1
Termination
Instructions
GORE
®
Aerospace
Ethernet Cables
Amphenol
®
Oval Contact System (OCS 13-53)
for 24 Gauge Cables
The following procedures are based on Gore’s best practices
for terminating GORE
®
Aerospace Ethernet Cables with the
Amphenol
®
Oval Contact System (OCS) for both plug and
receptacle versions. These procedures should be used as a guide
in conjunction with current connector manufacturing instructions.
Preparing the Cable and Parts
1. Gather the tools and materials required for assembly and
termination (Figures 1–8). Note: This assembly requires SN63
leaded solder.
2. Be sure to evaluate the tools and procedures in these
termination instructions for potential hazards; collect the
proper personal protective equipment you will need.
3. Verify that you have the correct parts for your assembly by
checking the part numbers for the connectors and the GORE
®
Aerospace Ethernet Cables listed on drawing DDA0238.
4. Cut two 1.5-inch pieces of 0.75-inch thin-walled adhesive-lined
tubing (TAT).
5. Cut the cable to the desired assembly length minus 4.5
centimeters (cm) to allow for length of the connectors (i.e.,
2.2 cm for the plug connector and 2.3 cm for the receptacle
connector).
6. Print any labels required by the end-user, and slide the center
label onto the cable.
7. To identify the end for the plug connector, place a piece of tape
on the end in which the pairs rotate clockwise in order
of green
orange blue brown (Figure 9).
Figure 9: Pairs configuration at
plug end
1
Gore recommends using copper foil tape instead of polyimide tape during termination
procedures because copper tape is easier to use and improves signal integrity.
Figure 1: Needle nose pliers, scalpel, tweezer scissors, and hand strippers
Figure 3: Soldering iron
Figure 5: Clamp tool (Tie-Dex
®
II)
Figure 7: Braid brush
Figure 8: Probe/pick
Figure 6: Copper foil tape
1
(3M-3313)
Figure 2: Cutters
Figure 4: Solder wick
2
Termination Instructions —
Amphenol
®
Oval Contact System (OCS 13-53)
for 24 Gauge Cables
GORE
®
Aerospace
Ethernet Cables
Terminating the Plug Connector (Termination A)
1. Slide one piece of the TAT onto the cable.
2. Slide the backshell onto the cable with the smallest end
facing the cable (Figure 10).
Figure 10: Inserting backshell on the cable
Figure 11: Marking the cable
Figure 14: Exposing the foil
Figure 12: Slitting the cable jacket
Figure 15: Taping each pair
Figure 13: Exposing the braid
3. Measure and mark the cable 0.5 inch from the plug end of
the cable (Figure 11).
4. Using a scalpel or scissors, slit the cable’s jacket from its edge
to the mark (Figure 12).
5. Using needle-nose pliers, gently pull the outer jacket down the
cable until you have exposed approximately 3.5 inches of braid
(Figure 13).
6. With your fingers, push the braid back over the cable to expose
approximately 3.5 inches of the foil (Figure 14).
7. Remove the white filler as far down as possible.
8. Cut a piece of 0.25-inch polyimide tape, and tape the foil at
the end of each pair (Figure 15).