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 brown blue
orange (Figure 9).
AMPHENOL
®
OVAL CONTACT SYSTEM
(OCS 13-53) FOR 26 GAUGE CABLES
GORE
®
Aerospace Ethernet Cables
Termination Instructions
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
GORE
®
Aerospace Ethernet Cables
Termination Instructions
2 Termination Instructions for Amphenol
®
Oval Contact System (OCS 13-53) for 26 Gauge Cables
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).
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).
Terminating the Plug Connector (Termination A)
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