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The cables used to connect NED modules to one another
eventually wear out.
Unfortunately, no matter how sturdy a
connector is, it occasionally needs to be repaired. |
When cable ends break, you have several options:
- Order new cables from NED
Refer to this order form
(click here) to order new cables.
New cables are the most expensive option, but if you're in a hurry,
NED can have your order processed and your new cables to you in less
than one week.
Order new cables from a supplier other
than NED
Many other suppliers,
including your local RadioShack, sell cables that will work with
your NED buzzer system. Your institution's computer-repair group may
also have spare cables on-hand. The important thing to specify
when ordering new cables is the following:
> Connector Style: RJ45, 8 conductor
> Wiring: "Straight-through" wiring ("pin 1 to pin 1")
> Conductor Size: 24AWG is preferred, but 26AWG is
acceptable (the lamps may be a little dimmer with the 26AWG cable).
Important: damage caused by using the wrong kind of cable
voids the system's warranty.
Have NED replace the broken cable ends
NED offers CABLE REPAIR to its customers as an alternative to buying new cables.
The cost of the repair is $2 per cable. When a cable is repaired, both cable ends are replaced.
When repairing cables, NED installs its exclusive snag-resistant
connectors (click here for a picture
of the connectors).
Procedure:
Send broken cables to Novel Electronic Designs (use this
order form -- suggestion:
send cables via USPS Priority). We will bill you for the repair when we return your
cables. We will have the repaired cables back to you a couple of days
after we receive them. We will charge actual shipping
expenses ($5 or less... for example, shipping for two short cable is
typically $1).
Replace the cables
ends yourself
If you have the right tools and
a supply of cable ends, repairing the cables yourself is not
difficult. Simply follow these instructions.
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Cable
Repair (do-it-yourself option!) |
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CAVEATS
Cable repairs are very straight
forward but you must have the right tools
or the repairs may be intermittent.
Good crimpers are industrial-grade and
made of metal.
The only crimper we can recommend without hesitation is
the following:
Tyco 2-231652-1
available at electronic distributors, including:
http://www.mouser.com/Search/Refine.aspx?Keyword=2-231652-1&Ns=P_SField
and
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail?name=A9900-ND
We strongly suggest that you test a cable after
it's been repaired to
ensure that all 8 conductors are connected correctly. At
a minimum, you can visually inspect both ends of the
cable to ensure the order of the colored wires is the
same. The best option is to obtain an electrical tester
(as shown in the following instructions).
If wires get out of order,
modules can be damaged.
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Tools needed for cable
repair:
- Crimper
Cuts and strips wires; crimps
connectors onto cables.
- Tester
Our experience has shown that testing
cables is essential.
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Plugs
You can use any RJ45 plug. You can
obtain plugs from your local electronics shop, or you
can order them from us. Plugs are on our replacement
part order forms and
here.
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Cable tester, plugs, and crimper. |
Step 1: Remove broken plug from cable.
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A. Cut the cable.as close
as possible to the old connector. |
B. Cut it squarely, not at an angle. |
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Step 2: Strip the
jacket from the cable.
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A. Strip the cable. Be careful not
to nick the wire insulation. |
B. Wire ends be squared off (as shown) |
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Step 3: Push the wires
into the plug.
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Orient the wire color order the same way in both
connectors. With the latching-tab towards you, the
wire colors from left-to-right must match
the order used on plug at the opposite end of the cable
(as shown) |
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Note: latching tab is towards you.
Also, note the left-to-right color order
(make
sure both connectors
are the same) |
Seat cable firmly in connector. |
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Step 4: Crimp the
plug.
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Install the plug in the crimper. |
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Squeeze crimper until crimp is complete. Not squeezing hard
enough will result in a "weak" crimp (which may result in
intermittent connections). |
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The golden contacts must be fully seated (as shown). |
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Step 5: Test the cable.
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A. Plug the cable into the cable tester. |
B. Green LEDs means the cable is good. If any LEDs flicker,
re-squeeze the plug with the crimper. |
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The cable is now
ready for use! |
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