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:


  • Splice Box (a)
  • Threaded Cable Glands (b)
  • Potting Compound (c)
  • Insulated Butt Connectors in various sizes (d and e)
  • Nitrile Gloves (f)
  • Sand Paper (g)



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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.


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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. 


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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.


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Figure 4: ShapeArray cabling with the PVC jacket and wires stripped



Step 4 - Connect the Wires

 

Connect same wire colors together using supplied butt connectors (Figure 1.d and 1.e). For standard ShapeArray cable (#SKUCAB018), the 18 AWG power wires (RED and BLACK) use the larger pink butt connectors. The communications wires (WHITE and BLUE) and shield wire use the smaller yellow butt connectors. Make sure to crimp the butt connectors using a crimper designed for use with insulated butt connectors. Ensure that the wires are not loose.


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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.


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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.


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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.


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Figure 8: Splice box after potting and attaching the cover