Cable assemblies are the heart of any cable management system. You want to make sure they’re easy to work with and perform well. A faulty cable system can bring down a lot of problems and is one of the leading causes of fire outbreaks in establishments.
So, how do you know if your cable assembly needs fixing? Here are some pointers, which will be delved into further below:
- Know the Signs: Conduct Testing
- Possibility A: Insufficient Initial Testing
- Possibility B: Pressure Imbalance
- Possibility C: Micro-fretting
- Final Steps: Regular Maintenance
This guide will show you the various ways to troubleshoot your cable assembly and the possible issues your cable assembly may have. If you’d like to know more, keep reading!
#1 Know the Signs: Conduct Testing
To give your cable assembly proper troubleshooting, you should know precisely how you can test your assembly out for problems.
- Electrical Testing: This means testing the electrical performance of your cable assembly. Does the construction seem properly sound? Are they performing correctly? Here are some standard modes of testing out your cable assembly for issues:
Generally, you will need to look out for incorrect wiring, open wires, or possibilities of the wirings shorting out.
You can efficiently conduct electrical testing by hooking the assembly to an electrical fixture. With the help of a connector, you will tick all three boxes of the items mentioned above.
- Environmental Testing: This testing method is especially crucial if your cable assembly is located in a space with extreme conditions. What is the temperature like? What about the levels of humidity, salt spray, and vibration?
Some cable components are more resistant to specific environmental conditions than others. If your cable assembly is shorting out, and you think it is due to a change in the environment, perhaps it is time to replace some of these materials.
- Visual Testing: Check if the entire assembly seems to be visually present. Are there any components missing or appearing loose? Make sure every part of the assembly is correctly secured in place.
You should also keep an eye on any signs of damage. Examine each part and look out for any evidence of corrosion or deterioration.
This testing method will be significantly easier if your cable assembly incorporates a sound marking system. This can consist of properly coloring the wires or labeling But even if you’re a pro, it’s always best to try everything again before installing it.ach component.
- Mechanical Testing: Make sure the properties of the cable assembly meet the requirements. Check the length, strength, flexibility, impact, and crush resistance.
- Signal Integrity Testing: This means testing the assembly’s capability of carrying signals. It also measures the strength of the signals and whether or not it fluctuate if it is connected to splicers and filters. Perhaps the issue lies in the crosstalk between wires or other cable systems, for example.
Furthermore, the types of issues that you might find from troubleshooting can vary wildly. A way to categorize these issues is by determining whether they are constant or intermittent.
Constant errors are noticeable at all times. Essentially, they are solid defects. Meanwhile, if a mistake is intermittent, that means it does not occur consistently. Hence, sporadic errors tend to be harder to spot than constant errors.
#2 Possibility A: Insufficient Initial Testing
Your cable assembly should have been tested in the factory to ensure that it will work properly with your equipment. If your cables haven’t been appropriately tested, there’s a good chance they won’t perform as expected. But even if you’re a pro, it’s always best to try everything again before installing it.
Cable certifiers are handy tools for troubleshooting your assembly. This tool is meant to help you identify all the cables and connections in your assembly.
This tool can be very useful when dealing with crosstalk issues, especially if you’re dealing with older cable assemblies that have many different wires. This can help determine which wires are causing the problem, so you can decide on what type of repair you need to do to resolve it.
You can also use this tool for testing purposes to check for electrical hazards or circuit problems that faulty cables might cause.
You’ll want to ensure that all of your components are properly aligned so that they’re able to connect with the correct ports at both ends when they’re put together in an assembly.
Ideally, your cable assembly and its components would have gone through a thorough testing period before being shipped to you. They should be following standardized laws and regulations, which usually vary depending on where you are located.
This is why it is essential to check for certifications when you get your cable assembly. A good rule of thumb is to look out for a mark of approval from the International Electrotechnical Commission (IEC), the International Organization for Standardization (ISO), or the Underwriter Laboratories (UL).
However, the laws may differ from region to region, so make sure to do your research to determine what safety certifications your cable system should have.
All of these reasons are why a rigorous period of initial testing is highly advisable and why your cables must be all up to spec.
#3 Possibility B: Pressure Imbalance
Pressure imbalance can cause some of the most common problems in a cable assembly. When there is an imbalance between the two cables, one cable may start to feel loose or bulge out of its casing.
It could also appear twisted and kinked, making it hard to use appropriately. The result is that one end gets more stress than the other, causing all sorts of damage to your device and, sometimes, the entire system itself.
For example, equal pressure should be on both sides when a cable assembly is compressed. If you notice uneven pressure, the cables will likely come apart or develop micro-cracks in the connectors.
A pressure imbalance in the cable assembly can cause many unwanted things, such as eventual deterioration of the components and cable efficiency. The poor crimp in the imbalance pressure may cause the cables to fray over time.
These cracks may eventually result in complete disconnection of individual wires if they aren’t repaired quickly enough before significant damage occurs to their respective connecting points inside the cable itself.
If your cables are fraying, there are many options to try and remedy it. This includes using electrical tape, heat shrink tubing, or repurposing a spring to cover the fraying part of your cables.
This type of damage can be something that happens from wear and tear or because of proper installation in the first place. Make sure your cables have gone through a pressure test to avoid this.
#4 Possibility C: Micro-fretting
Micro-fretting, or fretting corrosion, is a condition that can occur when there’s a loose connection in the cable.
This micro-fretting can happen due to changes in heating and cooling cycles. It could be caused by static electricity or mechanical vibrations, for example. If you see small cracks in the cable, this is probably what’s happening.
The constant micro-motion movements can cause oxidation on the surface of the assembly. The result? Your component will no longer work properly, as the oxidation can lead to an open circuit, which could eventually end up in a signal loss or power failure.
The same thing happens if the wires are being pulled out of their sockets on either side of the connector. This often results in misaligned connections so that one end appears slightly longer than the other.
Using oil will give your assembly an extra layer of protection against possible corrosions. This is why you may want to invest in connector grease to minimize the chances of this happening. You can also check for micro-fretting by having a fretting wear test.
#5 Final Steps: Regular Maintenance
It’s crucial to maintain your cable assembly regularly. This will help you keep it in good working order and prevent any problems. Here are some things that you can do to help ensure a long lifespan for your cables:
1. Check the Sockets: When you’re connecting components, it’s important to ensure that all connectors are securely connected. You should also look for any signs of corrosion or deterioration on their surface, as this could indicate a weak connection.
2. Keep Your Cables Clean: There is no such thing as clean enough when working with cables; they need to be maintained at all times so that they remain in good condition and prevent them from becoming damaged or broken down over time.
Regularly wipe away dirt and dust with a cloth or paper towel, especially if there is something blocking the connections inside the cable itself – such as dirt buildup inside an Ethernet connector port on your network device.
4. Use Cable Ties: If you want to keep your cables in good condition, it’s important to use cable ties. These can help prevent a block from occurring inside the assembly and ensure that they are organized and neatly tied together.
5. Check the Connection Points: Make sure that all connections are secure and firmly connected.
In the end, it’s essential to know how to troubleshoot your cable assembly, as it can help you get the most out of your cable system. By reading this article, you will be able to make sure you are making the best possible use of your cables.
