TH19 Lab                                                             Name ___________________

Cable Making and Testing.                      

 

Description:  Each student will “tin” a wire, produce a wire-to-wire solder splice, a connection to an XLR connector, and a connection to a TRS connector.  In addition, each student will test and identify faults from among a group of cables, which may or may not be functioning.

 

Remember:

1.        Wear goggles or eye protection when soldering

2.        Do not shake soldering iron to remove solder.  Use wet sponge.

3.        Make sure the shell of the connector is on the cable before soldering conductors.

4.        Heat the work not the solder.

5.        Start with a small amount of molten solder on the tip

6.        Tin conductors before joining with connectors.

 

I)   Cable Making 

 

A)     Starting with an 18” piece of 22 gauge wire, “Tin” one end as indicated below:

1)       Strip 1/2” of insulation from the end of the wire.

2)       Heat the conductor from below and apply solder from above. (Apply some solder to the tip before heating the work.  This will speed up the heating process.)

3)       Allow the solder to flow evenly until it provides a thin coating around the length of the entire conductor.  You can move the soldering iron along the length of the conductor starting near the insulator and finishing at the end.

4)       Label and submit your work

 

 

 

 

 

 

 


B)      Splice the ends of the 22 gauge wire together making (1) a mechanical connection first , and (2) using the solder to assure an electrical connection.

 

1)     Strip ½” of insulation from each wire end.

2)     Loop the wire around so that the ends meet.  Mechanically connect these wires together by twisting the center conductors together.

3)     Heat the splice by placing the soldering iron tip under the work.  (Apply a some solder to the tip before heating the work.  This will speed up the heating process.)

5)      

Apply solder from the top

 
When the wire is hot, apply the solder to the top of the work allowing it to flow evenly over the entire splice. 

6)       Once completed, label and submit your work

               

 


Heat from the bottom

 
       

 

 


C)    Construct a cable with an XLR connector at one end: (balanced line audio cable)

1)     Measure and cut approximately 2 feet of 2 conductor shielded cable.

2)     Strip outer insulation back approximately 1 Ό”

3)     Unbraid the shield (or remove the foil shield and use the drain wire) and twist it together to form a single conductor.  Remove any plastic of fabric packing.

4)     Strip a 3/8” of insulation off each internal wires.

5)     “Tin” the ends of each conductor including the shield.  Trim as needed so very little conductor is exposed when soldered to the connector.  See figure B.1 below. 

a)  If mating to an XLR-3M, also “tin” the connector.

6)     On one end, solder an XLR-3M (or XLR-3F.  This assumes white as the hot wire.  The hot/positive wire can also be Red or Green.  White stands for any color other than black.

Notes:

·         Make sure connector shell is on the cable before soldering. 

·         Check the number on the pin before soldering

·         It is easier to “tack” solder the shield first and use it to keep the connector and wire in place.  (If necessary re-solder the shield after the pins 2 and 3 are complete.)

·         Once the shield is soldered, place each internal connector in their corresponding cup and solder.

·         Line Callout 3 (No Border): 2 - Positive (hot) White/Red/Green/etcIn all cases, the insulator needs to be tight to the connector cup, leaving very little conductor exposed.  This will prevent shorting between conductors.

XLR 3M – Soldering side

 
 


(a)   Pin 1 – Shield (Ground)

Line Callout 3 (No Border): 1 - Ground or Shield(b)   Pin 2 - White (Positive)

(c)     Pin 3 - Black (Negative)

Can: 3,Can: 1,Line Callout 2: Very Little Conductor Exposed
 

 

 

 

 

 

 

 

 

 

 


XLR – 3F

 

XLR – 3F

 


D)    Construct a cable with a Ό” phone plug on one end and an RCA plug on the other.  

1)     Strip 1Ό” of outer insulation from the cable,

2)     Unbraid the shield (or remove the foil shield and use the drain wire) and twist it together to form a single conductor.  Remove any plastic or  fabric packing.

3)     Trim the wires so they line up with their soldering locations, approximately Ό” past the hole for the hot and cold wires.  If there is no hole for the shield, leave it at the original length.

4)     Strip a Ό” of insulation off each internal wires

5)     “Tin” the ends of each conductor.  Include the shield if there is a hole for it.  Otherwise, the shield wraps around one side of the crimp tab.

6)     Connect the wires as follows,  connect the shield first so that when done, the outer insulation will be crimped for strain relief.  See diagrams below.

(a)

Tip – White (positive)

(b)

Sleeve – Shield (ground)

        Note the diagram is for a TRS connector.  Ignore the Ring.

 

7)       Once completed, label and submit your work

 

 

 

 

 

 

 

 

 


 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 


II)  Cable Testing:  Select one cable of each type and test for defects as follows:

1)    Cable ID # 1901

 

TRS to XLR

TRS

Tip to 1 continuity ______

Tip to ring continuity ______

Tip to 2 continuity ______

Tip to sleeve continuity ______

Tip to 3 continuity ______

Ring to Sleeve continuity ______

Ring to 1 continuity ______

 

Ring to 2 continuity ______

 

Ring to 3 continuity ______

XLR

Sleeve to 1 continuity ______

Pin 1 to 2 continuity ______

Sleeve to 2 continuity ______

Pin 1 to 3 continuity ______

Sleeve to 3 continuity ______

Pin 2 to 3 continuity ______

 

 

 

Is the cable OK? ______

 

If not what is wrong? ____________________________________________________________

 

______________________________________________________________________________

2)    Cable ID # 1902

 

Left side to Right side

Left connector

Pin 1 to 1 continuity ______

Pin 1 to 2 continuity ______

Pin 1 to 2 continuity ______

Pin 1 to 3 continuity ______

Pin 1 to 3 continuity ______

Pin 2 to 3 continuity ______

Pin 2 to 1 continuity ______

 

Pin 2 to 2 continuity ______

 

Pin 2 to 3 continuity ______

Right Connector

Pin 3 to 1 continuity ______

Pin 1 to 2 continuity ______

Pin 3 to 2 continuity ______

Pin 1 to 3 continuity ______

Pin 3 to 3 continuity ______

Pin 2 to 3 continuity ______

 

Is the cable OK? ______

 

If not what is wrong? ____________________________________________________________

 

______________________________________________________________________________

3)       Cable ID # 1903

               

               

Left side to Right side

Left connector

Pin 1 to 1 continuity ______

Pin 1 to 2 continuity ______

Pin 1 to 2 continuity ______

Pin 1 to 3 continuity ______

Pin 1 to 3 continuity ______

Pin 2 to 3 continuity ______

Pin 2 to 1 continuity ______

 

Pin 2 to 2 continuity ______

 

Pin 2 to 3 continuity ______

Right Connector

Pin 3 to 1 continuity ______

Pin 1 to 2 continuity ______

Pin 3 to 2 continuity ______

Pin 1 to 3 continuity ______

Pin 3 to 3 continuity ______

Pin 2 to 3 continuity ______

Is the cable OK? ______

 

If not what is wrong? ____________________________________________________________

 

______________________________________________________________________________

 

 

 

 

4)     Cable ID #1904

 

TRS to XLR

TRS

Tip to 1 continuity ______

Tip to ring continuity ______

Tip to 2 continuity ______

Tip to sleeve continuity ______

Tip to 3 continuity ______

Ring to Sleeve continuity ______

Ring to 1 continuity ______

 

Ring to 2 continuity ______

 

Ring to 3 continuity ______

XLR

Sleeve to 1 continuity ______

Pin 1 to 2 continuity ______

Sleeve to 2 continuity ______

Pin 1 to 3 continuity ______

Sleeve to 3 continuity ______

Pin 2 to 3 continuity ______

 

 

Is the cable OK? ______

 

If not what is wrong? ____________________________________________________________

 

______________________________________________________________________________

 

5)     Cable ID#1905

Left side to Right side

Left connector

Tip to Tip continuity ______

Tip to sleeve continuity ______

Tip to Sleeve continuity ______

Right connector

Sleeve to Sleeve continuity ______

Tip to sleeve continuity ______

 

Is the cable OK? ______

 

If not what is wrong? ____________________________________________________________

 

                ______________________________________________________________________________

 

6)  Cable ID# 1906

Left side to Right side

Left connector

Tip to Tip continuity ______

Tip to sleeve continuity ______

Tip to Sleeve continuity ______

Right connector

Sleeve to Sleeve continuity ______

Tip to sleeve continuity ______

 

Is the cable OK? ______

 

If not what is wrong? ____________________________________________________________

 

                ______________________________________________________________________________

 

7) Cable ID# 1908

       

Left side to Right side

Left connector

Tip to Tip continuity ______

Tip to sleeve continuity ______

Tip to Sleeve continuity ______

Right connector

Sleeve to Sleeve continuity ______

Tip to sleeve continuity ______

 

Is the cable OK? ______

 

If not what is wrong? ____________________________________________________________

 

                ______________________________________________________________________________