Wiring, Tools & materials, Locating the junction box & cable routing – Airmar CS4500-610—Ultrasonic Speed User Manual

Page 5: Preparing the cables, Be sure the power is ‘off

Wiring

Tools & Materials

Pencil
Drill
Drill bit: 3mm or 1/8"
Cutting pliers
Phillips screwdriver
Wire strippers
Heat-shrink tubing
Heat gun
Blade screwdrivers

Locating the Junction Box & Cable Routing

CAUTION: Minimize electrical interference by separating the
sensor cables from other electrical wiring and the engine.

CAUTION: Be careful not to tear the cable jackets when passing
them through the bulkhead(s) and other parts of the boat. Use
grommets to prevent chafing.

1. Select a convenient, dry, mounting location for the water-

resistant junction box, about 1–2m (3' – 5') from the instrument
(see Figure 6).

2. Route the sensor cable to the proposed location of the junction

box. Do not fasten the cable in place at this time.

3. Hold the junction box at the selected location and mark the

position of the four screw holes with a pencil.
NOTE: If the junction box will be mounted on a vertical surface,
face the compression bushings downward to avoid water
seeping into the box.

4. At the marked locations, drill a 3mm or 1/8" hole to a depth of

10mm (3/8"). Do not screw the junction box in place at this time.

5. Route the instrument cable to the junction box. Cut the cable

50cm (2') beyond the junction box to allow for wiring ease.
Do not fasten the cable in place at this time.

6. Route the power cable from the battery to the junction box.

Allowing 25cm (10") at each end for wiring ease, cut the cable
to length. Do not fasten the cable in place at this time.

Preparing the Cables

CAUTION: Be careful not to damage the printed circuit board.

Be sure the power is ‘OFF’.

Remove the junction box cover

and set it aside along with the screws (see Figure 7).

2. Carefully push approximately 200mm (8") of the power cable

through the left compression bushing.

3. Carefully push approximately 200mm (8") of the instrument

cable through the center compression bushing.

4. Carefully push approximately 200mm (8") of the sensor cable

through the right compression bushing.

5. Strip 60mm (2-1/2") of the outer jacket and foil shielding from

the cut ends of the power and instrument cables (see Figure 8).

NOTE: The grey wire is covered with protective sleeving and
this must remain in place.

6. Strip 11mm (3/8") of conductor insulation from the end of each

insulated wire in the power and instrument cables.

7. Protect the cable’s foil shielding from causing a short inside the

junction box. Place heat-shrink tubing around the jacket where
the wires emerge from the cable. It must overlap the wires a
minimum of 6mm (1/4"). Use a heat gun to shrink the tubing.

Figure 6. Cable layout

compression

Figure 7. Junction box

screw hole (4)

BR
N

WHT

GRN

BLK

RE
D

GR
N

BA
R

BR
N

RE
D

BL
K

BATTERY

INSTRUMENT

SENSOR

bushing (3)

sensor

instrument

power panel

(battery)

grey

wire with

protective

sleeving

60mm (2 1/2")

remove outer jacket

10mm

(3/8")

cable

jacket

remove

insulation

Figure 8. Preparing the cable—instrument cable shown

heat-shrink

tubing