This instructable will demonstrate how to create a serial control cable having a DB9 connector at one end and a Phoenix connector at the other.
This instructable is specific to OIT at COE-UGA. The resulting cable is only intended for use in this setting.
Step 1: Tools
These are the tools you will need:
Fine Slot Blade Screwdriver
Soldering Iron & Solder
1.5" of heat shrink tubing
male DB9 connector
You will also need:
4-pin Phoenix connector
Step 2: Identify Cable Type
OIT has two serial cables types; one with a blue connector, the other has a black connector.
The wires within each cable are colored differently, dependent upon connector color.
This demonstration will use the black connector.
The blue connector uses the same procedure, but with differently colored conductors.
Step 3: Snip Male Connector
Snip the MALE connector from the cable.
Step 4: Strip Sheath
Strip approximately 1" of the sheath. Be careful not to nick or damage the conducting wires.
Step 5: Snip Extra Conductors
Snip extra (unneeded) conductors. Remember, the conductor colors are dependent upon cable type (connector color).
For the BLACK connector, retain RED, BLUE, and BROWN conductors
For the BLUE connector, retain, ORANGE, GREY, YELLOW conductors
Step 6: Tin the Conductors
Strip approximately 1/4" of the insulation from each conductor and tin each conductor.
The Phoenix connectors are particularly notorious for coming loose if the conductors are not tinned.
For instructions on how to tin conductors, play the video below.
Step 7: Non-example
This a non-example of correctly tinned conductors. If the results of step 6 look like this, start over.
Step 8: Install Heat Shrink Tubing
Install the heat shrink tubing BEFORE securing the conductors to the connector.
Step 9: Secure Conductors
Secure the conductors to the a four port Phoenix connector. Remember, the connection sequence is dependent upon the cable type.
For a BLACK connector cable,
Slot 1 = blue
Slot 2 = brown
Slot 3 = red
For a BLUE connector cable,
Slot 1 = orange
Slot 2 = grey
Slot 3 = yellow
Step 10: Qualify Cable
Having secured the conductors in the connector, qualify the cable by measuring resistance between corresponding pins of the Phoenix connector and the DB9 connector. Also check for cross connections (short circuits)
Plug the DB9 connector into a blank male DB9 Connector. Test each pin pair for continuity.
Full continuity = 0 Ohms
Test across pins (i.e. pin 5 to poles 2 and 3). The circuit should be open (no continuity).
Step 11: Melt Heat Shrink Tubing
Gently apply heat, using the heat gun, to the previously installed heat shrink tubing to secure it. One achieves the best results by pushing the tubing towards the connector upon initial application of heat.
Step 12: Congratulations!
Congratulations, you have completed construction of the serial cable.