In developing the ICOS10 ASSIMILATE SENSOR HUB, I needed to verify the panel circuits as they were made. Also as the pins were being soldered on the 3P headers, I wanted a 3P male pins inserted in them to stop any deformation during soldering. Also key to this design: I had already developed a circuit tester for the 6 wire IDC cables.

Okay the constraints were:

Used in conjunction with the HEADER JIG during soldering on the panels.
Used after full assembly of the ICOS10 if needed.
Reuse the IDC CABLE TESTER.
Be able to run the continuity and isolation tests.

The approach I took was:

Have a simple IDC 6 wire cable from the IDC HEADER installed on the panel to one header on the IDC CABLE TESTER.
Use a 1" Double sided protoboard to breakout 6 male pins, fitting the ASSIMILATE SENSOR BREAKOUT, and not obstructing use of the HEADER JIG. Also on the board is another IDC HEADER.
Have a simple IDC 6 wire cable from the header on the protoboard to the other header on the IDC CABLE TESTER.

Step 1: Materials and Tools

1" Double sided protoboard (1)

6 Wire Ribbon Cable (~60cm)

6 Pin Shrouded IDC Male Header (1)

IDC-6 Socket 2×3 Pins Connector (4)

Male Header (3P, 3P, 1P, 1P)

Hookup wire (~7)

Solder and Iron (1)

Wire Cutters (1)

Step 2: Preparing the Cables

There will be 2 cables created, using the same steps:

Cut 30cm of 6 wire ribbon cable.
Line up blue wire with arrow.
Loop the ribbon to the other side of the Middle part of the Socket.
Link the strain relief part into the other parts of the Socket.
Tighten slack out of ribbon and tighten Piercing part onto ribbon with fingers.
Place Socket in vice and tighten till all pieces fully compacted.

Step 3: Prepare the Protoboard

On the top, insert 1P Male Headers (1)(2) and 3P Male Headers (3)(4), and solder on bottom.
On the top, cut the pins on 1P Male Headers (1)(2) off at the plastic collar; these are used for spacers.
On the bottom, insert IDC Headers (5) with key to outside, and solder on top.
On the top, trace a white wire from WHITE1 to WHITE2 and solder.
On the top, trace a yellow wire from YELLOW1 to YELLOW2 and solder.
On the top, trace a red wire from RED1 to RED2 and solder.
On the top, trace a black wire from BLACK1 to BLACK2 and solder.
On the top, trace a green wire from GREEN1 to GREEN2 and solder.
On the top, trace a blue wire from BLUE1 to BLUE2 and solder.

Step 4: Next Steps

As stated in the constraints, we have the following scenarios:

DURING SOLDERING

Photos above after hot glue, but more sense to test after solder and before hot glue.

Assemble Header Jig parts as per instructions.
Attach 1" PCB Test Unit to 3P Headers on underside.
Continue steps to and including soldering the IDC Header.
Attach first IDC cable from Panel IDC Socket to first IDC CABLE TESTER IDC Socket.
Attach second IDC cable from 1" PCB Test Unit IDC Socket to second IDC CABLE TESTER IDC Socket.
Power up IDC CABLE TESTER with 5V Micro USB.
Turn SPDT on.
For continuity testing, leave all DIP Switches on, and all LEDS should glow.
For isolation testing, alternate off and on, and alternate LEDS should glow.

AFTER ASSEMBLY

Attach 1" PCB Test Unit to 3P Headers on outside of shell.
Attach first IDC cable from inside Panel IDC Socket to first IDC CABLE TESTER IDC Socket.
Attach second IDC cable from 1" PCB Test Unit IDC Socket outside to second IDC CABLE TESTER IDC Socket.
Power up IDC CABLE TESTER with 5V Micro USB.
Turn SPDT on.
For continuity testing, leave all DIP Switches on, and all LEDS should glow.
For isolation testing, alternate off and on, and alternate LEDS should glow.

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