MicroDot-connector assembly guide

Caution: This procedure requires a skilled personnel with adequate technical experience from electronic assembling or from assembling delicate connectors. Personnel without such requirements may succeed through extreme care and several attempts only.

Cable

DYJ6005

DDB6000 DYM0415

DYA6000

DYJ0233

DDB0601 DJL0028

Extra MicroDot connectors can only be ordered as complete connector. Order no.: DUA6000

Tool: DQA0035

Epoxy Araldite S2 or equivalent standard 2-component (24hour hardening time).

Pincers

Scalpel

Wire stripper

1. Insert the cable strain relief (DYJ 6005) over the cable (relief end first).

2. Strip off 15-20 mm of the cable insulation (be careful not to soar the screen cores).

3. Mount the ferrule DDB 6000 in the B part of the mounting tool.

4. Turn the ferrule partly onto the cable (there is a thread inside the ferrule).

5. Place a small drop of epoxy at the joint of the screen and cable insulation (use a toothpick or similar).

6. Now, screw the ferrule onto the cable until it tightens against the cable insulation.

7. Use the A part of the tool to keep the 8. Unbraid the screen cores (be careful 9. Bend the dielectric away and cut the ferrule and the cable steady while not to soar the dielectric of the inner screen cores and kevlars 1,5 mm from removing the B part of the tool. conductor). the ferrule.

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10. Fold the remaining 1,5 mm screen cores back against the ferrule.

11. Cut the dielectric 1,5 mm from the rear lock screw (Warning: Use a wire stripper with extreme care if the inner threads are soared the whole process must be restarted).

12. Lock the kevlar with the dielectric by placing a small drop of epoxy at the joint of the kevlar and the dielectric. (Note: Preferably, leave the epoxy to harden partially for approx. 2 hours before completing the remaining part of the mounting procedure).

13. Place the axial stand-off ring - DYA 14. Place the assembly in the lock cap DYM 0415 as shown. 6000 over the jerk tube DDB 0601

15. Mount the lock cap assembly on the B part of the tool. Ensure that the lock tabs on the jerk tube DDB 0601 fits into the corresponding split in the tool.

16. Insert the insulator DYJ 0233 in the assembly.

17. Route the inner conductor through the lock cap assembly and mount the assembly loose on the ferrule; Guide the inner conductor out through the split in the tool.

18. Use the A part of the tool to keep the ferrule steady while tightening the assembly firmly with the B part.

19. Unscrew the lock cap from the B part of the tool.

20. Now, the MicroDot connector should look like this.

21. Place the C part of the tool over the B part as shown.

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22. Mount the connectors on the B part; 23. Press the C part of the tool over Let the inner conductor slide out the lock cap DYM 0415 in order to through the split in the tool. keep the inner conductor fixed.

24. Place the connector pin in the C part of the tool as shown.

25. Mount the C part into the B part

26. Tighten the tool parts firmly

27. Push the C part back towards the B parts handle.

28. Unscrew the lock cap from the B part of the tool.

29. Carefully cut the inner conductor close to the insulator.

30. Gently, mount the cable strain relief DYJ 6000 over the groove in the ferrule DDB 6000.

31. Allow the epoxy to harden thoroughly in 24 hours before the connector is taken into use.

SI4060_2.doc