Amphenol connectors are typically used to connect a ShapeArray (SAA) in environments where there is a reasonable chance of water exposure with the connector. They provide a small amount of splash-proofing to ensure a solid connection to the ShapeArray.
In some cases, you may be required to re-wire a ShapeArray's Amphenol connector in the field. This is often the case when the ShapeArray's cabling has been accidentally cut. This guide will help you re-wire the male Amphenol connector.
Step 1 - Disassemble the Male Amphenol Connector
Remove the cable nut by unscrewing it.
Figure 1: Male Amphenol connector with cable nut unscrewed
Remove the grommet by pulling it out of the connector body.
Figure 2: Male Amphenol connector with cable nut unscrewed and grommet removed
Remove the connector body by unscrewing it.
Note: It is much easier to unscrew the connector body if the male Amphenol connector is plugged into a female end, such as the one available on an SAA Field Power Unit.
Figure 3: Male Amphenol connector with body unscrewed
Step 2 - Remove Cable Support
Unscrew the clamps in cable support.
Figure 4: Removing the cable support in the male Amphenol connector
Unclip the cable support from connector.
Figure 5: Disassembled Male Amphenol connector with cable support unclipped
Step 3 - Back Off Wire Screws and Remove Connector
Loosen the wire screw for each wire on the connector so that the wires are no longer secured.
Figure 6: Male Amphenol connector disassembled - note the cable screws securing each wire
Remove the connector.
Figure 7: Male Amphenol connector disassembled with wires removed
Step 4 - Strip Cable Insulation and Trim Wires
Remove 51 mm (2”) of insulation from the end of the cable to which the connector will be reattached using a cable insulation cutter.
Figure 8: (Left) Removing ShapeArray cable insulation with cable insulation cutter and (Right) ShapeArray cable with insulation removed
When using the cable insulation cutter, make only ONE turn around while paying close attention to the depth of the cut. DO NOT cut the insulation on the wires inside the cable. Cut the black, red, white, and blue wires to approximately 16 mm - 19 mm (5/8" – 3/4”) in length.
Note: DO NOT trim the shield wire.
Figure 9: Black, red, white, and blue wires trimmed back, shield wire untrimmed
Step 5 - Strip Wires and Wrap Ground Wire
Strip approximately 6 – 7 mm (1/4") of insulation from the wires.
Figure 10: Wire stripped, shield wire untouched
Wrap the shield wire around the black wire. Please ensure you twist the shield wire into the stripped portion of the black wire.
Figure 11: Shield wire wrapped around black wire
Step 6 - Insert Cable into Bottom of Connector
Slide the bottom three pieces of the male Amphenol connector over the cable to which the connector is being reattached.
Figure 12: The bottom three pieces of the male Amphenol connector slid over the cable
Step 7 - Connect Wires to Male Connector
Ensure the tightening screws on the male end of the Amphenol connector are loose. With the bottom of the male connector head facing up, insert the following wires:
- White wire – hole 1
- Blue wire – hole 2
- Red wire – hole 3
- Black wire – hole with ground symbol
Figure 13: Locations for inserting the stripped wires from the ShapeArray cable
Place the connector top flush to workbench with the cable straight up. While pressing the cable wires into the connector, tighten the screws.
Step 8 - Attach Cable Support
Snap on the cable support to the head of the connector.
Figure 14: Reattaching the cable support to the male Amphenol connector
Attach the metal clamp with screws to the cable support. Ensure you thread the screws into the metal clamp from the opposite side of the cable support; otherwise, they will not tighten.
Figure 15: Attaching the metal clamp to the cable support
Step 9 - Complete Bottom Connector Assembly
Slide the bottom three pieces of the connector to the top of the cable. Screw the body onto the connector head.
Note: It is much easier to screw the body to the connector if the male Amphenol connector is plugged into a female end, such as the one available on an SAA Field Power Unit.
Figure 16: Reassembling the male Amphenol connector, body screwed on first
Push grommet into the connector body.
Figure 17: Reassembling the male Amphenol connector, grommet pushed in
Securely screw the cable nut to the body.
Figure 18: Rewired male Amphenol connector