 V model: 120 VAC, 4 A, 50–60 Hz • 240 V model: 240 VAC, 2 A, 50–60 Hz AIR • 60 psi /413 kPa /4 bar minimum, 5 cfm, oil free DIMENSION • 152 x 108 x 89 mm (6 x 4.25 x 3.5”) with regulator WEIGHT • 1kg (2.2 lb.) TEMPERATURES • Standard Tool as Supplied: 375°C to 400°C • Tool with Needlepoint Tip: 283°C to 306°C • Tool with Mini SolderSleeve Reflector: 347°C to 459°C (Temperatures achieved within the specified pressure switch operating range as shown on the front of controller.) AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 24 Application Tooling Ordering Information AA-400 Super Heater Model Voltage AC Description Part No. AA-400 Super Heater 120 AA-400-32-Mk3 (120 V) 582602-000 (With stand, needlepoint tip, Mini SolderSleeve reflector, 240 CE AA-400-200-CE-SUPERHTR 281917-000 and input air filter Note: Controller is not sold separately. Accessories and Replacement Parts *Indicates parts that come with the Super Heater Parts Description Part No. NSN Stock No. SolderSleeve Reflector AA-400-94-SLD-SLV-TIP-KIT 979646-000 4940-00-609-4993 *Needlepoint Tip AA-400-96 979647-000 4940-00-148-9847 Boot And Tubing Tip AA-400-101 979691-000 4940-00-148-9848 *Mini SolderSleeve Reflector AA-400-102 979663-000 4940-01-043-7634 Low-Flow Tip AA-400-103 979672-000 3439-01-173-8810 Heating Element Replacement Kit, 120 V AA-400-128 013750-000 Heating Element Replacement Kit, 240 V (CE) AA-400-228-EL-KT-240V-CE 444179-000 *Stand AA-400-09 979649-000 *Input Air Filter AA-400-P-Y-92-Filter 979673-000 Air Hose Replacement Kit AA-400-136 156553-000 Gun And Air Hose Replacement Kit AA-400-229-GUN-HSE-KIT 238231-000 ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/ This product must not be disposed of as municipal waste. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 25 Raychem HT-900B Compressed Air Nitrogen Heater Tools CAPABLE • 290°C to 495°C temperature range • Compressed air/nitrogen 80 to 200 psi • Regulated air/nitrogen through the hose • Air/nitrogen monitored by small sensing hose EASY TO USE HT-900B Compressed Air Nitrogen Heater Tools • Temperature is controlled by the (Available in the US only) controller setting and on thermo- Tools are used for the field installation of heat-shrinkable couple feedback insulation and termination products. • On/Off power switch handle with HT-900B-1-HT-TOOL-YELLOW (115 V) overload protection controls HT-900B-30-HT-TOOL-OLIVE (115 V) electrical supply HT-920B-10-HT-TOOL-YELLOW (230 V) HT-920B-1-HT-TOOL-OLIVE (230 V) SAFE The Raychem HT900B compressed air/nitrogen heating • Automatic shutdown if air supply tool from TE supplies a stream of heated air or nitrogen to aid in the field installation of heat-shrinkable insulation and falls below 5.0 psi termination products. • Compressed air/nitrogen runs The heating tool consists of a heat gun and a control module. through four orifices to cool handle The tool comes with hot air reflectors, a spare heating of tool element, thermocouple, and operating instructions. The heat gun is permanently attached to the control module by a hose • Power on light for unit assembly, which contains air hoses and electrical wires. • Heated air light for heating element The compressed air/nitrogen heating tool operates by passing a stream of air or nitrogen through an electrical heated element located in the body of the heat gun. Specifications ELECTRICAL • HT-900B: 115 VAC, 50-400 Hz, single-phase, 7 A • HT-920B: 220 VAC, 50-400 Hz, single-phase, 3.5 A WEIGHT • 9 kg (20 lb.) DIMENSION • Tool Case: 246 x 440 x 292 mm (9.7” x 17.3” x 11.5”) OUTPUT TEMPERATURE • 290°C to 495°C COMPRESSED AIR/NITROGEN • 80 to 200 psi, 4 SCFM (Dry and oil-free) AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 26 Application Tooling Ordering Information HT-900B Compressed Air Nitrogen Heater Tools (Available in the US only) Model Voltage Description Case Color Part No. HT-900B 115 HT-900B-1-HT-TOOL-YELLOW Yellow 910987-000 HT-900B 115 HT-900B-30-HT-TOOL-OLIVE Olive Drab 837097-000 HT-920B 230 HT-920B-10-HT-TOOL-YELLOW Yellow 303754-000 HT-920B 230 HT-920B-1-HT-TOOL-OLIVE Olive Drab 712121-000 Accessories and Replacement Parts Part Description Part No. Supplied with HT-900B and HT-920B tools, and as replacement parts Heating Element HT-900A-112-SPAR-ELE-115V 252997-000 Thermocouple HT-900A-114-TC-RPLMT-KIT 729711-000 1. Boot and Tubing Reflector AA400-101-STAINLESS-BOOT 979691-000 2. Miniature Termination Sleeve Reflector AA-400-102-MINI-SOLD-TIP 979663-000 3. Termination Sleeve Reflector HT-900A-103-REFL-RPLMT-KT 491878-000 4. Needle Point Reflector AA-400-96-NED-PNT-TIP-KIT 979647-000 5. Large Boot and Tubing Reflector HT-900A-100-LBT-RPLMT-KIT 444100-000 Additional Replacement Parts Heater Element, 120 V HT-900A-123-HTR-RPLMT-KIT 508744-000 Heating Element, 230 V HT-920A-124-HTELE-RPL-KIT 011349-000 Handle Kit 115 V HT-900A-32-HNDLE-KIT-115V 980123-000 Handle Assembly HT-900A-34-HANDLE-ASSMBLY 074594-000 1 2 3 4 5 ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/ This product must not be disposed of as municipal waste. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 27 Raychem AD-5000 Installation Tool EASY TO USE • Designed specifically to install Tinel-Lock ring screened terminations in the correct position • Tinel-Lock rings have thermochromic patch to aid in consistent installation • Thermochromic patch color changes to black to provide visual verification of correct installation • Tool switches off when pressure on jaws is released FAST • 5 to 15-second typical installation time for a Tinel-Lock ring AD-5000 Installation Tool • Simple line-up and squeeze-handle Tool is used to correctly position and install size TR04 to TR24 installation Raychem Tinel-Lock rings in screened terminations. VERSATILE AD-5000-TINEL-ASSY • Accommodates Tinel-Lock rings The AD-5000 tool is a manually operated resistance-heating from size TR04 to TR24 inclusive tool designed to install Raychem Tinel-Lock rings in screened terminations. Intended for small batches, the tool makes it easy • Various electrode types can be used to consistently and quickly install Tinel-Lock rings. Machine cycle to install other Tinel-Lock ring sizes time is typically 5 to 15 seconds, depending on ring size and and types braid type on the termination. The tool accommodates Tinel-Lock rings from size TR04 to TR24. Various electrode (jaws) types can be used to install other ring sizes and types. Specifications POWER • Supply: 220–240 V, 50 Hz • Main Fuse: 240 V, 2 A (Type T) Anti-surge • System Noise: Silent operation DIMENSION • 340 x 320 x 170 mm (13.4” x 13” x 6.7”) WEIGHT • 4.2 kg (9.5 lb.) AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 28 Application Tooling Ordering Information A complete tool includes the hand tool assembly and electrodes. Three types of electrodes are available: • Standard electrodes are used for Tinel-Lock rings, sizes TR04 through TR24 • Conduit electrodes are used when terminating Tinel-Lock rings on conduit or double braids • Square profile electrodes are used with TC02 and TC03 rings Tinel installation tool AD-5000-TINEL-ASSY includes both the hand tool assembly (AD-5000-TINEL-HAND-TOOL) and standard electrodes (AD-5000-TINEL-STD-ELECT). AD-5000 Installation Tool Model Description Part No. AD-5000 Installation Tool AD-5000-TINEL-ASSY 411993-000 Note: AD-5000 is being phased out and will be replaced with AD-5020. Accessories and Replacement Parts Parts Description Part No. Hand Tool Assembly AD-5000-TINEL-HAND-TOOL 795257-000 Standard Electrodes AD-5000-TINEL-STD-ELECT 180245-000 Conduit Electrodes AD-5000-TINEL-COND-ELECT 747235-000 Square Profile Electrodes AD-5000-TINEL-SQ-EXT-ELEC 065583-000 ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/ This product must not be disposed of as municipal waste. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 29 Raychem AD-5020 Installation Tool CONVENIENT • Designed specifically to install Tinel-Lock ring screened terminations in the correct position • Foot pedal operated on and off • Controller “POWER OUTPUT” is adjustable from 80% to 100% EASY TO USE • Ring’s thermochromic patch color changes to black to provide visual verification of correct installation • Tool switches off when foot pedal is released FAST AD-5020 Installation Tool for Tinel-Lock Rings Tool is used to correctly position and install size TR04 through • 5 to 15-second typical installation TR24 Raychem Tinel-Lock rings in screened terminations. time for a Tinel-Lock ring AD-5020-TINEL-HAND-TOOL-230V • Simple line-up and press foot pedal EG1245-000 switch installation The AD-5020 tool is a manually operated resistance-heating tool designed to install Tinel-Lock rings in screened terminations. Intended for small batches, the tool makes it easy to consistently and quickly install Tinel-Lock rings. Machine cycle times typically 5 to 15 seconds, depending on ring size and braid type on the termination. The tool accommodates Tinel-Lock rings from size TR04 through TR24. A foot pedal is used to cycle the tool on and off. Specifications POWER • Supply: 220–240 V, 50 Hz • Main Fuse: 230 V, 4 A (Type T) Anti-surge • System Noise: Silent operation DIMENSIONS • 160 x 120 x 250 mm (6.3” x 4.7” x 9.8”) • Power Lead: 1.3 m (51”) • Foot Pedal Lead: 2 m (78”) WEIGHT • 7.9 kg (17.4 lb.) AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 30 Application Tooling Ordering Information AD-5020 Installation Tool Model Description Part No. AD-5020 Hand Tool AD-5020-TINEL-HAND-TOOL EG1245-000 Accessories and Replacement Parts Model Description Part No. Standard Electrodes AD-5020-TINEL-ELECTRODE EG7238-000 Jaws AD-5020-TINEL-JAWS EG7239-000 PCB for Controller AD-5020-TINEL-PCB EG7240-000 ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/ This product must not be disposed of as municipal waste. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 31 RH-3960 and RH-3965 Tinel-Lock Installation Tools EASY TO USE • Designed specifically to install Tinel-Lock ring screened terminations in the correct position • Tinel-Lock rings have thermochromic patch to aid in consistent installation • Thermochromic patch color changes to black to provide visual verification of correct installation • Tool switches off when pressure on jaws is released FAST • 5 to 15-second typical installation time for a Tinel-Lock ring RH-396X Tinel-Lock Installation Tool • Simple line-up and Tool is designed specifically to install TE Connectivity’s squeeze-handle installation Tinel-Lock rings for screened terminations. VERSATILE RH-3960-1-TINEL-KIT-120V RH-3965-1-TINEL-KIT-220V • Accommodates Tinel-Lock rings from size TR04 to TR24 inclusive The RH-396X manually operated resistance heating tool is designed specifically to install TE Connectivity’s Tinel-Lock rings for screened terminations. Available in 120 V and 220 V versions, it is designed to accommodate our Tinel-Lock rings from size TR04 through TR24 inclusive. The tool makes it easy to install Tinel-Lock rings consistently and quickly. The operator uses the hand-held tool to install the Tinel-Lock ring in its correct position on screened terminations. The ring has a patch of thermochromic paint, which turns to a black color upon successful installation. The operator positions the ring on the termination, ensuring that the patch of thermochromic color is visible. The jaws of the installation tool are then clamped onto the ring to start the installation. When the thermochromic paint turns black, installation is complete. The RH-396X Tinel-Lock ring installation tool is available in North America and Asia Pacific only. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 32 Application Tooling Specifications POWER • Supply: 250 W/2.8 VAC TRANSFORMER DIMENSIONS • 260 mm x 210 mm x 165 mm (10.25” x 8.25” x 6.5”) WEIGHT • 3.18 kg (7.0 lb.) Ordering Information Recommended for installing Tinel-Lock rings TC series and TR04 thru TR20. A complete tool includes the hand tool assembly and electrodes. • Standard electrodes are used for Tinel-Lock rings, sizes TR04 through TR24 • Resistance Heating Tool: 915088-01 • Use with American Beauty Transformer 105-A12 (110 V) or 105-A12-220V (220 V) and Foot Switch 10519 TH-3960 and TH-3965 Installation Tools Model Description Part No. TH-3960 Installation Tool (120 VAC) RH-3960-1-TINEL-KIT-120V 173643-000 TH-3965 Installation Tool (220 VAC) RH-3965-1-TINEL-KIT-220V 859855-000 Accessories and Replacement Parts Parts Description Part No. Hand Tool Assembly 915088-01-TINI-RING-HEATR 170224-000 Foot Switch IR-500-P-FOOT-SWITCH 993702-000 120 VAC Transformer AES-RH3960-TRNSFMR-120V 9951119-000 220 VAC Transformer TRNSFMR-220V-105-A12-250W 574557-000 ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/ This product must not be disposed of as municipal waste. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 33 Raychem Underwater Cable Splice (UWCS) Kit CONVENIENT • Portable • Available in 110 V and 220 V • Full range of spares available HIGH PERFORMANCE • Tested to 86 bar (on specified cables) • Operating temperature range: -55°C to +95°C • NATO Codified (110 V option) Raychem Underwater Cable Splice Kit Tool is used for jointing of TE specified polyethylene ROHS Information can be found at the following jacketed cables. website: http://www.te.com/customersupport/ productcompliance/ UWCS-AT3535-110V This product must not be disposed of as municipal waste. UWCS-AT3535-220V The Raychem underwater cable splice (UWCS) from TE is suitable for jointing of TE specified polyethylene jacketed cables, which are subject to water immersion and pressure. The splice consists of molded polyethylene inserts, which are encased in a heat recoverable sleeve. The joint is placed in a purpose-made oven, which melts the joint components with the cable jacket and, when cooled, gives a water- and pressure-tight joint with the insulated conductor connections embedded within it. Specifications ELECTRIC • 110 V • 220 V TEMPERATURE • -55°C to +95°C AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 34 Application Tooling Ordering Information Raychem Underwater Cable Splice Kit Product Description UWCS 2 U / 76 PRODUCT FAMILY UWCS Underwater Cable Splice NUMBER OF CONDUCTORS 1, 2, 3, 4 CABLE TYPE U Unscreened S Screened C Coaxial CABLE OUTER DIAMETER Specify in mm Product Range Part No. Cable Description (Diameter first) EPD No. Splice Kit End Cap 2 6.8 mm, 6 mm unscreened 26732C UCWS-1U/6.8 UWCS-END-CAP/6.8 2 6.8 mm, 6 mm unscreened 26732C UCWS-1U/10.9-1U/6.8 TO 2 10.9 mm, 25 mm unscreened UCWS-2U/7.6 7.6 mm, 2 core unscreened 21735F UWCS-END-CAP/7.6 7.6 mm, 2 core unscreened 21735F UCWS-2U/7.6-1C/5.8 TO 5.8 mm, 25 mm Coaxial 26640A UCWS-2S/8.3 8.3 mm, 2 core screened 21291G UCWS-2S/8.3 UWCS-END-CAP/8.3 8.3 mm, 3 core screened 24171E UCWS-3S/8.3 UWCS-END-CAP/8.3 8.3 mm, 4 core screened 21736E UCWS-4S/8.3 UWCS-END-CAP/8.3 10.3 mm 45572Q UWCS-END-CAP/8.3 2 10.9 mm, 25 mm unscreened 31451A UCWS-1U/10.9 11.2 mm, 50’Ω Coaxial 25984G UCWS-1C/11.2 UWCS-END-CAP/11.2 12.7 mm, 3 core unscreened 36892C UCWS-3U/12.7 Tool Kits Voltage Description Part No. 110 V UWCS-AT3535-110V 921209-000 240 V UWCS-AT3535-220V 866776-000 AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 35 Raychem AD-1319-9 Holding Fixture EASY TO USE • Holding fixture simplifies and speeds installation of terminations and splices • Two lateral clamps, simple to adjust and align • Fixture secures wire or cable for consistent installation VERSATILE • Designed for use with Raychem heat-shrinkable devices • Adjustable jaws set distance between clamps AD-1319-9 Holding Fixture Tool is used to quickly and accurately install Raychem heat-shrinkable devices. AD-1319-9 The AD-1319-9 holding fixture is a tool that simplifies and speeds installation of Raychem devices. The fixture contains two wire clamps that are easily adjusted to center and secure the wire or cable for installation. Specifications DIMENSION • 180 x 150 mm (7”x 6”) approx. WEIGHT • 300 g (.67 lb.) PRODUCT RANGE • SolderSleeve splices • DuraSeal splices • MiniSeal splices • One-Step BNC/TNC connectors • Shield terminators: D-100-XX, D-144-XX, SO63, SO96 • SolderTacts contacts: D-602-XX AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 36 Application Tooling Ordering Information AD-1319-9 Holding Fixture Model Description Part No. AD-1319-9 Holding Fixture AD-1319-9 993850-000 Note: For holding fixtures for our SolderTacts products, please refer to TE’s SolderTacts brochure, 1-1773722-5. Accessories and Replacement Parts Parts Description Part No. SolderTacts Adapters 38999 Size 8 Contact AT-1319-22 395241-000 38999 Size 16 Contact AT-1319-78 413186-000 Subminiature Contact AT-1319-12 993872-000 748 Contact AT-1319-14 993877-000 723 Contact AT-1319-19 993938-000 482 Size 16 Contacts AT-1319-17 993917-000 ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/ This product must not be disposed of as municipal waste. AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 37 Application Tooling Selecting the Equipment Needed To Install TE Connectivity Heat-Shrinkable Products Selecting the proper tool is very important in order to ensure correct and efficient installation. Our application equipment has been designed, selected, and engineered for maximum production efficiency, providing optimal heating temperatures, performance and control features. TE has developed installation Codes of Practice and Product Installation Procedures that give instructions to our customers in the correct methods for successfully installing our heat-shrinkable products. These are either available as stand-alone documents, or are incorporated into the product drawings themselves. Below are listed some of our heat-shrinkable products along with the recommended tooling that can be found within this catalog. Please note that there are some tools that can be used for the installation of several of our product families, such as our various types of heat gun. In order to ensure the correct and focused delivery of heat, reflectors are recommended and available in a variety of sizes. For more details, see the Codes of Practice and Product Installation Guides, or contact your TE representative. Product Family Recommended Application Tooling Page MiniSeal Crimp Splices AD-1377 Hand Crimping Tool 3 UL Approved MK5 Infrared Hand-Held Tooling 10-11 Mini-Ray MK4 Infrared Hand-Held Tooling 12-13 CV2014 Series ThermoGun Heating Tool 15-16 AA-400 Super Heater 24-25 DuraSeal Crimp Splices AD-1522-1 Hand Crimping Tool 4 CV1981/CV1983 Series ThermoGun Heating Tools 17-19 Reflectors for CV1981/CV1983 Tools 19 Heat Guns 22-23 Reflectors for Heating Guns 23 AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 38 Application Tooling Product Family Recommended Application Tooling Page Heat-Shrinkable Molded Boots and Shapes CV1981/CV1983 Series ThermoGun Heating Tools 17-19 Reflectors for CV1981/CV1983 Tools 19 HG Series ThermoGun Heating Tools 20-21 Heat Guns 22-23 Reflectors for Heat Guns 23 Heat-Shrinkable Tubing (For example DR-25, RNF-100 Tubing) CV1981/CV1983 Series ThermoGun Heating Tools 17-19 Reflectors for CV1981/CV1983 Tools 19 Heat Guns 22-23 Reflectors for Heat Guns 23 Tinel-Lock Rings for TXR Backshells AD-5020 Installation Tool 30-31 RH-3960/RH-3965 Tinel-Lock Installation Tool 32-33 Please note that our infrared tools are not suitable for installation of black-colored tubing. The above are recommendations only. Please consult your TE representative for further details on our tooling or any of our Raychem heat-shrink tubing and molded shapes AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING PAGE 39 LET’S CONNECT We make it easy to connect with our experts and are ready to provide all the support you need. Just call your local support number or visit www.te.com/industrial to chat with a Product Information Specialist. Technical Support te.com/support-center North America +1 800 522 6752 Asia Pacific +86 400 820 6015 North America (Toll) +1 717 986 7777 Japan +81 044 844 8180 EMEA/South Africa +800 0440 5100 Australia +61 2 9554 2695 EMEA (Toll) +31 73 624 6999 New Zealand +64 (0) 9 634 4580 India (Toll-Free) +800 440 5100 te.com/Raychem-tooling AMP, AGASTAT, CII, DEUTSCH, DuraSeal, HARTMAN, KILOVAC, LL ROWE, MICRODOT, MiniSeal, NANONICS, POLAMCO, Raychem, SEACON, SolderSleeve, SolderTacts, ThermoGun, Tinel-Lock, TE, TE Connectivity and the TE connectivity (logo) are trademarks of the TE Connectivity Ltd. family of companies. Other products, logos, and company names mentioned herein may be trademarks of their respective owners. While TE Connectivity (TE) has made every reasonable effort to ensure the accuracy of the information herein, nothing herein constitutes any guarantee that such information is error-free, or any other representation, warranty or guarantee that the information is accurate, correct, reliable or current. The TE entity issuing this publication reserves the right to make any adjustments to the information contained herein at any time without notice. All implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose are expressly disclaimed. The dimensions herein are for reference purposes only and are subject to change without notice. Specifications are subject to change without notice. Consult TE for the latest dimensions and design specifications. © 2016 TE Connectivity Ltd. family of companies All Rights Reserved. 1-1773872-1  12/16    AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING