Doc. No. 13006-90090-ASM (Rev 0) SLICE6 3-CHANNEL SENSOR CONNECTOR ASSEMBLY DOCUMENT INSTRUCTIONS TO PREPARE AND ASSEMBLE THREE-AXIS SENSOR TO SLICE6 CONNECTOR AND INSTALL BACKSHELL Prepared by: Diversified Technical Systems, Inc. Seal Beach, California USA (562) 493-0158 Fabrication process shall meet IPC-610 Class 3 Standard unless otherwise specified in writing on Purchase Order. INTELLECTUAL PROPERTY STATEMENT This document contains information that is the property of Diversified Technical Systems, Inc. (DTS). All copyright, patent and ownership rights are retained. This information shall not be disclosed, reproduced in whole or in part, or used for manufacture without prior written consent from DTS.
Finished Assembly Page 2 of 16 Doc. No. 13006-90090-ASM (Rev 0)
Components Description P/N Notes SLICE6 Sensor Connector, 3-Channel 80000-04086(-R) SLICE6 Sensor Connector Backshell, 3-Channel 89100-22030-R Sensor (varies) See Mfr data sheet for signal color code Sensor ID Microcard (3 ea) (optional) 22005-00001(-R) Heat shrink, black; 1.2 mm diam 99000-00340-R 1.2 mm preferred, but 3/64 will also work 26 AWG magnet wire (optional) Epoxy, LOCTITE Hysol E-20HP Isopropyl alcohol 70002-00044(-R) 99000-00217(-R) Page 3 of 16 Doc. No. 13006-90090-ASM (Rev 0)
** Please read entire document before beginning assembly. ** 1. Cut sensor cable(s) to length if necessary. Insert sensor wire(s) through backshell as shown below. Note: Depending on the diameter of the cable(s) and the fit through the backshell, you may wish to add heat shrink or need to modify the backshell. If heat shrink is used, do not shrink until all solder connections are completed and you have test fit the backshell (roughly step 7). Page 4 of 16 Doc. No. 13006-90090-ASM (Rev 0)
2. Prepare sensor(s): Remove 5/16 (8 mm) of cable jacket. Strip and tin sensor and ground wires as shown below. 5/16 Page 5 of 16 Doc. No. 13006-90090-ASM (Rev 0)
3. Prepare sensor ID microcards (optional 1 ): Cut sensor ID microcard leads to length (1/2 or 13 mm) as shown below. Strip and tin microcard wires as shown in step 2. 1/2 1 If not installing sensor ID microcards, go to step 5. Page 6 of 16 Doc. No. 13006-90090-ASM (Rev 0)
4. Solder sensor ID microcard to the Ch 3 pins 17 and 18 as shown below. You may solder all microcards at once, however it may be easier to proceed to the next step and finish assembly of Ch 3 before completing the remaining channels. Channel 3 sensor ID Pin 1 Pin 7 Pin 13 Pin 6 Pin 12 Pin 18 Pin Assignment Signal Color Code 5 -ID/Shield (Ch 1) Black 6 +ID (Ch 1) Blue 11 -ID/Shield (Ch 2) Black 12 +ID (Ch 2) Blue 17 -ID/Shield (Ch 3) Black 18 +ID (Ch 3) Blue Page 7 of 16 Doc. No. 13006-90090-ASM (Rev 0)
5. Assemble sensor(s): Add a short length of 1.2 mm diameter heat shrink to the sensor Shield wire 2 for Ch 3. Solder the Shield to pin 17, in tandem with -ID, as shown below. Solder the remaining Ch 3 sensor wires to the connector per the table below. Pin 1 Pin 7 Pin 13 Pin 6 Pin 12 Pin 18 Pin Assignment Signal 1 +Ex (Ch 1) 2 +Sig (Ch 1) 3 -Sig (Ch 1) 4 -Ex (Ch 1) 5 -ID/Shield (Ch 1) 2 6 +ID (Ch 1) 7 +Ex (Ch 2) 8 +Sig (Ch 2) 9 -Sig (Ch 2) 10 -Ex (Ch 2) 11 -ID/Shield (Ch 2) 2 12 +ID (Ch 2) 13 +Ex (Ch 3) 14 +Sig (Ch 3) 15 -Sig (Ch 3) 16 -Ex (Ch 3) 17 -ID/Shield (Ch 3) 2 18 +ID (Ch 3) Sensor Color Code* * Review the manufacturer s data sheet for the signal color code for your sensor. Write the color code next to the correct signal in the table above. 2 A triaxial sensor might have only one Shield wire and may be connected to pin 5, pin 11 or pin 17 (assembler s choice). Do not connect the Shield to more than one location. Page 8 of 16 Doc. No. 13006-90090-ASM (Rev 0)
Channel 3 assembly completed 6. Continue with Ch 2 sensor assembly (ID per step 4 and sensor per step 5), and finish with Ch 1 sensor assembly, as shown below. (Note: A triaxial sensor might have only one Shield wire and should be soldered to ONE location only.) Channel 2 assembly completed Channel 1 assembly completed Page 9 of 16 Doc. No. 13006-90090-ASM (Rev 0)
7. Ensure cable jacket is positioned as close as possible to the connector. If you have used heat shrink, apply heat to shrink, keeping the heat shrink aligned with the cut edge of the jacket as much as possible. 8. Carefully fold sensor ID microcards as shown below. (The PCBs should not touch the contacts.) The entire connector assembly should be as short as practical (~11/16 or ~17 mm) in order to fit within the backshell. ~11/16 Steps 7 and 8 Page 10 of 16 Doc. No. 13006-90090-ASM (Rev 0)
9. Carefully insert connector assembly into backshell to test fit. ** Note orientation of backshell tab to short leg of connector. ** Carefully separate connector and backshell and adjust wires as necessary until an easy fit is achieved. Carefully separate connector and backshell before proceeding. ~11/16 10. Add strain relief (optional): If the test fit indicates there is room for strain relief, you may add this. Wrap 26 AWG magnet wire around cable about 1/16 from jacket edge. Twist wire to gently pinch/squeeze jacket. Cut off excess wire leaving about 1/8. Bend twisted wire parallel to wrapped wire. Test fit the backshell again. The PCBs should not touch the contacts or magnet wire. If fit is too tight, do not use strain relief. Carefully separate connector and backshell before proceeding. Page 11 of 16 Doc. No. 13006-90090-ASM (Rev 0)
11. Carefully apply epoxy (Loctite E-20HP Hysol recommended) as shown below. Proceed immediately to next step. Page 12 of 16 Doc. No. 13006-90090-ASM (Rev 0)
12. Carefully insert connector with uncured epoxy into backshell, pushing the two pieces together tightly. ** Note orientation of backshell. ** Carefully wipe excess epoxy immediately from connector assembly using isopropyl alcohol. Page 13 of 16 Doc. No. 13006-90090-ASM (Rev 0)
13. Use Kapton tape as shown below to secure the assembly while epoxy cures overnight. (The connector and backshell should be pushed together tightly.) Page 14 of 16 Doc. No. 13006-90090-ASM (Rev 0)
Finished Assembly Page 15 of 16 Doc. No. 13006-90090-ASM (Rev 0)
Revision History Rev Date By Description 1 0 11 July 2018 EK Initial release. Page 16 of 16 Doc. No. 13006-90090-ASM (Rev 0)