R/V Oceanus, whoi
Zen and the art of Termination
- The best time to re-terminate the CTD wire is between cruises. If the
cable has not been used in awhile (2 or 3 months), or more than 40 stations
have been done, it is probably time to re-terminate. Spool off or payout
at least 10m of cable, check that the cable feels smooth and looks
clean (not too rusty, at least better than it looked at the termination).
Figure 1. First things first...
- Cut the cable. Melt out
the old termination . Put the boot (strain-relief guard) on first, then
the adapter plug. The stainless steel termination goes on last.
Figure 3. Wrap bus wire around cable....
- Pull about three feet of wire through the termination. About 2ft back
from the end wrap tinned bus wire around the 322 cable.
This will hold the strands together while the cable is birdcaged.
Figure 4. Figure out size of birdcage....
- The birdcage must fit into the hollow of the stainless steel termination,
the length is about 3.25". The distance can be measured using a tape measure or
a piece of wire.
Figure 5. Mark the wire ....
- Mark the 322 wire from the tinned bus wire towards the bitter end, the
legnth of the hollow, with a permanent marker. Wire strands should be unwound
and then cut at this mark.
Figure 6. Peel off the wire and bend it back ....
- The jacket strands of the 322 wire can easily be bent, however they
will only bend once, make sure to pull directly back along the cable, when
bending the wire.
Figure 7. Sand the wire strands....
- It is a good idea to sand each wire after it is cut. This will enable
the cerrobend to adhere better.
Figure 8. Tie the first birdcage back, then do the second....
- The 322 has two metal jackets. Each one should be pulled back and tied
off using the tinned buss wire.
Figure 9. Save the legnth and give to bridge....
- Inside the second wire jacket is a plastic liner which shows the total
legnth of the 322 wire. This should be brought to the bridge and entered
into the Wire Log Book.
Figure 10. Yank birdcage....
- When both jackets have been secured, the birdcage should then be pulled
and seated into the termination.
Figure 11. Floss the wire....
- Once the birdcage has been seated, the black cable, which has the three
copper conductors in it, should the threaded through the small hole on
the side of the termination.
Figure 12. Monkey Dung the ends.....
- Monkey dung (plas-dus), should be formed around the cable between the
adapter and the termination and around where the black cable exits the
termination. The monkey dung is used to keep the melted cerrobend from
leaking out all over the place.
Figure 13. Pour melted cerrobend.....
- Heat the cerrobend up and pour it into the termination. If it is cold
preheat the termination using a propane torch. If a crater forms in the top
of the termination, reheat it with the propane torch.
Figure 14. Completed cerrobend pour.....
- When the cerrobend has been poured and solidified, let the termination
cool down to just about room temperature before proceeding further.
Figure 15. Peel back wire cable.....
- Peel back about an inch of the wire cable to expose 3 plastic coated
Figure 16. Strip wires.....
- Strip about 1/4 -1/2 an inch of the copper wire, and about an inch of
a mecca connector. Wrap the copper wire about the mecca.
Figure 17. Solder wires.....
- Solder each of the copper wire/ mecca wraps.
Figure 18. Scotchkote the wire.....
- After the solder has dried, paint scotch kote over the solder joint.
Let this sit for about five minutes, or until it is tacky, then wrap with
scotch 23 tape.
Figure 19. Wrap wire in scotch 23.....
- Paint each solder joint individually with scothkote and then wrap it with
scotch 23, three times.
Figure 20. Splice each wire seperately....
Figure 21. Wrap all three wires together...
- Holding all three splices together smear with scotch kote, then wrap
all three together with scotch 23 tape. On the second wrap, bring the
tape between 1 and 2, then between 2 and 3. Then do a third scotch kote and
Figure 22. Final tape...
- Wrap the whole sheebang once with either scotch 33 or 88. Make a new
ground mecca before putting the termination
back on the package.
Do a pull test to 2500lb for five minutes, and don't forget to ohm
out the seacable.