Sure-Seal Connectors
COST-EFFECTIVE ENVIRONMENTALLY-SEALED CONNECTOR
A low-profile, resilient and rugged construction, with multiple moisture seals makes the Sure-Seal connector a natural choice for outdoor applications where contaminants are a concern. Only two parts are required to complete a Sure-Seal connector: the connector body and the contacts. Sure-Seal was developed to address Department of Transportation safety regulations for automotive connectors. Sure-Seal is ideal for a range of environmental applications where a small, low-cost connector is needed. These sealed connectors meet or exceed DOT requirements for shock, vibration, temperature cycling, salt water spray and immersion, petroleum derivatives, and industrial gas while insuring low milli-volt drop and low contact resistance. Sure-Seal connectors are excellent for motorcycles, automobiles, boats, and demanding off-road vehicles.
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FEATURESSURE-SEAL® CONNECTOR FEATURES
MATERIALS & FINISHESSURE-SEAL® CONNECTOR MATERIALS & FINISHES
Body Elastomeric material (PVC Nitrile standard, Also available in silicone & EPDM)
Contacts Copper alloy
Contact Platings Tin standard; gold plating optional
ELECTRICAL DATASURE-SEAL® CONNECTOR ELECTRICAL DATA
Operating Voltage 400 Vac Maximum
Dielectric Withstanding Voltage 1,200 Vac at sea level
Current Rating 15 Amps (Sure-Seal®)
8 Amps (Mini Sure-Seal®) 85 Amps (Power Sure-Seal®) Wire Range Sizes 14-18 AWG (Sure-Seal®)
18-20 AWG (Mini Sure-Seal®) 4-10 AWG (Power Sure-Seal®) Contact Resistance 10 Milliohms maximum
Insulation Resistance 100 Megohms (minimum)
MECHANICALSURE-SEAL® CONNECTOR MECHANICAL
Operating Temperature -40°F to + 221°F (-40°C to +105°C)
Sealing ≈IP67, DIN 400 50, 3 foot depth in 5% salt solution 24 hours min. ≈NEMA 6 p
Wire Sealing Range See Wire Insulation Diameter under the Contacts and Tooling section
Insulation Strip Length See Strip Length under the Contacts and Tooling section
Mating Life 50 cycles minimum (stamped & formed) 100 cycles (machined)
Salt Spray To MIL-STD-202D Method 101D
Heat +221°F (+115°C) for 1000 hours
Weather, Ozone, & Ultraviolet In accordance with ASTM D-1149 (100pphm) & ASTM D-1171 (outdoor exposure)
Vibration 5 to 55 Hz .06" DA 1 hour; radial & longitudal axes
Shock 50g 11ms, 30 cycles; radial & longitudal axes
Contact Type crimp: using hand or semi automatic tooling
Number of Circuits 1 to 10
Contact Insertion From rear with simple hand tool or simultaneous insertion of multiple contacts with semi-automatic insertion machine. Removable, 5 cycles minimum
Contact Retention 7.5 lbs. (35 N) minimum
Polarization Stepped plane positive polarization, indexing ribs, and visual polarization all permanently molded into body
Agency Listing UL (E176866) & CSA (LR109871-1)
Color Black (alternate colors optional)
TEST DATASURE-SEAL® CONNECTOR TEST DATA
Typical: Power Sure-Seal®, Flange Sure-Seal®, and Mini Sure-Seal® are essentially the same except for mechanical and amperage capacity differences. Sure-Seal® products are designed to meet specification CS-155. Items of most general interest to users and designers are listed below. With its current capability and large size, Power Sure-Seal® contacts and currents are covered in CS-169. Test/Description Reference Paragraph Requirements Environmental Sealing 3.5.1 Sure-Seal® connectors when mated shall form an environmental seal against water, moisture, aqueous solutions, oils and certain chemicals as well as dust and dirt. Tests include immersion in 3 feet depth in water solution containing 5% salt. Contact Tensile 3.6.12 The minimum tensile load required to separate the wire from the contact, either by pulling the wire out of the crimp joint or breaking the wire within the crimp joint, shall not be less than the applicable limits as specified. Wire breakage, or contact damage not due to crimping, at less than tensile loads shall not constitute failure. Crimp Tensile Strength, Pounds Minimum Wire Size AWG Without Insulation Support Contacts With Insulation Support Contacts 4 140 - 6 100 - 8 90 - 10 80 - 14 35 35 16 35 35 18 25 25 20 - 20 Insulation Resistance 4.4.1 Properly assembled and mated connectors shall be tested in accordance with MIL-STD-202, Method 302, except a potential of 500 ± 15 volt DC shall be used. The resistance shall be measured between adjacent parts of contacts (or contacts to ground for SS-1) and shall not be less than 100 M. If the specimen has been immersed in fluid in the preceding test, it shall be placed wet on a conducting surface and insulation resistance measured within 5 minutes between each contact and also between each contact and the conducting surface (except for SS-1 to be measured contact to ground while immersed). Dielectric Withstanding Voltage 4.4.2 Assembled and mated connectors shall show no evidence of breakdown between adjacent contacts (or contact to ground for SS-1) when tested in accordance with MIL-STD-202, Method 301, and a test voltage of 1200 ± 15 volts AC. Contact Resistance 4.4.3 The contact resistance of mated contacts shall be such that the resistance measured across the contacts and 5/8" behind the crimp junction shall not exceed 10 mΩ. Test current to be 1 amp, and MIL-STD-202, Method 307. Shock 4.4.4 Mated connectors properly mounted shall be subjected to the shock test in accordance with MIL-STD- 202, Method 213B, CONDITION B. The shock test shall be repeated three (3) times in each of X, Y & Z axis. Suitable means shall be employed to monitor the current flow. Current discontinuity of 1 microsecond or more, disengagement of the mated connectors, evidence of cracking, breaking or loosening of parts shall be cause for rejection. Vibration 4.4.5 Properly assembled and mated connectors shall be mounted to the vibration table, with the wire leads strapped to a vibrating member approximately 3 inches from each end of the connector body and vibrated with a peak-to-peak amplitude of .25 inch across a frequency range of 5 to 39Hz, and a ±20g acceleration across 39 to 55 Hz, swept up in one minute and down in another minute. The vibration shall be swept up and down for a total of 36 hours under the following conditions: Durability 4.4.6 The connectors shall be subjected to 25 cycles of mating and unmating at -10°C and another 25 cycles at 50°C. There shall be no evidence of damage to the contacts, the contact plating, the insulators or sealing rings, which would be detrimental to connector function. Contact Retention 4.4.7 With the connector plug or receptacle held firmly, an axial dead weight of 7.5 lbs. shall be imposed on each wire for one minute without the contacts being dislodged from the connector. Plugs and receptacles to be tested separately. Maintenance Aging 4.4.8 Each wired receptacle and plug shall be subjected to 5 cycles of contact insertion and extraction in the same cavity using the approved tools. Plug and receptacle are to be tested separately. After the 5 cycles of insertion and extraction, each plug and receptacle in turn will be subjected to the contact retention test of 6 lbs. per paragraph 4.4.7. Connector Separating Force 4.4.11 Using an assembled and mated connector with the receptacle held firmly by the wires, a load shall be applied to the wires of the plug until the connector is completely separated. The rate of loading shall be one inch per minute. The sample shall fall within the limits specified as follows: Connector Size Unmating Force (lbs) Max. Unmating Force (lbs) Min. SS-1 12 6 SS-2 15 6 SS-3 18 8 SS-4 20 9 SS-5/7 30 10 SS-8/10 55 10 Solvent Resistance 4.4.13 4.4.14 4.4.15 4.4.16 4.4.17 4.4.18 4.4.19 Wired and mated connectors shall be subjected to the applicable fluids for the length of time specified. Following the test the connectors shall be immersed to a depth of 3 feet in salt water for 24 hours at room temperature. At the completion of the salt water immersion test and while still immersed insulation resistance shall be measured. Failure to meet the insulation resistance requirements shall be cause for rejection. Gasoline Splash 1 second dip - 3 minute air dry for 80 cycles at room ambient temperature. Diesel Fuel Splash 1 second dip - 3 minute air dry for 80 cycles at room ambient temperature. Automotive Lubricating Oil Immersed in S.A.E. 30 weight lubricating oil for 1 hour. Antifreeze Immersed at 120°F (49°C) for 48 hours. Brake Fluid Immersed at room ambient temperature for 24 hours. Brake Fluid Immersed at room ambient temperature for 24 hours. Automatic Transmission Fluid Immersed at 120°F (49°C) for 48 hours. Gasoline Vapor Immersed in a gasoline vapor atmosphere at room temperature for 48 hours Weather and Ozone Resistance 4.4.20 Wired and properly mated connectors shall be subjected to ozone test per ASTMD-1149 except that 100 ppm of ozones shall be used. The duration of the test shall be 7 days. Outdoor exposure to be conducted per ASTM D-1171. The connector shall show no cracking or other degradation which would result in loss of sealing integrity. High Temperature 4.4.23 Wired mated connectors shall be tested in accordance with MIL-STD-202 Method 108A, Test Condition D at 105°C for 1000 hours. Following the test, they shall be subjected to 3 feet salt water immersion for 24 hours. While immersed, insulation resistance shall be determined. Failure to meet the insulation resistance requirements shall be cause for rejection. UV - Sure Seal Connections has recently completed testing of the Sure Seal PVC Nitrile material (SM 3400-06) for UV resistance. The material was tested in accordance with ASTM G-26 (Xenon Arc), 720 hours exposure with no loss in tensile strength and greater than 75% retention of elongation. Caution: “Sure-Seal® connectors are rated for use between temperatures of -40 to + 105 degrees Celsius. However, if a Sure-Seal® connector is exposed for long periods of time to temperatures exceeding 85 degrees Celsius and is unmated, it may lose its environmental sealing integrity upon remating. Thus, we recommend that both the plug and receptacle be replaced if environmental sealing is required after remating.” |
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SURE-SEAL® CONNECTOR APPLICATIONS
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HOW TO SELECT PART NUMBERHOW TO SELECT SURE-SEAL® CONNECTORS & ACCESSORIES
STEP 1 Choose series: (Sure-Seal®, Mini Sure-Seal®, or Power Sure-Seal®) STEP 2 Determine number of circuits required per connector: STEP 3 Select connector with appropriate number of circuits STEP 4 Select Sure-Seal® body style (straight or flanged plug and receptacle) STEP 5 Select connector accessories:(Boots, Mounting Ring, Mounting Plates, Mounting Clip, Wire Hole Filler, Holding Blocks) HOW TO SELECT SURE-SEAL® CONTACTS & TOOLING
STEP 1 Determine current carrying and wire gauge requirements for application STEP 2 Select appropriate contacts from contact selection chart STEP 3 Choose appropriate crimp, insertion, and extraction tooling PART NUMBER CHARTSSURE-SEAL® CONNECTOR PART NUMBER CHART
NEW CONNECTORS
Notice that all multi-pin Sure-Seal® connectors use a combination of pin and socket contacts in each connector.
Layouts Number of Circuits AWG Wire Size Plug Flanged Plug Receptacle SURE-SEAL®
1 14-18 120-1832-000 Use Mounting Ring 120-1833-000
2 14-18 120-1807-000 120-8552-200 120-1804-000
3 First Make Last Break Verison 14-18 14-18 120-1808-000 120-1808-200 120-8552-201 120-8552-201 120-1805-000 120-1805-200
4 14-18 120-1809-000 120-8552-202 120-1806-000
5 14-18 120-1841-000 Use Mounting Ring 120-1839-000
6 14-18 120-1842-000 Use Mounting Ring 120-1840-000
7 14-18 120-1873-000 Use Mounting Ring 120-1874-000
8 14-18 120-1865-000 120-8552-305 120-1866-000
9 14-18 120-1867-000 120-8552-306 120-1868-000
10 14-18 120-1869-000 120-8552-307 120-1870-000 MINI SURE-SEAL®
2 18-20 120-8552-100 - 120-8551-100
3 18-20 120-8552-101 - 120-8551-101
4 18-20 120-8552-102 - 120-8551-102 POWER SURE-SEAL®
1 4-6 120-1905-000 - 120-1903-000
1 8-10 120-1906-000 - 120-1904-000 ACCESSORIES
Layouts Number of Circuits AWG Wire Size Boot(1) Mounting Ring(2) Mounting Plate(3) Posi-Lok Mounting Clip(4) Wire Hole Filler(5) Holding Block(6) SURE-SEAL®
1 14-18 - - - 026-0452-000 225-0093-000 317-1408-002
2 14-18 317-1398-000 351-1640-000 066-8516-000 029-0263-000 225-0093-000 317-1408-001
3 First Make Last Break Verison 14-18 14-18 317-1397-000# 317-1399-000# 351-1641-000 351-1641-000 066-8516-000 066-8516-000 029-0262-000 029-0262-000 225-0093-000 225-0093-000 317-1408-000 317-1408-000
4 14-18 317-1397-000# 351-1641-000 066-8516-000 029-0262-000 225-0093-000 317-1408-000
5 14-18 317-8657-000 351-1633-000 - 026-0450-000 225-0093-000 317-1408-003
6 14-18 317-8657-000 351-1633-000 - 026-0450-000 225-0093-000 317-1408-003
7 14-18 317-8657-000 351-1633-000 - 026-0450-000 225-0093-000 317-1408-003
8 14-18 317-8657-002 351-1634-000 066-8516-002 026-0451-000 225-0093-000 317-1408-004
9 14-18 317-8657-002 351-1634-000 066-8516-002 026-0451-000 225-0093-000 317-1408-004
10 14-18 317-8657-002 351-1634-000 066-8516-002 026-0451-000 225-0093-000 317-1408-004 MINI SURE-SEAL®
2 18-20 - - - 026-0452-000 225-1012-000 195-8508-013 Plug
3 18-20 - - - 026-0452-000 225-1012-000 195-8508-015 plug
4 18-20 - - - 026-0452-000 225-1012-000 195-8508-017 plug POWER SURE-SEAL®
1 4-6 - - - - - -
1 8-10 - - - - - - (1) Boot: Fits over the rear of the connector and seals the jacket of the cable. It also provides additional strain relief and abrasion resistance. See Accessories/Boots tab for Cable O.D. accommodations. (2) Mounting Ring: A Mounting Ring snaps into an appropriate sized hole in a panel or bracket and allows a non-flanged plug or receptacle to be panel mounted. (3) Mounting Plate: Metal mounting plates reinforce the molded flanges when attaching flanged connectors to a panel. (4) Mounting Clip: Mounting clips can be used free-hanging as a positive lock to provide a secondary means of securing the connector halves. Mated connector pairs can be snapped into the clip for fixed mounting using a screw or cable tie. The wires of one of the connectors can be passed through an integral retention ring which captivates one of the connector halves to the clip. (5) Wire Hole Fillers: Wire Hole fillers are inserted into unused cavities in place of a contact. Hole fillers are required to retain the watertight sealing if less than a full compliment of contacts are to be used. (6) Holding Block: A holding block makes insertion of contacts into the molded body faster and avoids personal injury or damage to the connector. It is highly recommended that the appropriate block be used when inserting contacts. See Assembly Instructions. * See Special Products for information on rectangular part numbers. # See Accessories/Boots tab for Cable O.D. accommodations. |
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CONTACTS & WIRE RANGESURE-SEAL® CONNECTOR CONTACTS & WIRE RANGE
Index Contacts(1) Wire Range Contact Style AWG Loose 5K Reel Pins(1) Loose 5k Reel Sockets(1) Strip Lengths Inches (MM) Wire Insulation Diameter Inches (MM) Wire Hole Filler(2) Sure-Seal® Insulation Support
Tin Plating 14-18 030-2196-001 110238-0195 031-1267-001 110238-0194 .155 - .185 .100 - .147 225-0093-000 Gold Plating* 14-19 030-2193-006 110238-0409 031-1267-005 110238-0408 .155 - .185 .100 - .147 225-0093-000 Sure-Seal® Non-Insulation Support
Tin Plating 14-18 030-2196-000 110238-0040 031-1267-000 110238-0085 .185 - .220 .100 - .147 225-0093-000 Gold Plating* 14-18 030-2196-008 110238-0440 031-1267-007 110238-0442 .185 - .220 .100 - .147 225-0093-000 Mini Sure-Seal® Insulation Support
Tin Plating RoHS 18-20 330-8672-100 121348-0100 031-8703-100 121347-0100 .118 - .130 .055 - .071 225-1012-000 Power Sure-Seal® (VE)**
4 030-2245-002 - 031-1295-001 - .460 - .480 .247 - .380 6 030-2245-001 - 031-1294-001 - .515 - .535 .247 - .380 8 030-2244-001 - 031-1299-001 - .460 - .480 .159 - .245 10 030-2244-002 - 031-1298-001 - .515 - .535 .159 - .245 New Machined First-Make Last-Break/ Pre-Earth Contacts for 120-1808-200 & 120-1805-200 for Cavity 1 only Silver plated 16-20 for 120-1808-200 use SSFMLB16-16S for 120-1805-200 use SSFMLB16-16P .245 (6.2) .100-.147 Gold plated 16-20 for 120-1808-200 use SSFMLB16-16SG for 120-1805-200 use SSFMLB16-16PG .245 (6.2) .100-.147 *Silver available 50K minimum, please contact us. **VE can be used with ITT Cannon VE Connectors and Deutsch HD Connectors. Note: Sure-Seal® and Mini Sure-Seal® contacts are available in machined contact versions. Contact us for more information. Power Sure-Seal® contacs are machined contacts. (1) Loose Piece or 5K Reel: Contacts are available loose piece or on continuous reels of 5000 pieces for use with semi-automated crimping systems. (2) Wire Hole Fillers: These fillers are inserted into unused cavities in place of a contact. Wire hole fillers are required to retain the watertight sealing if less than a full compliment of contacts are to be used. All dimensions in inches (millimeters in parentheses) TOOLINGSURE-SEAL® CONNECTOR TOOLING
Tooling AWG Wire Size Insertion Tool(1) Crimp Tool(2) Extraction Tool Power/Automatic Tool(3) Sure-Seal® Insulation Support
SSI-T-TOOL or
SSI-CS10
Sure-Seal® Non-Insulation Support
SS-T-TOOL or
CBIT-SS-150 Mini Sure-Seal® Insulation Support
M3000 Crimping Press Power Sure-Seal® (VE)**
Crimp Kit New Machined First -Make Last_Break/ Pre-Earth Contacts for 120-1808-200 & 120-1805-200 for Cavity 1 only 16-20 076303-000 AF8 with TH452 DRK 152 WA24F TH452 (2) Hand Crimp Tools: These are heavy duty tools with a ratchet mechanism that will only release the contact when the crimp is completed. These tools produce consistent, high quality crimps. They are the only hand crimping tools recommended for Sure-Seal contacts. (3) Semi-Automatic Crimp Tools: For high volume applications, several types of semi-automatic crimping tools are available for all Sure-Seal contacts.
(4) Mini applicator for insulation support: For Sure-Seal stamped contacts. Mini applicator modules are used in industry standard crmp presses. This allows for fast changeover for crimping different contacts and by using the same crimp press, saves valuable factory floor space versus having to use multiple presses. SEMI-AUTOMATIC CRIMP TOOLINGSURE-SEAL® CONNECTOR SEMI-AUTOMATIC CRIMP TOOLING
The Sure-Seal mini-applicator is designed for use in most common crimping presses and automatic wire processing systems. It utilizes a quick change mounting system, which allows the applicator to be installed or removed in two quick steps. This makes the change over from one applicator to another for crimping a variety of contacts utilizing the same press fast and easy. We offer this side-feed applicator for our most popular stamped and formed terminals (see below). Applicator Terminal SSMA-SSI 110238-0195 & 110238-0194 SSMA-SS 110238-0040 & 110238-0085 MSSMA-SSI 121348-0100 & 121347-0100
The M3000 crimping press is compatible with most side-feed mini-applicators for automated terminal crimping and is the most economical "state-of-the-art" crimping press on the market. The M3000 accommodates our mini-applicator listed above as well as most "left-to-right" and "rear" change "mini" style applicators. Other features include precision crimp height adjustment, electronically interlocking safety guard, jog cycle and 110V power supply. POWER SURE-SEAL CRIMP TOOLSURE-SEAL® CONNECTOR POWER SURE-SEAL® MACHINED CONTACT CRIMP TOOL
The 400BHD is a pneumatically power heavy duty crimp tool designed for contacts that are too large to be crimped by hand tools. The 400BHD comes with a power unit and bench mounting bracket. The 400BHD is actuated with either the standard handle actuating switch or optional Pneumatic Foot Pedal(PFP). Crimp Die Kits are ordered separately. It is highly recommended that you provide a sample of your wire when ordering these Crimp Die Kits. Your wire sample will be crimped and tested for proper crimp tensile strength. PNEUMATIC AUTOMATIC-INSERTION TOOLSURE-SEAL® CONNECTOR PNEUMATIC AUTOMATIC INSERTION TOOL (LEASED)
The CBIT-SS-150 Sure-Seal® insertion machine is pneumatically powered, and micro- processor controlled. It is designed to insert pre-crimped wires into the standard Sure-Seal® plug and receptacle housings for moderate to high volume applications. This machine is used for SS2P/R through SS10P/R including the 120-1873-007 and 120-1874-007 rectangular style Sure-Seal® connectors.
The benefits of using this insertion machine are:
Ease of operation Short operator training time reduces operator fatigue and insertion errors Quick change over for different connectors sizes
Low cycle time Much faster than manual insertion
High connector integrity Lower chance of damaging the wire sealing ripples
Power Requirements: Electrical = 115 Vac, 60 Hz
Pneumatic = 80 PSI, 10 CFM dry oil free filtered air |
PLUGS & RECEPTACLES 1-10SURE-SEAL® CONNECTOR PLUGS & RECEPTACLE 1-10
1 Circuit
2 - 4 Circuit
Body Identifier Plug Number Receptacle Number A Dia. Max. B Dia. Max. C Max. SS-1 P/R 120-1832-000 120-1833-000 .380 (9.65) .550 (13.97) .230 (5.84) SS-2 P/R* 120-1807-000 120-1804-000 .550 (13.97) .710 (18.03) .430 (10.92) SS-3 P/R* 120-1808-000 120-1805-000 .600 (15.24) .760 (19.30) .500 (12.70) SS-4 P/R* 120-1809-000 120-1806-000 .600 (15.24) .760 (19.30) .500 (12.70) 5 - 10 Circuit
Body Identifier Plug Number (P) Receptacle Number (R) A Dia. Max. B Dia. Max. C Max. D Max. SS-5 P/R* 120-1841-000 120-1839-000 1.010 (25.65) 1.160 (29.46) .810 (20.57) 1.610 (40.89) SS-6 P/R* 120-1842-000 120-1840-000 1.010 (25.65) 1.160 (29.46) .810 (20.57) 1.610 (40.89) SS-7 P/R* 120-1873-000 120-1874-000 1.010 (25.65) 1.160 (29.46) .810 (20.57) 1.610 (40.89) SS-8 P/R* 120-1865-000 120-1866-000 1.135 (28.83) 1.285 (32.64) .935 (23.75) 1.610 (40.89) SS-9 P/R* 120-1867-000 120-1868-000 1.135 (28.83) 1.285 (32.64) .935 (23.75) 1.610 (40.89) SS-10 P/R* 120-1869-000 120-1870-000 1.135 (28.83) 1.285 (32.64) .935 (23.75) 1.610 (40.89) All dimensions in inches (millimeters in parentheses) FLANGED PLUGSSURE-SEAL® CONNECTOR FLANGED PLUGS
2 - 4 Circuit
Body Identifier Plug Number A Dia. +.012 (.3) B Dia. +.008 (.2) C Dia. +.012 (.3) D Dia. +.012 (.3) E .008 (.2) SSF-2P 120-8552-200 .547 (13.9) .524 (13.3) .425 (10.8) .307 (7.8) .039 (1.0) SSF-3P 120-8552-201 .598 (15.2) .583 (14.8) .484 (12.3) .315 (8.0) .020 (.50) SSF-4P 120-8552-202 .598 (15.2) .583 (14.8) .484 (12.3) .354 (9.0) .039 (1.0) 8 - 10 Circuit
Body Identifier Plug Number SSF-8P 120-8552-305 SSF-9P 120-8552-306 SSF-10P 120-8552-307 MINI PLUGS & RECEPTACLESSURE-SEAL® CONNECTOR MINI PLUGS & RECEPTACLE
2 - 4 Circuit
Body Identifier Part Number (P) Receptacle Number (R) A Dia. Max. B Dia. Max. C Dia. Max. D Max. MSS-2 P/R* 120-8552-100 120-8551-100 .340 (8.64) .390 (9.91) .540 (13.72) .660 (16.6) MSS-3 P/R* 120-8552-101 120-8551-101 .360 (9.15) .420 (10.67) .580 (14.74) .550 (13.97) MSS-4 P/R* 120-8552-102 120-8551-102 .360 (9.15) .450 (11.43) .610 (15.50) .550 (13.97) All dimensions in inches (millimeters in parentheses) POWER SURE-SEAL®SURE-SEAL® CONNECTOR POWER SURE-SEAL®
Plug
Body Identifier Part Number AWG Size SS-1P-4 120-1905-000 #4 or #6 SS-1P-8 120-1906-000 #8 or #10 Receptacle
Body Identifier Part Number AWG Size SS-1R-4 120-1903-000 #4 or #6 SS-1R-8 120-1904-000 #8 or #10 |
BOOTSURE-SEAL® CONNECTOR BOOT
Fits over the rear of the connector and seals the jacket of a multi-conductor cable. Body Identifier Part Number B Dia. Max. Cable O.D. K Ref. D Dia. Max. SS-2 Boot 317-1398-000 .650 (16.51) .208-.228 2.050 (52.07) .380 (9.65) SS-3 Boot+ 317-1397-000 .610 (15.50) .220-.240 2.050 (52.07) .380 (9.65) SS-4 Boot+ 317-1399-000 .750 (19.05) .345-.380 2.050 (52.07) .500 (12.70) SS-5–7 Boot 317-8657-000 1.063 (27.00) .283-.331 2.441 (62.00) .492 (12.50) SS-8–10 Boot 317-8657-002 1.220 (31.00) .394-.488 2.480 (63.00) .732 (18.60) Note: In addition to boot, remember to use 225-0093-000 Wire Hole Fillers to fill any unused contact cavities. + May be used to cover industry standard BNC crimp style plugs. Contact us for more information. Shrink boots available. 120-2G & SB2. Contact us for details. All dimensions in inches (millimeters in parentheses) MOUNTING RINGSURE-SEAL® CONNECTOR MOUNTING RING
A Mounting Ring snaps into an appropriate sized hole in a panel or bracket and allows a Part Number A Dia. Max. B Dia. Max. C Dia. Max. F Max. H Ref. L Max. Hole Diameter Panel Thickness 351-1640-000 .410 1.275 .790 .230 .055 .690 .781 .060 351-1641-000 .470 1.275 .790 .230 .055 .690 .781 .060 351-1633-000 .755 2.200 1.445 .330 .065 .830 1.50 .060 351-1634-000 .875 2.200 1.445 .330 .065 .830 1.50 .060 All dimensions in inches (millimeters in parentheses) MOUNTING PLATESURE-SEAL® CONNECTOR MOUNTING PLATE
For 2 - 4 Circuit Plug
For 8 - 10 Circuit Plug
All dimensions in inches (millimeters in parentheses) MOUNTING CLIPSURE-SEAL® CONNECTOR MOUNTING CLIP (SURE-SEAL® ONLY)
Style Body Identifier Part Number Colors A Max. B +/-.01 C D E F Max. G Max. I SS-1C 026-0452-000 Black 3.185 .740 - - - .210 .390 II SS-2C 029-0263-000 Red 2.443 .886 1.000 .420 .420 .400 .650 II SS-3-4C 029-0262-000 Yellow 2.443 .926 1.053 .450 .480 .400 .650 III SS-5-7C 026-0450-000 Natural 3.045 1.395 - - - .610 .910 III SS-8-10C 026-0451-000 Black 3.045 1.520 - - - .660 .960 All dimensions in inches (millimeters in parentheses) SEALING SCREWSSURE-SEAL® CONNECTOR SEALING SCREWS
Sealing screws are designed with a groove underneath the head to incorporate an O-ring. When tightened, the O-ring is compressed against the connector flange to form an air, water, and gas-tight seal. Sealing screws are used in conjunction with the nut plates below.
Clear Hole Part Number Thread Length C Max. D Max. Min. Max. S440-1/2 4-40NC-2A 1/2" .220" .069" .125" .129" R440-1/2 4-40NC-2A 1/2" .238" .080" .125" .129" NUT PLATESSURE-SEAL® CONNECTOR NUT PLATES
Nut plates should be used in conjunction with mounting plates. Nut plates eliminate the need for loose nuts which are often difficult to negotiate in confined areas. As well, they effectively distribute the screw tension across the back of the panel. The bracket is aluminum alloy with Alodine plating, and the nuts are steel alloy plated cadmium. Nut plates mate with above sealing screws.
Nut Plate P/N (uses 4-40 screws) For Sure-Seal P/Ns
120-8552-200 120-8552-201 120-8552-202 120-8552-305 120-8552-306 120-8552-307 |
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RECTANGULAR SURE-SEAL® CONNECTOR
Part Number:
Order Socket Contacts Part Number:
Order Pin Contacts *Used with 18AWG SAE J1560TKL Wire (.078 insulator O.D.) All dimensions in inches (millimeters in parentheses) |
CABLE PREPARATIONSURE-SEAL® CONNECTOR WIRE/JACKETED CABLE PREPARATION
Strip wires to appropriate length (See Contacts & Tooling tab). If using a boot, strip jacket so no more than listed dimension is exposed when contact is full inserted. # Circuits Max. Exposed Length Inches (MM) 2, 3, 4 .87 (22) 5, 6, 7 1.02 (26) 8, 9, 10 1.02 (26) Note: Try stripping back jacket approximately 1.25inches (32mm) because strip lengths will vary depending on cable being used. HAND CRIMPSURE-SEAL® CONNECTOR HAND CRIMP TOOL OPERATION
The Sure Seal hand crimp tool has a full cycle ratchet controlled release and straight action crimp jaws. The flap locator makes it easy to load the terminal and the pre-positioner assures that the terminal is loaded for proper crimping. To open the tool, you must apply force to the
handles to allow the tool to spring open.
STEP 1: Open proper hand crimper (see Contacts & Tooling tab) by squeezing handles until handles spring open. STEP 2: Open flap locator. Insert contact up to stop. Make sure contact is inserted properly. STEP 3: Close flap locator.
STEP 4: Press pre-positioner downward firmly for contact alignment. (crimp area should be facing upward) STEP 5: Pre-close the handles.
STEP 6: Insert stripped wire into contact up to insulation stop. STEP 7: Squeeze handles until they pop open. Remove contact from the locator. Hand Tool Part Number Contact Type For Pin Contacts For Socket Contacts Wire Strip Lengths SSI-CS10 Insulation Support 030-2196-001 031-1267-001 .155-.185 (4.0-4.7) SS-CS10 Non-Insulation Support 030-2196-000 031-1267-000 .185-.220 (4.7-5.6) Tool Maintenance: Maintenance and inspection should be performed regularly. The tool should be wiped clean with special emphasis on crimping cavities. The tool may be cleaned by immersing in a suitable commercial solvent or cleaner that does not attack paints or plastic material. The tool should be re-lubricated after cleaning using a light film of a medium weight oil on bearing surfaces and pivot pins. When not in use, keep handles closed to prevent objects from becoming lodged in the crimping dies. Store in a clean dry area. MANUAL INSERTIONSURE-SEAL® CONNECTOR MANUAL INSERTION OF CONTACTS
STEP 1: Affix proper connector holding block to stable surface (i.e. vice or table) (See Contacts & Tooling tab for proper holding block) STEP 2: If a jacket wire sealing boot is to be used, it must be slid up the cable (isopropyl alcohol will help in doing this). STEP 3: Dip connector in isopropyl alcohol and place in holding block with the back end up (wire side)
STEP 4: Using the proper contact insertion tool (See Contacts & Tooling tab). STEP 5: Insert contact into proper cavity of the connector body by applying constant pressure until contact snaps into place. Isopropyl alcohol will help in doing this. (Warning: Do not tilt the tool during the insertion). STEP 6: Insert all remaining contacts. To insure environmental sealing of the connector any empty contact cavities must be filled with wire hole fillers.
STEP 7: Check mating side of the connector to be sure that all contacts are on the same plane (fully inserted). STEP 8: If you are using jacket sealing boot, slide the boot down the cable and onto the connector. STEP 9: Remove connector and wire assembly from holding block. CONTACT EXTRACTIONSURE-SEAL® CONNECTOR EXTRACTION OF CONTACTS
STEP 1: Slide up any rear accessories (i.e. jacket cable sealing boots). Using isopropyl alcohol will help you slide these up your cable. STEP 2: Grasp individual wire firmly and gently pull the contact out of the connector. CRIMP INSPECTIONSURE-SEAL® CONNECTOR CRIMP INSPECTION Micro Sections: Enlargement of micro section allows for final judgement of crimp quality. This test is recommended whenever new tools or new types of wire are used. Note: For accurate pull test results when crimping insulation support contacts (030-2196-001 &031-1367-001), strip wire back .3” so that the insulation support tine does not crimp onto insulation. For Machined Powered Contacts Correct Crimp Incorrect Crimp For Stamped Contacts Correct Crimp Incorrect Crimp Incorrect Crimp |
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