The inter-enclosure communication cables used for LoCO are simple: essentially, we take a length of gel-filled Ethernet cable and attach a cable penetrator at each end. Then, we terminate the copper wires of the Ethernet to Dupont-type connectors and connect them to any cables which require cross-enclosure communication.

Currently, we use the inter-enclosure communication cables (IECCs) for passing an Ethernet connection and passing a signal from the power switch. In the future, serial connections, USB2 connections, or other types of communication could be achieved using these cables.

IECC Fabrication

Since these are waterproof cables, there will be gel inside them. Have plenty of paper towels nearby.

Cutting and Stripping ethernet cables

Cut the ethernet cables to length, leaving at least 4 inches on each side for the cable to go through the penetrator and have ample room inside to connect to electronics.

Strip the outer insulation. Don't close the stripping tool all the way, as it will cut the copper cables. The blade is very sharp, so just apply light pressure and rotate the cable.

Use paper towels to remove the initial gel, be sure to separate the 4 pairs of wires and clean the gel from in-between each individual wire. Remove as much gel as possible with the paper towels. I found that rinsing the cables with water, then letting them stand cause the gel to expand, making it easier to clean off.

You want these cables to be completely gel-free. In reality, this is difficult, but try your hardest to remove all the gel. The gel can cause the potting epoxy to form a poor bond to the cable, weakening the joint. We don't want this!

Once the cables are clean, follow follow Blue Robotic's tutorial on cable potting.

Now that the cables are potted, we'll start putting the terminating crimps on the wires.

Crimping cables

Start by untwisting the pairs of wires on one side of the cable.

Next, strip about 2mm of the insulation.

Now we're going use the red-handled crimper. Secure the wire with the magnetic clamp and position it in the 'A' slot of the crimper. The stripped end of the wire should be flush with the front face of the crimper.

All 3 of the communication wires and the tether will have male crimp terminals on them. Align one of the terminals on the wire, as shown in the picture below.

Hold the terminal with one hand and crimp with the other. The crimper won't open back up until it is all the way closed.

Now you should have a crimped on terminal!

If the terminal falls off, repeat the process. This may mean that the wire has too much insulation stripped off, so the terminal crimp has nothing to grab. You can try shortening the wire a tiny bit.

Crimp all remaining wires.

Next we'll solder the crimp terminals to the wire to ensure a good electrical connection and to help stop the terminal from falling off.

Finally, use heatshrink tubing to insulate the terminal.

Do this for all terminals.

Ethernet connectors for Raspberry Pi and Orbitty

For the Raspberry Pi and Orbitty carrier we need a receiving ethernet connector. We only need ~1.5 inches of exposed twisted pairs for the female crimps, then ~.5 inches of exposed wire on the other side for the RJ-45 connector. Follow the crimping directions listed above, but use female crimps instead of male crimps.

On the other side of the wire, we'll crimp onto an RJ-45 connector. No need to individually strip each wire for the connector, just insert the wires into the connector in this specific order -

Orange, OrangeStriped, Blue, BlueStriped, Green, GreenStriped, Brown, BrownStriped

Put the connector and wires into the crimper and crimp it in place.Since these are waterproof cables, there will be gel inside them. Have plenty of paper towels nearby.

Cutting and Stripping ethernet cables

Cut the ethernet cables to length, leaving at least 4 inches on each side for the cable to go through the penetrator and have ample room inside to connect to electronics.

Strip the outer insulation. Don't close the stripping tool all the way, as it will cut the copper cables. The blade is very sharp, so just apply light pressure and rotate the cable.

Use paper towels to remove the initial gel, be sure to separate the 4 pairs of wires and clean the gel from in-between each individual wire. Remove as much gel as possible with the paper towels. I found that rinsing the cables with water, then letting them stand cause the gel to expand, making it easier to clean off.

You want these cables to be completely gel-free. In reality, this is difficult, but try your hardest to remove all the gel. The gel can cause the potting epoxy to form a poor bond to the cable, weakening the joint. We don't want this!

Once the cables are clean, follow follow Blue Robotic's tutorial on cable potting.

Now that the cables are potted, we'll start putting the terminating crimps on the wires.

Crimping cables

Start by untwisting the pairs of wires on one side of the cable.

Next, strip about 2mm of the insulation.

Now we're going use the red-handled crimper. Secure the wire with the magnetic clamp and position it in the 'A' slot of the crimper. The stripped end of the wire should be flush with the front face of the crimper.

All 3 of the communication wires and the tether will have male crimp terminals on them. Align one of the terminals on the wire, as shown in the picture below.

Hold the terminal with one hand and crimp with the other. The crimper won't open back up until it is all the way closed.

Now you should have a crimped on terminal!

If the terminal falls off, repeat the process. This may mean that the wire has too much insulation stripped off, so the terminal crimp has nothing to grab. You can try shortening the wire a tiny bit.

Crimp all remaining wires.

Next we'll solder the crimp terminals to the wire to ensure a good electrical connection and to help stop the terminal from falling off.

Finally, use heatshrink tubing to insulate the terminal.

Do this for all terminals.

Ethernet connectors for Raspberry Pi and Orbitty

For the Raspberry Pi and Orbitty carrier we need a receiving ethernet connector. We only need ~1.5 inches of exposed twisted pairs for the female crimps, then ~.5 inches of exposed wire on the other side for the RJ-45 connector. Follow the crimping directions listed above, but use female crimps instead of male crimps.

On the other side of the wire, we'll crimp onto an RJ-45 connector. No need to individually strip each wire for the connector, just insert the wires into the connector in this specific order -

Orange, OrangeStriped, Blue, BlueStriped, Green, GreenStriped, Brown, BrownStriped

Put the connector and wires into the crimper and crimp it in place.

Usage

To use the IECC, connect each end's cable penetrator to the end cap of the enclosure, then connect the cables you need to whatever you've got that needs communication.