Tether Termination and Strain Relief Assembly Instructions Rev6-1

Procedure: Document Number: VR-T-01-01 Section: 1 Rev: 3.
060
Title: Procedure for Installing Page 1 of 23 Effective Date:
Tether Connector. 01/21/11
Copyright © 2008, VideoRay LLC Approved by: Brett Kolb
1.0 Purpose
This procedure defines the methods used to assemble tether connectors.
2.0 Scope
Assembly of VideoRay tether connectors.
3.0 Responsibilities
Assembly Specialist.
4.0 Time for Assembly

1 hour.
5.0 Tools required

Wire strippers 22 AWG (Milba Model 7E), Ruler, Heat Gun, Label Maker, Soldering
Iron. (pg.3)
6.0 References
7.0 Procedure
7.1 The items used to build this assembly are shown here:
Flexane 80 Liquid Resin Flexane 80 Liquid Devcon Liquid Release FL-20 Primer
(2 pounds) Curing Agent Agent
FL-10 Primer
VideoRay LLC Proprietary Information. Disclosure, duplication, distribution or any other use not allowed
without written consent from VideoRay LLC.
Procedure: Document Number: VR-T-01-01 Section: 1 Rev: 3.060
Male Threaded
Locking Sleeve Snap Ring
Female Threaded (1 per connection)
(1 per female
locking sleeve
Tether Termination connection)
(1 per male
Mold connection)
Female Termination Oval Threaded

Male Termination
End Connector Strain Relief
End
(1 per female (1 per connection) (1 per connection)
(1 per male
connection) connection)
0.5” x 1” Clear Zip Tie

0.4” x 2” Shrink
Shrink Tubing (1 per connection)
Tubing 0.8” x 3 1/4”Shrink
(1 per tether Tubing (1 per female
connector) (1 per strain relief) connector)
Additional items included but not shown in the photograph:
Binder clip
Small (1/2” X 3/32" diameter) heat shrink tube (8 per connector)
Large (1/2” X 1/8" diameter) heat shrink tube (8 per connector)
O-ring (Buna 011) (1 per connector - for PPT and Negative tethers only)
Female locking sleeve tool
Male locking sleeve tool
Additional Tools required, but not provided
Disposable mixing cup

Mixing sticks
Measuring scale
Soldering iron
Solder
Super Glue
Heat gun
Small screw drivers
Utility knife
Wire cutter
Wire stripper
Ruler
Marker
Latex gloves
Figure 9 – Pin numbering is clockwise on the male

connector and counterclockwise on the female connector
when looking at the free end of the connector
Pin Function Tether Color Tether Conductors*

1 Black Video - Brown 1
2 White Video+ White 1
3 Red 48VDC + Red 2
4 Green Aux + Green 1
5 Orange Ground Black 2
6 Blue Aux - Yellow 1
7 Brown CAN Bus + Orange 1
8 Yellow CAN Bus - Blue 1
* - The tether contains ten conductors. Two conductor pairs are used
for power in order to reduce the overall tether stiffness.
Some very early versions with VideoRay 2000 or 2002 models did not include
an auxiliary spare pair and therefore only have seven or eight conductors.
Tethers with eight conductors cannot be used with accessories such as sonar
or ship hull inspection system.
Connector Preparation
Male and female tether connectors
To prepare a connector for molding, remove the white label from the wires and slide the
numbered labels toward the connector. Cut the wires to 1 inch (25 mm).
Spread the wires out. Strip 1/8 inch (3 mm) from each wire and tin the ends with solder.
Install Tether Strain Relief
Before stripping the yellow jacket off the tether, slide one piece of 0.8” x 3” shrink wrap
tubing onto the tether. Attach binder clip to loop end of black mesh strain relief to prevent
middle section of strain relief from sliding back through it. Push tether through middle
opening of strain relief until the end of tether reaches the loop end. Spread mesh at the
loop end and feed the tether through. Slide strain relief down to the 0.8” shrink wrap
tubing. Remove binder clip.
Install zip tie 1” from bottom of black mesh strain relief through both layers of mesh and tie
off, but do not tighten. (Do not wrap around tether)
Add oval threaded connector to mesh loop and close. Install the clear heat shrink. (this will
cover the serial number) Last, slide the other length of shrink wrap onto the tether. (0.8” x
2” for Neutral tether, 0.4” x 2” for PPT and Negative tether)
The Tether is now ready for preparation.
Tether Preparation
Remove 6 inches (150 mm) of the tether jacket (and flotation material for PPT and Neutral
tethers) being careful not to cut the wires or the Kevlar strand.
Pull the Kevlar strands out of the way and restrain it with one hand. Cut the wires 1 inch
(25mm) from the end of the jacket. Place O-ring over the tether and slide down over the
Kevlar strands to hold them aside for later use. The O-ring will also need to be used later
for the PPT and negative tethers.
Title: Procedure for Installing Page 10 of Effective Date:
Tether Connector. 23 01/21/11
After stripping the wire ends, connect the two red wires to each other and the two black
wires to each other and tin all wire ends with solder.
Solder the Connection
Each wire from the connector needs to be soldered to the appropriate wire from the tether.
Use the table below for reference. After soldering each wire pair, test the continuity before
proceeding to the next wire pair.
Pin Function Tether Color Tether Conductors*

1 Black Video - Brown 1
2 White Video+ White 1
3 Red 48VDC + Red 2
4 Green Aux + Green 1
5 Orange Ground Black 2
6 Blue Aux - Yellow 1
7 Brown CAN Bus + Orange 1
8 Yellow CAN Bus - Blue 1
A pair of table vises works well to hold the tether and connector in place for soldering.
Slide a 1/2 inch (12 mm) piece of small diameter heat shrink over one wire from the
connector and a short piece of large diameter heat shrink over the corresponding wire in the
tether.
Solder the wires, slide the heat shrink pieces so that they overlap over the joint and apply
heat to shrink the heat shrink wrap.
Repeat the process for each wire. When all wires have been soldered, apply some rotation
to the connector to slightly coil the wires. Test all connections for continuity and to ensure
there are no shorts.
Using the Kevlar strand, tie a half hitch knot on the connector side of the solder joints and
secure the knot with a drop of super glue.
Tie a second half hitch knot over the connector and secure it with super glue. The loose end
of the Kevlar can be wrapped around the connector and glued in place.
Slide the 2” heat shrink (0.8 for Neutral tether, 0.4 for negative and PPT) over the wires.
Do not cover over the connector. Wrap at least 1” of aluminum tape around the tether to
avoid melting and damaging the tether jacket.
After applying heat, remove the aluminum tape.
Set the connector assembly in the mold and make an indicator mark for priming.
Aggressively sand the metal connector, heat shrink, and tether that will be
molded. Prime the metal connector with Devcon FL-10 (blue). (do not sand or prime the
smooth section) Prime over top the metal blue primer, heat shrink and tether past the
mark with Devcon FL-20 (red) and let it dry.
Make sure this section is sanded & primed

past the indicator mark
Test each pin for continuity and for shorts one more time before proceeding
Tether Mold Preparation
Coat both halves of the mold with a light coat of release agent and let them dry for 5
minutes.
Insert the tether in the mold. For PPT and Negative Tether, the O-ring must be installed on
the tether to seal the mold around the tether. For Neutral tether, the O-ring is not needed.
Place the second half of the mold over the first and make sure the connection is centered in
the mold. Tighten the mold retaining bolts.
Potting the Connections
You will need to mix 1 pound (0.4545 kg) of potting compound for each tether termination.
You must possess a scale that can weigh this amount and reads to at least 2 significant
decimal digits.
Weigh 77 units by weight of the Flexane Resin into a large plastic cup. Add 23 units by
weight of the Flexane hardener for a total of 100 units.
Place the large plastic cup with the mixture in it into a container of hot water(not boiling),
ensuring that the water does not enter the mixture. Mix the Flexane for at least 2 minutes,
while in the heated water. Using a heat gun, heat the mold cavity and pour the Flexane mix
into the cavity, heating the Flexane while it is being poured. Tilt the mold back and forth
slightly so that it is completely filled. The Flexane should partially fill the upper funnel
shaped chamber. Once the cavity is completely filled, reheat the mixture 2-3 times with
heat gun so that air bubbles can escape.
Place the mold in a safe place and let it cure for 24 hours.
Optional – after 1 hour place the mold under a heat lamp to speed cure.
Once the Flexane has hardened, remove the connector from the mold.
Cut the off the excess flashing using a straight edge and utility knife.
Trim off any flashing left on the metal body of the connector.
For PPT and Negative tether, cut the O-ring off the tether.
Locking Sleeve Installation
Install the snap ring over the connector. Lubricating the connector and snap ring makes
this job easier. Work the snap ring over the end of the connector using a small screw
driver. Use the female threaded locking sleeve to push the snap ring onto the metal part of
the connector. You may need to use a screw driver to get the snap ring past the end of the
rubber part of the connection.
IMPORTANT: Use a male threaded locking sleeve (short) on the female

tether connector and a female threaded locking sleeve (long) on the male
tether connector.
Male Threaded
Snap Ring Locking Sleeve
Female Tether Connector
Place the correct locking sleeve over the connector with the threaded side towards the free end of the
connector. Screw on the mating locking sleeve tool and place the assembly in a vise. Using a pair of
small screw drivers, work the snap ring down into the groove in the locking sleeve. The groove in the
male locking sleeve is about halfway down and the groove in the female locking sleeve is at the top. Start
by working one side of the snap ring down into the space between the locking sleeve and the connector.
Then, work your way around the connector sleeve until the snap ring snaps into place in the groove within
the locking sleeve.
Install Strain Relief in Position
Print the serial number and position the clear heat shrink about 2” behind molded
connector. (hidden under the strain relief) Position strain relief and oval threaded
connector behind the molded connector.
Tighten zip tie.
Center the 3” section of 0.8” shrink tubing on the zip tie. Then wrap the tether strain relief
with metal tape (three times around). This is to keep the strain relief from melting when
the heat gun is used on the shrink tubing.
Place metal tape on the other end of the shrink wrap, on the tether.
Use a heat gun and shrink the heat shrink tubing. Be sure to not overheat (and possibly
melt the strain relief mesh or tether jacket).
Remove the metal tape.
Finished tether connecter and strain relief assembly

Tether Termination and Strain Relief Assembly Instructions Rev6-1

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Procedure: Document Number: VR-T-01-01 Section: 1 Rev: 3.

4.0 Time for Assembly

5.0 Tools required

Female Termination Oval Threaded

0.5” x 1” Clear Zip Tie

Additional items included but not shown in the photograph:

Additional Tools required, but not provided

Disposable mixing cup

Figure 9 – Pin numbering is clockwise on the male

Pin Function Tether Color Tether Conductors*

Male and female tether connectors

Install Tether Strain Relief

The Tether is now ready for preparation.

Solder the Connection

Pin Function Tether Color Tether Conductors*

After applying heat, remove the aluminum tape.

Make sure this section is sanded & primed

Tether Mold Preparation

Potting the Connections

Locking Sleeve Installation

IMPORTANT: Use a male threaded locking sleeve (short) on the female

Female Tether Connector

Install Strain Relief in Position

Tighten zip tie.

Remove the metal tape.

Finished tether connecter and strain relief assembly

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