30/06/2022
So there we were, ERROR E/S NOT PRESENT. Why? Well we knew why. The transducer cable had taken a lot of movement at the stem of the thread over the years as it is a portable system. On and off, treat with care... At some point it has to break internally.
Well, we asked the manufacturer if they could re-terminate it and they said 'Nahhhh'. We asked a reseller that makes echosounders if they could re-terminate it and they said 'Sorry, broken too close to the thread, irreparable'. We asked a rental group with technicians skilled in this sort of stuff and they said 'We have a plan, it'll cost you!'. Well, not in those words but you get the point.
So I said, 'Team, it's no good like this. Let's cut 30mm from the stainless thread and re-terminate it ourselves'. Now Lino is a keen repairer and loves to cut things so I gave him the pliers...
Ok, so I removed the outer mesh without contemplating that it formed the Earth for the circuit. Yes, forgot to go to the schematic. We fixed that problem as well by using a segment from the offcut.
Next, Lena (our Intern from France) and I started the re-termination...
We used some natural fibre rope to insulate between the wires as this was similar to that in the cable to start.
We exposed the wire mesh at the cut ends, wrapped the offcut wire mesh around to join the ends and make the Earth. Tested the continuity and finished off with amalgam tape.
Next comes the syringe... A perfect cylinder in which to pour the 2 part epoxy flex resin, 15min work time, 12 hour set time.
And finally, yes, it works. Pinging like a champ and a repair bill of A$20 in parts, maybe an hour in labour.
So next time you have kit that is broken, out of warranty and you want to train your staff in the technical side of equipment, set yourself free and fix it yourself.