The termination shown in this document provides an optimal connection between the Sanken COS-11 microphone and the Lectrosonics WP watertight connector used on the MM400 Series transmitters, This procedure includes the installation of a .08″ x .05″ surface mount 1k ohm resistor.
Because of the tiny size of the components, a viewing aid is needed for all but the most vibrant, young eyeballs capable of macro focus. For the rest of us, a microscope or bench magnifier will be needed. The sequence shown here was completed with a stereo microscope set at 7X.
We used a thermal wire stripper called HOTweezers® made by and a registered trademark of MEISEI. We used the #32 wire opening. You can contact them by phone at 1-805-497-2626 or look on ebay.
IMPORTANT: Look through all steps before starting.
1) IMPORTANT: First, slide the tubing and connector shell over the wire as shown. If you have ever forgotten to do this or put it on backwards, then discovered it later after a beautiful soldering job, you have known true dismay and frustration.
2) Cut the end of the microphone cable square across.
3) Strip the outer insulation back 1/4 inch.
4) Separate the conductors, shield and reinforcing fibers. If your mic also has a drain wire, simply bundle it with the shield.
5) Trim the fiber and twist the shield.
6) Strip the insulation back about 1/8 inch from the black and white wires. This shows the HOTweezers® tool.
7) Tin the end of the shield and conductors.
CAUTION: Don’t overheat or over solder the shield since you might melt the insulation on the inner wires.
8) Insert tinned shield through hole in connector strap.
DO NOTÂ solder the shield to the connector yet.
9) Fill the cup on the center conductor of plug with solder.
10) Solder the black wire to the center conductor of the plug by inserting the tinned wire into the cup while heated.
11) Pull the shield far enough into the hole so that the shield takes the strain from the cable, leaving the black and white wires with slack. Solder the shield to the connector strap.
12) Use a .08″ x .05″ surface mount 1k ohm resistor. Tin the connector strap and resistor.
(resistors are available from Lectrosonics if you cannot find them locally)
13) Solder the resistor to the connector strap. Angle the resistor inward to clear the outer sleeve of the connector.
14) The resistor soldered in place.
15) Solder the white wire to the resistor.
NOTE: the fibers will mix into the solder for added strength.
16) Crimp the connector clamp around the outer insulation. Push the outer insulation up far enough to leave slack in the black and white wires.
17) The finished crimp. Make sure there is slack in the black and white wires.
18) Soldered, crimped and ready for final assembly.
NOTE: THIS STEP IS CRITICAL TO ENSURE A RELIABLE MECHANICAL CONNECTION
Final Assembly
IMPORTANT – SEE WPMC INSTRUCTIONS
Refer to the complete instructions provided in the manual included with the connector kit.
For a copy of the manual, click on the url below, the photo at left, or enter this url into your browser.
To complete the watertight assembly, follow the instructions provided in the WPMC connector kits. This involves injecting silicone sealant into the stainless steel shell and tubing to provide a watertight seal.
Use the links on this page, or call (800) 821-1121 or (505) 892-4501 and request a hard copy or e-mail of the file: wpmcman.pdf.
There should be no slack in the shield wire, only in the black and white wires. The outer insulation will stretch slightly, so you can pull it up a little to make sure the clamp tabs have a firm grasp on it.
The object is to make sure that when tension is applied by pulling on the cable, the stress will only be on the shield, not on the black and white wires.