DFNEXT Cable Assembly

DC In Harness

The following parts are required for the assembly of the DC In Harness

1x Amphenol Connector - ACC02E14S-2P-025

2x lengths yellow 16 AWG cable - 163mm

2x lengths black 16 AWG cable - 163mm

1 Molex Minifit Jr. 2 row 4 way connector housing.

4x Molex Minift Jr. 2 female plug crimp 16 AWG

2x 3mm black Heat Shrink - 10mm long

2x 3mm yellow Heat Shrink - 10mm long

2x 5/6mm black Heat Shrink - 15mm long

Picture of Final Cable

Picture of Pinout

DC Camera, Video Camera power and Camera Trigger Harness

The following parts are required for the assembly of the DC Power harness to power the various components inside the enclosure.

• 1 Molex Minifit Jr. 2 row 8 way connector housing
• 6x Molex Minift Jr. female plug crimp 16 AWG
• 1x Camera Power Cable 4 pin
• 1x length yellow 18 AWG Cable - 155mm
• 1x length black 18 AWG Cable - 155mm
• 2x length purple 28 AWG - 150mm
• 1x 5mm black Heat Shrink - 10mm long
• 1x Video camera GPIO/Power connector

Obtain a FLIR video camera 6 pin GPIO/Power connector. Plug the connector in the camera and unscrew the housing to reveal the solder connectors. Two operations are required on the connector: soldering a 28 AWG purple wire length, and bridging two pins to provide a common ground. With the connector plugged in the camera, identify the pin that will have the purple wire soldered to it as illustrated in the image.

The two pins that will be bridged are 1 pin away from the purple-wire-soldered pin in the clockwise direction. The image also highlights the position of the bridged pins.

1: Solder bridge the marked connectors.

• 1x M20 female housing 2x5 pins + x10 22-30AWG female plug crimps

Crimp one contact to one end of one purple 28AWG wire. Insert into M20 housing. The position where the contact must be inserted is one position over from the position opposite to pin no. 1 (marked with an arrow). The figure illustrates the required position. The rest of the contacts must be filled with contacts.

IMAGE: LED_M20_proc.jpg

• 2

RS232 Serial Cable

1x 340mm length 10 wire ribbon cable.

1x IDC 02x05 female connector and strain relief

1x DE9 female connector with IDC termination.

Peel and remove the one wire opposite to the red wire on the ribbon cable over the whole length of the ribbon cable. The serial connection requires a 9-way ribbon cable.

Insert ribbon cable in the IDC 02x05 connector with red wire aligned with the first position on the IDC connector marked by an arrow. The ribbon cable is inserted from the side that has the marker visible on it. This is illustrated in the following figure.

FIGURE

Insert the other end of the ribbon cable in the DE9 female connector from the large base of the trapezoid formed on the back of the connector with the red wire aligned to position number 1.

Bend ribbon cable over the back of the connector and insert strain relief.