GORE Aerospace User manual

Termination

Instructions

GORE®Aerospace

Ethernet Cables

TE Connectivity®CeeLok FAS-X®Connector System

The following procedures are based on Gore’s best practices

for terminating GORE®Aerospace Ethernet Cables with the TE

Connectivity®CeeLok FAS-X®Connector System for both pin and

socket versions. These procedures should be used as a guide in

conjunction with current connector manufacturing instructions.

Preparing the Cable and Parts

1. Gather the tools and materials required for assembly and

termination (Figures 1–8).

2. Verify that you have the correct parts for your assembly by

checking the part numbers for the connectors and the GORE®

Aerospace Ethernet Cables listed on drawing DDA0238.

3. Cut two 1.5-inch pieces of 5/8-inch, thin-walled adhesive-lined

tubing (TAT).

4. Cut the cable to the desired assembly length minus 4.3

centimeters (cm) to allow for length of the connectors (i.e.,

2.0 cm for the plug connector and 2.3 cm for the receptacle

connector).

5. Print any labels required by the end-user, and slide the center

label onto the cable.

6. To identify the end for the pin connector, place a piece of tape

on the end in which the pairs rotate clockwise in order of

green orange blue brown (Figure 9).

Figure 9: Pairs conﬁguration

at pin end

Figure 1: Needle nose pliers, scalpel, tweezer scissors, and hand strippers

Figure 3: Crimpers (M22520/2-01)

Figure 6: Clamp tool (Tie-Dex®II)

Figure 7: Braid brush

Figure 8: Probe/pick

Figure 2: Cutters

Figure 4: Socket positioner (K40) Figure 5: Pin positioner (K42)

Termination Instructions —

TE Connectivity®CeeLok FAS-X®

Connector System

GORE®Aerospace

Ethernet Cables

Figure 10: Sliding the backshell onto the cable

Figure 11: Marking the jacket

Figure 12: Slitting the cable jacket

Figure 14: Exposing the foil

Figure 15: Wrapping the foil

Figure 13: Exposing the braid

3. Measure and mark the jacket 0.5 inches from the end

of the cable (Figure 11).

4. Using a scalpel or scissors, slit the cable’s jacket from

its edge to the mark (Figure 12).

5. Using needle-nose pliers, gently pull the outer jacket down

the cable until you have exposed approximately 1.5 inches of

braid (Figure 13).

6. With your ﬁngers, push the braid back over the cable to expose

approximately 1.5 inches of the foil (Figure 14).

7. Remove the white ﬁller as far down as possible.

8. Cut a piece of copper or polyimide tape for each pair. Wrap

a piece of tape around the foil 0.5 inches from the end of

the cable (Figure 15). Try to use as small a piece of tape as

possible to minimize the buildup of material.

Terminating the Pin Connector (Termination A)

1. Slide one piece of the TAT onto the cable.

2. With the smallest end facing the cable, slide the backshell

(i.e., rubber grommet) and washers onto the cable (Figure 10).

Termination Instructions —

TE Connectivity®CeeLok FAS-X®

Connector System

GORE®Aerospace

Ethernet Cables

Figure 17: Marking each pair

Figure 18: Stripping the primaries

Figure 16: Tearing the foil

Figure 19: Inserting pairs through the metal sleeve

9. With cutters, cut the foil edge where it meets the tape.

Then, tear the foil along the tape edge (Figure 16).

10. Mark each pair 0.15 inch from the end of the cable (Figure 17).

11. Install the K42 positioner for the pin contact into the

M22520/2-01, and select setting 3. To prevent stray wire

strands during crimping, strip and crimp one primary at a

time using contacts from the kit (Figure 18).

12. Slide the metal sleeve over the pairs (Figure 19).

13. Using an insertion tool, insert each primary into the connector

according to the following table. It may be necessary to twist

the pairs to align them with the appropriate position in the

connector housing. If so, tighten the twist of the pair rather

than loosen the twist of the primary.

Pin Wire

1Green

2 Green/White

3Brown

4Brown/White

5Blue

6Blue/White

7Orange

8Orange/White

14. Slide the metal sleeve to connector housing (Figure 20).

Figure 20: Seating the metal sleeve

15. Gently move the braid toward the connector, and fold it

over the metal sleeve. Use a braid brush or pick to loosen

the braid as you fold it over the backshell (Figure 21).

Figure 21: Folding the braid over the backshell

Figure 22: Returning the jacket to the connector

Figure 23: Trimming the excess braid material

Figure 24: Placing the washers near the connector

Figure 25: Afﬁxing the backshell

16. Push or slide the jacket back to the connector as

far as it will go, and trim the excess (Figure 22).

17. Trim the braid material to halfway over the metal

sleeve (Figure 23).

18. Slide the washers toward the connector (Figure 24).

19. Slide the backshell to the connector, and tighten it to

the manufacturer’s recommended torque value using the

appropriate torque ﬁxture (Figure 25).

20. Perform all required testing. At a minimum, verify proper

wiring and continuity, and check for shorts. Local authorities

and end-users may require additional testing.

GORE®Aerospace

Ethernet Cables

Termination Instructions —

TE Connectivity®CeeLok FAS-X®

Connector System

Figure 26: Sliding the backshell onto the cable

Figure 27: Marking the jacket

Figure 28: Slitting the cable jacket

Terminating the Socket Connector (Termination B)

1. Slide one piece of the TAT onto the cable.

2. With the smallest end facing the cable, slide the backshell

(i.e., rubber grommet) and washers onto the cable (Figure 26).

3. Measure and mark the jacket 0.5 inches from the end of

the cable (Figure 27).

Figure 29: Exposing the braid

Figure 31: Wrapping the foil

Figure 30: Exposing the foil

4. Using a scalpel or scissors, slit the cable’s jacket from

its edge to the mark (Figure 28).

5. Using needle-nose pliers, gently pull the outer jacket down the

cable until you have exposed approximately 1.5 inches of braid

(Figure 29).

6. With your ﬁngers, push the braid back over the cable to expose

approximately 1.5 inches of the foil (Figure 30).

7. Remove the white ﬁller as far down as possible.

8. Cut a piece of copper or polyimide tape for each pair. Wrap a

piece of polyimide tape around the foil 0.7 inches from the end

of the cable (Figure 31). Try to use as small a piece of tape as

possible to minimize the buildup of material.

GORE®Aerospace

Ethernet Cables

Termination Instructions —

TE Connectivity®CeeLok FAS-X®

Connector System

Figure 32: Tearing the foil

Figure 33: Marking each pair

Figure 34: Stripping the primaries

Figure 34: Inserting pairs through the metal sleeve

9. With cutters, cut the foil edge where it meets the tape.

Then, tear the foil along the tape edge (Figure 32).

10. Mark each pair 0.15 inch from the end of the cable (Figure 33).

11. Install the K40 positioner for the socket contact into the

M22520/2-01, and select setting 3. To prevent stray wire

strands during crimping, strip and crimp one primary at a

time using contacts from the kit (Figure 34).

12. Slide the metal sleeve over the pairs (Figure 35).

13. Using an insertion tool, insert each primary into the connector

according to the following table. It may be necessary to twist

the pairs to align them with the appropriate position in the

connector housing. If so, tighten the twist of the pair rather

than loosen the twist of the primary.

14. Slide the inner metal sleeve to connector housing (Figure 36).

Pin Wire

1Green

2 Green/White

3Brown

4Brown/White

5Blue

6Blue/White

7Orange

8Orange/White

Figure 36: Seating the metal sleeve

GORE®Aerospace

Ethernet Cables

Termination Instructions —

TE Connectivity®CeeLok FAS-X®

Connector System

15. Gently move the braid toward the connector and fold it over

the metal sleeve (Figure 37). Use a braid brush or pick to

loosen the braid as you fold it over the backshell.

16. Push or slide the jacket back to the connector as far as it

will go, and trim the excess (Figure 38).

17. Trim the braid material to halfway over the inner

metal sleeve (Figure 39).

18. Slide the washers toward the connector (Figure 40).

Figure 37: Folding the braid over the backshell

Figure 38: Returning the jacket to the connector

Figure 39: Trimming the excess braid material

Figure 40: Placing the washers near the connector

19. Slide the backshell to the connector, and tighten it to

the manufacturer’s recommended torque value using the

appropriate torque ﬁxture (Figure 41).

Figure 41: Afﬁxing the backshell

20. Perform all required testing. At a minimum, verify proper

wiring and continuity, and check for shorts. Local authorities

and end-users may require additional testing.

GORE®Aerospace

Ethernet Cables

Termination Instructions —

TE Connectivity®CeeLok FAS-X®

Connector System

W. L. Gore & Associates

gore.com

GORE®Aerospace

Ethernet Cables

TE Connectivity and CeeLok FAS-X are trademarks of the TE Connectivity LTD family of companies.

BAND-IT, Tie-Dex and Tie-Dex II are registered trademarks of BAND-IT IDEX, Inc.

Geo-Marine is a registered trademark of Glenair, Inc.

Termination Instructions —

TE Connectivity®CeeLok FAS-X®

Connector System

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