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Tornado TV TAB DU: wire harness

wire harness permalink: http://www.amateurtele.com/index.php?artikel=324&id=#1483
The TV TAB is equipped wit a very impressive wire harness. The wire quality is very good and every wire is marked with a color coded number. The wire harness connects all the connectors and boards. It's suprising that tie-wraps are used instead of wax wire. Tie-wraps tend to age and degrad in time. Wax coard takes less space, isn't sharp and doesn't age. It seems that high end quality tie-wraps are used and using tie-wraps takes less effort in making the wire harness and probably is 'good anough'. The part number is V22.498.815.

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connections permalink: http://www.amateurtele.com/index.php?artikel=324&id=#1489
Point to point connections are made directly. Every connector pin has only one wire connected. When a junction of more than two pins is needed, a solder joint is used. The solder joints are protected by shrink tubing. The open end of the tubing is insulated with a plastic 'plug'. All the interconnection joints are secured in the wire harness. The secured joints are shown on the rear part of the wire harness on the image below. The wire harness part in the front shows the joints after removing the tie-wraps. Every wire is clearly marked with a colour coded number.

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reverse engineering (raw data) permalink: http://www.amateurtele.com/index.php?artikel=324&id=#1490
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unsorted images permalink: http://www.amateurtele.com/index.php?artikel=324&id=#1491
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wire coding permalink: http://www.amateurtele.com/index.php?artikel=324&id=#1492
The engineering of the device is amazing! The quality is great and it's very nice to see that the device is built logical and well thought. See the image below for example. Every wire is marked with a number. Due to the large amount of wires, coloured wires are probably not that practical. So almost every wire is white. To distinguish every wire, every wire is coded with a 0...9 number. This is very convenient for service. The thing I'm surprised by, is that every number ring is also colour coded according to the resistor table! Black = 0, brown = 1, red = 3 and so on. So if the number is unable to read, it's possible to know the number based on the colour code. This is convention since the number is 'always' at the opposite side of the viewing angle. ;-) There are a maximum of four digits used. The digit towards the end of the wire is the least significant number. For example: If red, blue and green is used as marking where red is towards the wire end, the wire number is 265. Every piece of wire had a unique number. The conductor of a coax and the shielding has a different number. But the wire type and colour are relevant! It's possible that a white wire and a green wire can have the same number. For example, the three phase 208 VAC 400 Hz main power input wires are all three marked with [308] but the colours are red, yellow and blue. Another exception is that a double coax wire can have the same number. The two coax cores are distinguished by a black line on the coax insulator. After finding out the system of coding its 'just' a matter of ours redrawing the wire harness connections. This is relevant for (non destructive) reverse engineering parts of the device. I think green wires are used for power and I think white wires are used for internal communications. But this has to be validated yet...

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connector permalink: http://www.amateurtele.com/index.php?artikel=324&id=#1497
After a lot of research I found out that the conncetor type is Series II JT.

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rear panel permalink: http://www.amateurtele.com/index.php?artikel=324&id=#1520
The wiring goes to seven connectors and one hour counter at the rear panel.

identification
type
color
wire number
wire type
function
A
100 pin circular (f)
-
multiple
multiple
main connector: data/power
B
TNC (f)
green
8
coax
unknown (video in?)
C
TNC (f)
red
86
coax
unknown (video in?)
D
TNC (f)
violet
87
coax
unknown (video in?)
E
TNC (f)
brown
88
coax
unknown (video sync?)
F
TNC (f)
yellow
81
coax
unknown (video in?)
-
hour counter
-
84 (2x)
white wire (2x)
counter powersupply
-
circular
-
multiple
multiple
diagnose connector?

wirte links (raw data) permalink: http://www.amateurtele.com/index.php?artikel=324&id=#1521
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filtering (raw data) permalink: http://www.amateurtele.com/index.php?artikel=324&id=#1522
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pcb bus connections (raw data) permalink: http://www.amateurtele.com/index.php?artikel=324&id=#1523
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