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Soldering wires to deans-T connectors is a very important process.

There are two best methods of the soldering 'at home'. Both are characterized by a very low resistance.

Suggested tools:

  • Soldering iron

  • Solder, rosin

  • Pliers

  • Tweezers

  • Small vice

  • Sandpaper 600 (or finer)

  • Paper knife

  • Pincers

  • Scissors

  • Lighter

ATTENTION

  • Electrical resistance of solder is six times higher than resistance of copper. In general, solder serves as mechanical and electrical connection.

  • Always use flux or rosin when soldering. This is necessary to achieve the correct connection.

  • The 0.5 mm diameter wire can be made out of 8-conductor cable UTP (unshielded twisted pair).

  • It is suggested to use a copper wire, as an aluminum wire is prone to breaking.

FIRST METHOD

  1. Deans-t connectors preparation:

  • Clean out with fine sandpaper the part that is going to be soldered

1-1b1-1a

  • Cover it with a thin layer of solder (always use flux or rosin during soldering, especially when the solder melts. This is necessary to achieve the correct connection).

  • Remove excess solder

1-2a1-2b

 2. Wire preparation:

  • Put 2 cm of heat shrink tube on a wire

  • Take off the wire’s insulation to the desired length - about 6mm (using a knife, score carefully the external part of the silicone insulation. Then use your nail to pull it away)

  • Never twist subcables in a wire (twisting increases space between the subcables, which is going to be filled with solder)

3. Wire fitting and soldering

  • Attach the stripped wire to the contact

  • Pulling strongly, coil the contact around with the additional 0.5 mm diameter wire

  • Pour over the wires with solder. The tightly twisted wires should  perfectly fit the contact

1-3a1-3b

 4. Connection verification

  • Have a look at the connection and check if it is done properly. Pay attention to solder – it should fill soldered space correctly and solder should not be oxidised

  • Try to pull out the wire

1-4a1-4b

5. Protection of the soldered connection

  • Remove excess rosin from the connection

  • Prepare heat shrink tubes and close them

  • Heat the heat shrink tube carefully from all sides. Do it over the flame of a gas range or lighter

1-5a1-5b

SECOND METHOD

Second method is easier than the first one, but the connection parameters are a bit worse than in the previous method.

 1. Deans-T connectors’ preparation:

  • Clean out with fine sandpaper the part that is going to be soldered

  • Cover it with a thin layer of solder (always use flux or rosin during soldering, especially when solder melts. This is necessary to achieve the correct connection). 

  • Remove excess solder

2-1a2-1b

 2. Wire preparation:

  • Put 2 cm of heat shrink tube on a wire

  • Take off the wire’s insulation to the desired length of about 6mm (using a knife, score carefully the external part of the silicone insulation, your nail should pull it away)

  • Twist the subcables at a slight angle

  • Apply solder to the wire ends

2-2a2-2b

 

3. Soldering wire to the contact

  • Attach an end of wire to the contact, and hold it firmly with tweezers (using great force ensures the right connection)

  • Heat it and pour over with solder

2-3a2-3b

 4. Connection verification

  • Have a look at the connection and check if it is done properly. Pay attention to solder – it should fill soldered space correctly and solder should not be oxidised

  • Try to pull out the wire

2-4a

 5. Protection of the soldered connection

  • Remove excess rosin from the connection

  • Prepare heat shrink tubes and close them

  • Heat  the heat shrink tube carefully from all sides. Do it over the flame of a gas range or lighter

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