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SPX Flow, Inc. – LIGHTNIN – 135 Mount Read Blvd., Rochester, NY. 14611

Lightnin Lab Procedure

Title: Strain Gauge Telemetry

Author:

Version Date Comments1.0 03/21/2016 First Issue

DescriptionThe purpose of this document is to detail the installation of strain gauge wiring to the gauges and plugs for the strain measurement telemetry system. Also detailed will be the installation of strain gauges and one time case assembly. An overall summary of the wiring can be described as solder each side of the strain gauges to SX+ and SX-, and connecting the other leads of the gauges in the middle and soldering to ground. This is illustrated in figure one.

Figure 1: Basics of strain gauge wiring

Created ByThomas J Klaben JR

Equipment List Soldering Iron

11 April 2016 Error: Reference source not found of 9


Solder 8 strain Gauges 3 conductor 22-28AWG Wire Shielded or not 4 Aircraft Grade 7 Pin IP68 Male plugs 2 Aircraft Grade 7 Pin IP68 Female Plugs Soldering stand Liquid Electrical Tape Adhesive Lined Heat Shrink wrap Heat Gun 4 colors of electrical tape to help coordinate wires

ResourcesLab technician

Reference DocumentsStrain Gauge Wiring Schematic “P16315 Strain Gauge Wiring Schematic”Wire Tables “P16315 Wire tables”



Procedure for Strain Gauge Wiring1. Plug in Soldering Iron and wait a few minutes for it to heat up.2. While iron is heating cut 4 sections of wire 12 inches long, or long enough to go from strain

gauge to shaft extension cable (one section per blade for installation of strain gauges).3. Cut four sections of cable a bit longer than the shaft length, enough to reach from bottom plugs to

telemetry case while ensuring at least 2 revolutions per foot around the shaft.4. Place copies of wire tables in front of soldering station for reference.5. While placing cable assemblies into plugs, use pieces of different colored tape, or tape with wire

numbers written on them to be able to know what wire is which went they are soldered into the plug.

6. Take plug and wire pins JP1-(1-3) with 3 signal wires in a cable assembly. Using wire tables and cable assembly one as reference for to and from location of wires.

a. Take plug and separate into its two pieces.b. Slide wires through the back side of plug (side without any pins) and remove a small

portion of the cable insulation.c. Using wire tables solder wires onto pins JP1(1-3) (Insert Pictures)

7. Take plug and wire pins JP1-(5-7) with 3 signal wires in a cable assembly. Using wire tables and cable assembly one as reference for to and from location of wires.

a. Slide wires through the back side of plug (side without any pins) and remove a small portion of the cable insulation from the wires.

b. Using wire tables solder wires onto pins JP1-(5-7)8. Check for good connections and then close the pieces of the plug together9. Check continuity of connections using a Multimeter and going from cable ends to pin coming out

of plug.10. If continuity is good then build up the wires size with adhesive lined shrink wrap until the plug

can be sealed tightly around the wires use heat gun to shrink but be careful of heat. (insert Picture)

11. Repeat steps 4-9 with plug JP2 and wire assemblies 3 and 4 (insert Final picture).12. Following wire tables and schematics take the shaft length sections of wire and two male and two

female plugs.13. Prepare to solder the plugs (INSERT PICTURES)

a. Solder all 6 wires to the female plug according to wire tables. Pins JR3(1-3 and 5-7)b. Check pins electrical connection with multimeterc. Again use adhesive lined shrink wrap to build up the wires in the plug to seal, but get two

pieces of each shrink wrap so the wrap for the other side will already be set out.d. Place other pieces of heat shrink tape on wire and then solder other ends to plugs JP3(1-3

and 5-7)e. Check all wires with multimeterf. Shrink heat shrink wrap and seal all wires and again check plug to plug conductivity for

marginal <2 ohms and ideal <1ohm.14. Repeat step 13 with plugs JP4 and JR4.15. Take the wires at the end of plugs JP1 and JP2 and remove a small amount of insulation from the

end of the wires.16. Using the Wire tables and schematics wire to the solder pads installed with the strain gauges.

Strain Gauge “TOP” is the gauge on the physical top of the blade and pin 1/5 gets soldered to the solder tab on the back side of the blade (closest to the non-leading edge



a. During soldering solder wire and strain gauge ribbon lead at the same time. b. Cut a small section of wire to go around the leading edge of the blade. Use this wire to

solder one tab from each strain gauge to pin 2 or pin 6 from the plug, this is ground of each circuit. (pictures)

c. Cut each strain Gauge lead after it is soldered so that none overhangsd. Repeat for all strain gauges. (pictures)

Procedure for Wiring Telemetry Extension Cable:1. Gather Wire, and 2 each male and female IP68 Aircraft grade plugs along with solder while

soldering iron heats up.2. Take two sections of three conductor wire and put through back end of a disassembled female

plug, remove a small amount of insulation. a. Solder Wires to plugs 1-3 and 4-6 for the second wire and then build up wire with

adhesive lined shrink wrap to fit snuggly in plug when assembled. b. Count exactly the number of pieces you used and place over the other end of the two

sections of wires.3. Place other end of wires through a disassembled male plug and remove small amount of

insulation off this end.a. Solder these wires to the inside of the plug according to wire tables but all wires should

be straight through. I.E. pin 1 on one end to pin 1 on the other endb. Use pre placed adhesive lined shrink wrap and build up wire so that plug fits snuggly

against the shrink wrap and reassemble all plugs. (pictures)4. Extension cable is now complete and can be placed between telemetry system and strain gauges,

repeat steps 2 and 3 for the second cable.



Acceptance/Validation Criteria1. All wiring prior to soldering of strain gauges has a low resistance (<2 ohms acceptable <1 ideal)

after wires are soldered into plug.2. All connections are waterproofed IE no exposed wire can be seen after procedure is completed.

Use a Multimeter to check first dry, and test again with connections in salt water to find any unsealed connections.

3. All connections checked with a multimeter for conductivity and sealed with liquid electrical tape as needed.



AppendicesWire Tables:



Strain Wiring Diagram:



Telemetry Wiring Diagram:



Extension Cable Wiring Diagram:
