Geokon 4500HT-9-5 Manual

©2019, GEOKON, INCORPORATED. All rights reserved.
Document Revision: A | Release date: 1/30/19
4500HT-9-5 Sensor
Connection Procedure

WARRANTY STATEMENT
GEOKON warrants its products to be free of defects in materials and workmanship,
under normal use and service for a period of 13 months from date of purchase. If the
unit should malfunction, it must be returned to the factory for evaluation, freight
prepaid. Upon examination by GEOKON, if the unit is found to be defective, it will be
repaired or replaced at no charge. However, the WARRANTY IS VOID if the unit shows
evidence of having been tampered with or shows evidence of being damaged as a
result of excessive corrosion or current, heat, moisture or vibration, improper specifi-
cation, misapplication, misuse or other operating conditions outside of GEOKON’s
control. Components that wear or are damaged by misuse are not warranted. This
includes fuses and batteries.
GEOKON manufactures scientific instruments whose misuse is potentially dangerous.
The instruments are intended to be installed and used only by qualified personnel.
There are no warranties except as stated herein. There are no other warranties,
expressed or implied, including but not limited to the implied warranties of merchant-
ability and of fitness for a particular purpose. GEOKON is not responsible for any
damages or losses caused to other equipment, whether direct, indirect, incidental,
special or consequential which the purchaser may experience as a result of the instal-
lation or use of the product. The buyer’s sole remedy for any breach of this agreement
by GEOKON or any breach of any warranty by GEOKON shall not exceed the purchase
price paid by the purchaser to GEOKON for the unit or units, or equipment directly
affected by such breach. Under no circumstances will GEOKON reimburse the
claimant for loss incurred in removing and/or reinstalling equipment.
Every precaution for accuracy has been taken in the preparation of manuals and/or
software, however, GEOKON neither assumes responsibility for any omissions or
errors that may appear nor assumes liability for any damages or losses that result
from the use of the products in accordance with the information contained in the
manual or software.
No part of this instruction manual may be reproduced, by any means, without the written consent of GEOKON. The
information contained herein is believed to be accurate and reliable. However, GEOKON assumes no responsibility
for errors, omissions or misinterpretation. The information herein is subject to change without notification.
The GEOKON® wordmark and logo are registered trademarks with the United States Patent and Trademark Office.

FIGURES
FIGURE 1: DETACH THE 20 MM END PIECE USING VICE GRIPS ...................................... 1
FIGURE 2: SLIDE THE SWAGELOK NUT AND FERRULES ONTO THE SHEATHING ......... 2
FIGURE 3: MELT THE SOLDER AND ADHERE THE WIRES TOGETHER ............................ 2
FIGURE 4: HEAT SHRINK TUBING SECURELY BONDED TO THE WIRES ......................... 3
FIGURE 5: TWIST AND COIL THE WIRES TO SIMPLIFY INSERTING THE SPLICE ............ 3
FIGURE 6: TIGHTEN THE SWAGELOK ................................................................................... 4

GEOKON | 4500HT SENSOR CONNECTION PROCEDURE | 1
SENSOR CONNECTION PROCEDURE
If this splice will be subjected to high temperatures, all permanent materials
used in the splice must be rated for the anticipated temperature.
TOOLS AND MATERIALS
High temperature solder
High temperature heat shrink tubing (rated to more than 250 °C)
Grinder with cut-off wheel
Torch
Soldering iron
Wire cutters/strippers
Vice grips
Two 12mm (1/2") wrenches
File
PROCEDURE
1. On the length of cable to be spliced to a sensor, use an ohm meter to
ensure continuity for each signal wire from one end of the cable to another.
Also check that there are no short-circuits between each signal wire and the
stainless steel (SS) sheathing.
2. If there appears to be a problem with short-circuits or continuity, most likely
the problem is near the end where the signal wires are exposed. You can
use steps 3-5 to strip the SS sheathing back and prepare the end for the
splice.
3. Use the grinder with a cut-off wheel to score the tubing about 20mm from
the ends of each cable. Do NOT cut through the SS casing, due to the risk to
cutting the internal signal wires. Once scored, use the vice grips to work
that 20mm piece back and forth until it separates from the main section.
Discard this piece and ensure there are no nicks in the sheathing of the
internal wiring.
FIGURE 1: Detach the 20 mm end piece using vice grips

2| 4500HT SENSOR CONNECTION PROCEDURE | GEOKON
4. Slide the new 4mm Swagelok nut and ferrules on the SS sheathing, making
sure the orientation and order of the ferrules is correct. If the ferrules cannot
be put on, the end of the SS sheathing may be flared from cutting. Use a file
to remove the flare.
FIGURE 2: Slide the Swagelok nut and ferrules onto the sheathing
5. Strip the jacket off each of the four signal wires approximately 3mm to
5mm. Pre-tin the exposed ends with the high temperature solder. A
temperature of about 415 °C is recommended for GEOKON solder.
NOTE: High temperature solder contains lead (Pb). Slide an 8mm length
piece of heat shrink tubing on each of the four lead wires.
6. Overlap the pre-tinned parts of the corresponding signal wires from the
cable and the sensor. The black, red, and white wires of the sensor should
be attached to the matching wires of the signal cable. The green wire of the
sensor should be attached to the blue wire of the signal cable. Apply
enough heat to the overlapped wires to melt the solder and adhere the
wires together.
FIGURE 3: Melt the solder and adhere the wires together

GEOKON | 4500HT SENSOR CONNECTION PROCEDURE | 3
7. Slide the high temperature heat shrink tubing so it is centered on each of
the solder joints. Heat the shrink tubing so it is securely bonded with the
signal wires.
FIGURE 4: Heat shrink tubing securely bonded to the wires
8. Twist together and coil the wires in the piezometer so they become more
stiff and make inserting the splice easier.
FIGURE 5: Twist and coil the wires to simplify inserting the splice
9. Check continuity from the end of the signal cable to the transducer.
10. Check that there are no short-circuits between the black/red pair and the
blue/white pair, or to the SS cable housing. The black/red and blue/white
pairs should both read 50 Ohms ±5, although long lengths of cable can
affect this.
11. Slide the signal cable into the 4mm Swagelok on the back end of the
piezometer until it makes a positive stop, being careful not to pinch the
signal wires. Tighten the 4 mm Swagelok 270 degrees past finger tight with
the two 12mm wrenches (see Figure 6).
NOTE: If the ferrule of the 4mm Swagelok is already crimped on the tube, the
nut needs to be only slightly tightened with a wrench.
GREEN WIRE
BLUE WIRE

4| 4500HT SENSOR CONNECTION PROCEDURE | GEOKON
FIGURE 6: Tighten the Swagelok
Perform continuity and short-circuit checks to verify that the splice was
successful.

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