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 or when the cabling must be routed through small diameter conduit or holes. This guide will help you re-wire the male Amphenol connector. To rewire an Amphenol connector, the following tools are required.

• Cable insulation cutting tool, wire strippers, or wire cutters
• Small flat-headed screwdriver (e.g. 2.5 mm)
• A female Amphenol connector, such as the one on an SAA Field Power Unit (SAAFPU)

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. 

Figure 3: Attach the male Amphenol connector to an SAA Field Power Unit to make unscrewing the body easier

NOTE: It is much easier to unscrew the connector body if the male Amphenol connector is plugged into a female connector, such as the one available on an SAA Field Power Unit.

Figure 4: The male Amphenol connector attached to an SAA Field Power Unit with body unscrewed

Step 2 - Remove Cable Support

Unscrew the clamps in cable support.

Figure 5: Removing the cable support in the male Amphenol connector

Unclip the cable support from connector.

Figure 6: 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 7: Male Amphenol connector disassembled - note the cable screws securing each wire

Remove the connector.

Figure 8: 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, wire stripper, or wire cutter.

Figure 9: (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 10: 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 11: 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 12: 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 13: 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 14: Locations for inserting the stripped wires from the ShapeArray cable

Place the connector top flush to a flat surface 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 15: 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 16: 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 17: Reassembling the male Amphenol connector, body screwed on first

Push grommet into the connector body. 

Figure 18: Reassembling the male Amphenol connector, grommet pushed in

Securely screw the cable nut to the body.

Figure 19: Rewired male Amphenol connector