OIT Serial Control Cable

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:
Diagonal Cutters
Wire Stripper
Fine Slot Blade Screwdriver
Soldering Iron & Solder
1.5" of heat shrink tubing
Heat Gun
Ohm-meter
male DB9 connector

You will also need:
Serial Cable
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.