Cable Splice Instructions

Tools and Materials Needed

  1. Coaxial Cable Splice Kit (#111058)
  2. Heat Gun
  3. Wire Cutter (suitable for cutting stainless steel)
  4. Wire Stripping Tool with 14-22 AWG (see photo)
  5. Crimping Tool with 14-22 AWG (see photo)
  6. Tweezers

solinst 102 water level indicator coaxial cable splice kit

Coaxial Cable Splice Kit (#111058)

 

Instructions

  1. To begin, cut the original cable at a FT or M marking. Cut the replacement (splice) cable at 3/100 ft (3 markings), or 10 mm (10 markings).

    2. cut locations on the original and replacement solinst 102 coaxial cables

    Note:

    You are starting with an extra 0.03 ft (10 mm) of splice cable to maintain the overall length of the Water Level Meter cable. During the splice you will be removing the extra 0.03 ft (10 mm).


  2. Prepare the cable ends that will be spliced together, the original cable and the splice cable, by doing the following:
    1. Use the recommended stripping tool (see photo below) to pre-cut the jackets using the 14 AWG size slot at 0.4" distance.
      recommended wire stripping tool 10-22 awg ideal #45-092 or similar to perform this procedure on solinst 102 water level meter coaxial cable
    2. Use the heat gun (7.5 setting if applicable) to soften the outer cable jackets by pre-heating for 5 seconds.
    3. Use the recommended stripping tool at the 14 AWG slot to strip the outer cable jackets by 0.40" (10 mm) to expose the braided shielding wires.
      solinst 102 coaxial cable shown with stripped tip
    4. Undo the braided shielding wires and push them back out of the way.
    5. Trim the centre leads to 0.30" (7.6 mm) from the shielding wires.
      solinst 102 coaxial cable shown with trimmed tip and sheilding wires pulled back
    6. Using the 18 AWG size slot, strip the inner insulation on the centre leads by 0.20" (5 mm).
      solinst 102 coaxial cable with inner insulation removed
  3. Slide the larger 1/4" diameter piece of Heat Shrink onto one of the cables, and push out of the way. Slide the Solder Heat Shrink Butt Splice onto the cable, and push out of the way. Slide the smaller piece of 1/8" diameter Heat Shrink onto the cable and push out of the way.
  4. Slide the stripped ends of both centre leads into the Stainless Steel Tube. The ends will be overlapping.
old and replacement solinst 102 water level meter coaxial cables lined up for crimping
  1. Using the crimping tool (see photo below), crimp the Stainless Steel Tube to the cable leads. Pull the cables to check the crimp connection.
crimp tool options
  1. Fold the shielding wires back over the Stainless Steel Tube, so the piece of 1/8" diameter Heat Shrink can slide over the wires.
crimped 102 coaxial cables with shielding wires folded back over the crimped splice
  1. Use the tweezers to pull the wires from underneath the 1/8" Heat Shrink.

    2. tweezers pulling the shielding wires on the 102 water level meter coaxial cable splice

    Note:

    Make sure there are no strands of wire left under the Heat Shrink. This could cause an electrical short in the splice


    shielding wires pulled out from under the heat shrink on the 102 water level meter coaxial cable splice

  2. Centre the 1/8" Heat Shrink over the Stainless Steel Tube.
heat shrink centered over the stainless steel tube on the 102 coaxial water level meter
  1. Use the heat gun to apply the 1/8" Heat Shrink.
activated heat shrink on the 102 coaxial water level meter
  1. Fold the shielding wires from both cables over the Heat Shrink. Start with the wires from the original cable, then overlap with the wires from the splice cable.
sheild wires placed over the activated heat shrink on the 102 coaxial wate level meter cable splice
  1. Before proceeding, check for proper electrical continuity by ensuring no shielding wires remain under the Heat Shrink. Do this by turning the Water Level Meter to the ‘ON’ position. If the buzzer or light turn on without pushing the test button, check for wires under the Heat Shrink.
  2. After confirming there are no shielding wires under the heat shrink, slide the Solder Heat Shrink Butt Splice over the shielding wires.
crimpping heat shrink on the solisnt 102 water level meter
  1. Apply heat to the middle of the Solder Heat Shrink Butt Splice, until most of the red band changes to silver (some of the red band may still be visible).
  2. Continue to apply heat to the ends of the Butt Splice, until they form a round shape around the jacket.

    3. Note:

    Do not overheat the Solder Heat Shrink Butt Splice at its ends, as this may melt the outer jacket of the cable.


    activated crimpping heat shrink on the solinst 102 water level meter

  3. Centre the 1/4" diameter piece of Heat Shrink over the Butt Splice, and use the heat gun to apply the 1/4" Heat Shrink.
activated heat shrink cover the cable splice on the solinst 102 water level meter
  1. With Probe in a glass of tap water, turn the Water Level Meter to the ‘ON’ position. If the connections are correct the buzzer and light on the Meter will be activated, and they will stop as soon as the probe is removed. Check the splice if the buzzer does not sound.