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Quiz Buzzer Lockout Player System

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CABLE REPAIR

 
Options
 

The cables used to connect NED modules to one another eventually wear out.
Unfortunately, no matter how sturdy a connector is, it occasionally needs to be repaired.

When cable ends break, you have several options:

  • Order new cables from NED
    Refer to this order form (click here) to order new cables.  New cables are the most expensive option, but if you're in a hurry, NED can have your order processed and your new cables to you in less than one week.
     
  • Order new cables from a supplier other than NED
    Many other suppliers, including your local RadioShack, sell cables that will work with your NED buzzer system. Your institution's computer-repair group may also have spare cables on-hand. The important thing to specify when ordering new cables is the following:
    > Connector Style: RJ45, 8 conductor
    > Wiring: "Straight-through" wiring ("pin 1 to pin 1")
    > Conductor Size: 24AWG is preferred, but 26AWG is acceptable (the lamps may be a little dimmer with the 26AWG cable).
    Important: damage caused by using the wrong kind of cable voids the system's warranty.
     
  • Have NED replace the broken cable ends
    NED offers CABLE REPAIR to its customers as an alternative to buying new cables.  The cost of the repair is $2 per cable.  When a cable is repaired, both cable ends are replaced.  When repairing cables, NED installs its exclusive snag-resistant connectors (click here for a picture of the connectors). 
    Procedure:
     Send broken cables to Novel Electronic Designs (use this order form -- suggestion: send cables via USPS Priority). We will bill you for the repair when we return your cables. We will have the repaired cables back to you a couple of days after we receive them. We charge $5 for shipping.
     
  • Replace the cables ends yourself
    If you have the right tools and a supply of cable ends, repairing the cables yourself is not difficult.  Simply follow these instructions.
 
Cable Repair (do-it-yourself option!)

 
CAVEATS

Cable repairs are very straight forward but you must have the right tools
or the repairs may be intermittent.

Good crimpers are industrial-grade and made of metal.
The only crimper we can recommend without hesitation is the following:
Tyco 2-231652-1
available at electronic distributors, including:
http://www.mouser.com/Search/Refine.aspx?Keyword=2-231652-1&Ns=P_SField
and
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail?name=A9900-ND

We strongly suggest that you test a cable after it's been repaired to
ensure that all 8 conductors are connected correctly. At a minimum, you can visually inspect both ends of the cable to ensure the order of the colored wires is the same. The best option is to obtain an electrical tester
(as shown in the following instructions).
If wires get out of order, modules can be damaged.

Tools needed for cable repair:
  • Crimper
    Cuts and strips wires; crimps connectors onto cables.
  • Tester
    Our experience has shown that testing cables is essential.
  • Plugs
    You can use any RJ45 plug. You can obtain plugs from your local electronics shop, or you can order them from us. Plugs are on our replacement part order forms and here.


Cable tester, plugs, and crimper.

Step 1:  Remove broken plug from cable.
 
   


A. Cut the cable.as close as possible to the old connector.


B. Cut it squarely, not at an angle.

   
Step 2: Strip the jacket from the cable.
   


A. Strip the cable. Be careful not
 to nick the wire insulation.


B. Wire ends be squared off (as shown)

   
Step 3: Push the wires into the plug.
       


Orient the wire color order the same way in both connectors. With the latching-tab towards you, the wire colors from left-to-right must match the order used on plug at the opposite end of the cable (as shown)

 


Note: latching tab is towards you. Also, note the left-to-right color order
(make sure both connectors
 are the same)


Seat cable firmly in connector.

       
Step 4: Crimp the plug.
         


Install the plug in the crimper.

 


Squeeze crimper until crimp is complete. Not squeezing hard enough will result in a "weak" crimp (which may result in intermittent connections).

 


The golden contacts must be fully seated (as shown).

         
Step 5: Test the cable.
   


A. Plug the cable into the cable tester.


B. Green LEDs means the cable is good. If any LEDs flicker, re-squeeze the plug with the crimper.

   

The cable is now ready for use!

 
 
 

The most durable electronics in the buzzer business… the highest level of commitment to customer satisfaction.
2006-2017, Novel Electronic Designs, Inc. *** Chillicothe, Illinois USA
Orders/Service: 309-224-9945   Fax: 309-274-8454
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Page Content Updated: 04 November 2008          Reviewed: 07 January 2017