RLE Cable Construction - Manual (Page 2)

Non-Sensing Cable Assembly
(White 4-conductor, plenum-rated cable, RLE #1657)
1 Spool the cable to the desired length (1' minimum to 100' maximum
recommended).
2 Strip the white jacket off of both ends (0.60") to expose the wires inside.
Place a boot (Part #2410), a grip (Part #2409) and the shrink tubing (Part
#2428 & 2550) over each end of the cable.
Note: Install in the previously stated order.
3 Strip the wires 0.10” on both sides.
4 Crimp the connector sockets (Part #1295) on one side. Crimp the connector
pins (Part #1296) on the opposite side.
5 Snap the sockets into the plug (Part #1298). Snap the pins into the
receptacle (Part #1294). White: pin 1; Black: pin 2; Green: pin 3; Red: pin 4.
6 Shrink the heat shrink tubes with a heat source 1 inch from the plug and
receptacle as shown below.
Note: Place the smaller shrink tube inside the larger one and shrink together.
7 Screw the grips onto the plug and receptacle as shown below.
8 Screw the boots onto the grips as shown below.
9 The finished cable should look like the one below.
Testing Cable Once It’s Complete
All the sensing cables produced at RLE are tested for quality and continuity
before they are shipped. When you create your own cables, you should test them
as well.
Pin and socket mapping for the cable connectors is as follows:
To test your finished cable, you will need an ohmmeter with a pointed probe tip
on one lead and a miniclip or microclip on the other lead.
1 Insert the probe tip in the connector socket.
2 Attach the miniclip to the corresponding connector pin. If the cable has
been constructed properly, the ohmmeter will register values according to
the table below:
Shrink Tube Part #2505 & 2550 Grip Part #2409
Boot Part #2410 0.60”
Strip 0.10” (8 places, 4 per side)
Part #1295 Socket (4) Part #1295 Pin (4)
Part #1298 Plug Part #1294 Receptacle
Shrink 1.00” from plug
and receptacle
1.00” 1.00”
Screw grips onto plug & receptacle
Cable Pin Resistance Values
Pin Resistance +/- 10%
1 Less than 0.1 ohm per foot
2 2.8 ohms per foot (orange cable)
4.0 ohms per foot (purple cable)
3 2.8 ohms per foot (orange cable)
4.0 ohms per foot (purple cable)
4 Less than 0.1 ohm per foot