CAT7 CABLE PROCUREMENT SPECIFICATION...CAT7 Cable Assembly Procedure, Procurement Specification Doc No: H0020 -4201 002 Rev No: 01 Form Number SSA-00001E-001 Rev 02 Page 3 of 12 This

CAT7 Cable Assembly Procedure, Procurement Specification

Doc No: H0020-4201-002

Rev No: 01

Form Number SSA-00001E-001 Rev 02 Page 1 of 12 This document is the property of SARAO and shall not be used, reproduced, transmitted or disclosed without prior written permission.

Organisation : NRF (National Research Foundation) Facility : SARAO (South African Radio Astronomy Observatory) Project : HERA (Hydrogen Epoch of Reionisation Array) Document Type : Procedure, Procurement Specification Function/Discipline : Systems Engineering (0000)

CAT7 CABLE PROCUREMENT SPECIFICATION

Document number ........................................................................................ H0020-4201-002

Revision ............................................................................................................................... 01

Classification .................................................................................. Commercial in Confidence

Prepared By ............................................................................................................... Z Halday

Approval Date ............................................................................................... 26 January 2021


Doc No: H0020-4201-002

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DOCUMENT APPROVALS

Name Designation Affiliation Date Signature

Released By Z Halday HERA Project Engineer SARAO

DOCUMENT HISTORY Revision Date Of Issue Prepared By Comments (e.g. ECN Number or changes to document)

01 26 January 2021 Z Halday First Release

DOCUMENT DISTRIBUTION

Publish in eB and Distribute to all signatories on the document and the relevant line managers.

DOCUMENT SOFTWARE

Package Version Filename

Word Processor Ms Word Word 2016 H0020-4201-001 CAT7 Cable Assembly Procedure, Procurement Spec_REV1.docx

COMPANY DETAILS

Name SARAO, Johannesburg Office (Rosebank, Gauteng)

SARAO, Cape Town Office (Pinelands, Western Cape)

SARAO, HartRAO (Hartebeeshoek, Gauteng)

SARAO, Karoo Astronomy Reserve (Carnarvon, Northern Cape)

Physical / Postal

Address

1st Floor, 17 Baker Street Rosebank, Gauteng 2196, South Africa

2 Fir Street, Black River Park, Observatory 7405, South Africa

P.O.Box 443, Krugersdorp, 1740, South Africa

Posbus 69, Carnarvon, 8925, South Africa

Tel. 27 11 268 3400 +27 21 506 7300 +27 12 301 3100 +27 21 506 7300 Fax. 27 11 442 2454 +27 21 506 7375 +27 12 301 3300 +27 86 538 6836

Website www.ska.ac.za www.ska.ac.za www.hartrao.ac.za www.ska.ac.za

http://www.ska.ac.za/http://www.ska.ac.za/http://www.hartrao.ac.za/http://www.ska.ac.za/


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TABLE OF CONTENTS

1 INTRODUCTION ................................................................................................................................ 5

1.1 Background & Information ........................................................................................................ 5 1.2 Facility, Equipment, Resources & Materials Required ........................................................... 5

2 ASSEMBLY PROCEDURE STEPS ................................................................................................... 6


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ABBREVIATIONS

CAT7 Category Seven HERA Hydrogen Epoch of Reionization Array FEM Front End Module

Terminology

May Indicates a non-mandatory suggestion or permission.

Should Non-mandatory desire, preference or recommendation.

Shall Mandatory requirement.

Will Declaration of purpose or expression of simple futurity.


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1 INTRODUCTION

1.1 BACKGROUND & INFORMATION

The HERA project requires cat7 cable assemblies to be manufactured; these cables will be used to

connect the HERA front-end module (FEM) to the digitisation node. This document aims to detail the

procedure which shall be followed to manufacture the cable assembly.

1.2 FACILITY, EQUIPMENT, RESOURCES & MATERIALS REQUIRED

The table below summarises the facility, equipment, resources & materials needed for manufacturing.

Facility Equipment Resources Materials

1 x

electronics

assembly

bench

1 x cut

resistant desk

top mat

Access to a

mains power

supply

Electronics fine

point tweezers x1

One skilled

electronics

technician is

required to

complete the

assembly process,

an average of

90min is spent per

assembly

Belden CAT7 as cable, length as per

schedule

19mm combination

spanner x1

12.7mm adhesive lined heat shrink x2 100mm

pieces per assembly

2500mm water

pump pliers x1

25mm adhesive line heat shrink x1 40mm

piece per assembly

Flush cutters x1 0.25 inch tinned copper cable braid x1 10m

length per assembly

180mm wire cutter

x1

Harting RJ Industrial CAT7 connector – Part

No. 09 45 100 1560/99 00 x2 per assembly

Utility Knife x1 25mm adhesive lined copper tape – 1

x120mm piece per assembly

Cat cable tester

Sharpie x1

Tape measure x1

150mm ruler

Bench top vice x1

Hand held

magnifying glass x1

Heat gun x1

Anti-slip rubber

gloves x1 pair

Table 1: Facility, Equipment, Resources & Materials


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2 ASSEMBLY PROCEDURE STEPS

Step 1: Using the cable marking provided on the cable sheath, uncoil the specified length of cable from the drum. Using the wire cutters snip the cable at required mark. Visually inspect the cable for

any signs of damage while coiling the cable into a neat bundle.

Step 2: Using the tape measure, measure a 10m length of the tinned copper braid and cut to length as needed with the wire cutters.

Step 3: Thread the braid over the cat 7 cable, use gloves to protect your hands from any cuts while doing this.

Step 4: Using the measuring tape and the utility knife cut a 100mm length of the 12.7mm heat shrink. Thread this over the cable; leave it at the tail end of the cable braid junction.

Step 5: Using the measuring tape and the utility knife cut a 40mm length of the 25mm heat shrink. Thread this over the cable and keep at the connector end of the cable.

Step 6: At the connector end of the cable, push back the braid so that 300mm of the cat7 cable is exposed as shown in Figure 1.

Step 7: Unbox the connector, select the 7.5 - 8.6mm plastic grommet and thread the remaining parts on the cable in the order shown in Figure 1. Note the orientation of the grommet.

Figure 1: Connector Insertion Procedure


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Step 8: Strip back 40mm of the outer shield to expose the inner cores. This will reveal 4 foil covered twisted wire pairs as well as either a multi strand or single strand ground wire. Step 9: If the cable has a multi strand ground wire, twist them together and then trim the bundle with the wire cutters so that the exposed length is 10mm long. If a single strand ground wire is used, only trim to 10mm. Step 10: Using the wire cutter trim back the foil armouring on each of the four twisted pairs so that 10mmthe armouring remains. Step 11: Calm the cable in the desktop vice as shown in Figure 2. Step 12: Use your fingers to lightly compress the remaining foil armouring and ground wire to form a neat bundle as shown in Figure 2.

Figure 2: Step 8, 9, 10, 11 & 12


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Step 13: Using the ruler and wire cutters measure and then trim the blue-white and green-white

pairs so that 17mm remains as shown in Figure 3.

Step 14: Insert the blue and green pairs into the bottom slots of the Harting connector as shown in

Figure 3. Note that the wires should remain in their original pairings.

Step 15: Similarly insert the brown – white and orange – white pairs into the top of the connector

using the electronics fine point tweezers, again ensure that the remain in their original pairings, as

shown in Figure 3.

Step 13

Figure 3: Step 13, 14 & 15

Step 13

Step 14

Step 14

Step 15

Step 15


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Step 16: Ensure that all the cables are seated correctly, use a pliers to gently close the connector and

wait to hear an audible “click” once this is heard the connector has seated correctly and is closed.

Step 17: Install the shield by gently compressing the connector and shield together with a pliers, once an

audible click is heard the shield is seated correctly.

Step 18: Push the connector housing over the connector, ensure that the connector snaps onto the

insert, this is confirmed with an audible click.

Step 19: Clamp the connector housing in the bench vice and use the 19mm spanner to tighten the nut

until it sits flush with the connector housing.

Step 20: Run your hand along the length of the cable to bring the braid back over the connector such

that 10mm of braid sits over the connector nut. Use the glove on your hand when doing this.

Figure 4: Step 16 & 17

Figure 5: Step 18, 19 & 20


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Step 21: Measure and cut a 120mm piece of copper tape and wrap it around the connector nut and

braid. Clamp the connector in the bench vice when doing this.

Step 22: Slide the 25mm heat shrink onto the connector nut so that it sits flush with the housing, hold in

place with the water pump pliers and shrink in place. The fitment is complete once the adhesive liner can

be seen seeping out from the heat shrink.

Step 23: Hold the heat shrink in place for 30 seconds after removing the heat, allow the connector to

cool while still being clamped in the vice for an additional 2 minutes before removing. Ensure the

connector is cooled to a safe temperature before handling with bare hands.

Step 22: Once the heat shrink has cooled, using the glove over your hand run your hand over the braid

to stretch it out towards the tail end of the braid. Ensure that 50mm of the heat shrink installed in step 4

is on the cable and the other 50mm overlaps the cable braid assembly. Use the heat gun to heat in

place. Hold in place for 2 minutes to allow the glue to set.

Step 23: Repeat step 7 to 20 to install the connector on the other end of the cable.

Figure 6: Step 21, 22 & 23


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In addition to the 23 steps described above the following requirements shall be met:

[R1] The connectors used shall be Harting RJ Industrial CAT7 connector – Part No. 09 45 100 1560/99

00.

[R2] The cable used shall be Belden LSZH CAT7 cable.

[R3] The colour of the cable used in [R2] may be any available colour.

[R4] Each cable shall be serialised with a unique three-digit number. The serial number shall be visible

on both ends of the cable.

[R5] The length of each cable shall be clearly marked at both ends.

[R6] The markers used in [R4] shall be the Hellermann Tyton Ovalgrip Slide On Cable Marker, Pre-

printed, Black on Yellow type or an equivalent alternative.

[R7] A cable tester shall be used to test for faults such as: mis-wiring, short, reversed wires or broken

connections, in both the twisted pairs as well as the outer sheath.

[R8] A QC record of all tested cables shall be kept, this QC sheet shall be submitted along with any

deliveries. Example below:

Cable Serial Number Test 1: Pass/Fail Next Steps Test 2: Pass/Fail Next Steps

001 Pass Ship to client NA

002 Pass Ship to client NA

003 Fail Rework connectors Pass Ship to client

Pass – A cable that when tested with the method described in [R6], achieves a pass result as defined by

the OEM of the testing equipment.

Fail – A cable that does not meet the criteria described above.

[R9] Cables that fail the QC test, [R6], shall be reworked and retested until a pass result is achieved.

SARAO will sample 10% of the deliveries and retest as confirmation.


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[R10] The table below indicates the quantity and length of each of the required cables.

Item Number Cable Length (meters) Quantity Needed

1 420m 6

2 380m 8

3 360m 6

4 340m 5

5 260m 5

6 60m 6

7 50m 72

[R11] For item numbers 1, 2, 3, 4, 5, each assembly shall be delivered neatly coiled onto its own cable

drum.

[R12] Item number 7 shall be neatly coiled and bound so as to not uncoil during transportation. A drum is

not necessary for these assemblies.

[R13] Delivery shall be the following location:

For delivery to SKA SA Klerefontein Site (30°58'24"S 21°59'40"E)

Attention: Ms. Mathakane Molewa & Mr. Franklin Hartnick

1 INTRODUCTION1.1 Background & Information1.2 Facility, Equipment, Resources & Materials Required

2 Assembly Procedure Steps

Documents

CAT7 CABLE PROCUREMENT SPECIFICATION...CAT7 Cable Assembly Procedure, Procurement Specification Doc No: H0020 -4201 002 Rev No: 01 Form Number SSA-00001E-001 Rev 02 Page 3 of 12 This