Each ShapeArray (SAA) comes with 15 m of communication cable attached. In cases where longer cables are required, splice kits will be needed to properly extend the cable in the field.
The SAA Cable Splice Kit is used to make water tight splices in Measurand ShapeArray cables.
The kit includes the following items, as shown in Figure 1 below:
- Potting Compound
- Splice box
- Cable glands
- Nitrile gloves
- Blue butt connectors, 14 - 16 AWG
- Pink butt connectors, 18 - 22 AWG
- Yellow butt connectors, 22 - 26 AWG
- Sand paper
Figure 1: An SAA cable splice kit
You will also need the following equipment to complete a splice:
- Wire Cutters
- Wire Strippers
- Crimper for Insulated Butt Connectors
- Standard Flat Screw Driver
Note: Always disconnect cables from communication and power before splicing. Test communications to the ShapeArray as detailed in the Communications section of the SAARecorder manual prior to potting. Remove power prior to potting and do not re-power until the potting compound is cured.
Step 1 - Prepare the Splice Box
Remove the top plate from the splice box included in the splice kit. Assemble the splice box and cable glands together before inserting the cables into the splice box.
Figure 2: A prepared splice box
Step 2 - Strip PVC Cable Jacket from ShapeArray Cable
Insert the ShapeArray cables into the splice box. Remove the PVC cable jacket from the ShapeArray cable to reveal the wires inside the cable. Clear away the water block cloth and plastic and metal insulation surrounding the blue and white wires.
Figure 3: ShapeArray cable with PVC cable jacket stripped
Step 3 - Strip Wires and Abrade the Cable Jacket
Strip the insulation from the red, black, white, and blue wires in the stripped ShapeArray cables. Use the butt connectors as a guide for length. When stripped to the proper length, the insulation around the wires will end up a few millimeters inside the butt connector. Abrade the blue PVC cable jacket using supplied sandpaper to clean the surface. This is to ensure good contact with the potting compound.
Figure 4: ShapeArray cabling with the PVC jacket and wires stripped
Step 4 - Connect the Wires
Connect same wire colours together using supplied butt connectors (Figure 1.5, 1.6 and 1.7). For standard ShapeArray cabling make the following connections based on the gauge of the Measurand cable:
- SKUCAB018: splice the RED and BLACK 18 AWG power wires using the medium sized pink 18 - 22 AWG butt connectors
- SKUCAB014: splice the RED and BLACK 14 AWG power wires using the larger sized blue 14 - 16 AWG AWG butt connectors
- SKUCAB018 and SKUCAB014: splice the WHITE and BLUE communications wires and the SHIELD wire using the smaller yellow 22 - 26 AWG butt connectors.
Figure 5: ShapeArray cable wires connected together using crimped butt connectors
Step 5 - Place Wires in Cable Box and Test Communication
Turn the wire bundle and position the wires inside the splice box. Tighten cable glands to hold the cables in place and sealing them in preparation for potting with supplied sealing compound. Test the splice to make sure you can collect valid data before proceeding to the next step.
Figure 6: Wires in cable box with tightened cable glands
Step 6 - Prepare the Potting Compound
Mix the two part potting compound. Make sure to follow the instructions provided on the potting compound envelope.
Figure 7: Mixing the potting compound
Step 7 - Pot and Cover the Splice Box
Fill the splice box with potting compound, making sure to cover the wires. Place and tighten the cover on the splice box so that the potting compound does not leak.
Figure 8: Splice box after potting and attaching the cover