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
© 2014 Tyco Electronics Corporation, a TE Connectivity Ltd. Company. All Rights Reserved. TE Proprietary & Confidential Information.
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
© 2014 Tyco Electronics Corporation, a TE Connectivity Ltd. Company. All Rights Reserved. TE Proprietary & Confidential Information.
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
© 2014 Tyco Electronics Corporation, a TE Connectivity Ltd. Company. All Rights Reserved. TE Proprietary & Confidential Information.
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
© 2014 Tyco Electronics Corporation, a TE Connectivity Ltd. Company. All Rights Reserved. TE Proprietary & Confidential Information.
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
© 2014 Tyco Electronics Corporation, a TE Connectivity Ltd. Company. All Rights Reserved. TE Proprietary & Confidential Information.
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
© 2014 Tyco Electronics Corporation, a TE Connectivity Ltd. Company. All Rights Reserved. TE Proprietary & Confidential Information.
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.