University of Minnesota Unmanned Aerial Vehicle Research Lab Common Harness Wiring Instructions

1 Solder the 50 pin male harness connector Refer to the tab “50 Pin Male Harness Wiring” inside the Wiring Diagram spreadsheet –Solder ground and power wires to pins 16 and 17 of the 50 pin connector –Solder a female JST connector to the other end of the wires. The avionics battery plugs in to this connector

2 Referring to the 50 Pin Male Harness Wiring Diagram, solder the rest of the interconnections. Label the connectors as necessary. 6V out male JR servo extension I 2 C connector Ethernet connector COM 4 TTL connector COM 1 TTL connector Data dump connector COM 0 RS232 connector COM 1 RS232 connector NOTE: This harness does not include the 8 ADC signals or the ADC power and ground wires. Also, place female caps on all unused connectors coming off the 50 pin harness when installed in the aircraft to prevent shorting wires.

Referring to the 50 Pin Male Harness Wiring Diagram, solder the Ethernet receptacle breakout board and Data Dump switch. 3

Wing Harness Refer to the tab “Wing Harness” inside the Wiring Diagram spreadsheet –Solder the following: I 2 C connector Four aircraft telemetry wires (later to be soldered telemetry connector) –Cut the female ends of two servo extension wires. Strip the yellow signal wire back half way down the length of the extension. Solder the power and ground wires to pins 16, 22, 23, and 24 of the wing harness connector. See the next slide for a complete wiring harness diagram 4

5 Wiring Harness Diagram

Solder four actuator signal wires in between the wing harness and the Output 15-pin male D-Sub connector. Wire length is dependent on the particular aircraft size that the harness is to be used in. Four to six inches is typical. Use the “Wing Harness” tab of the wiring diagram to connect the four wing actuator wires. 6

Solder the two hanging Left and Right Aileron actuator wires to the Input A 15-pin female D-Sub connector. Refer to the Wing Harness wiring diagram Input A 15-pin D- Sub connector Output 15-pin D- Sub connector 7

Make two modified actuator extension wires for the Throttle, Elevator, and Rudder actuators. Clip the female JR plug off of the end of a servo extension wire. Pull the yellow signal wire back as far as the signal wires on the aileron servo extension wires were pulled (see slide 3). Take another servo extension wire and clip it in half. Discard the male end. Pull back the yellow signal wire to about half the length of the extension. Solder the power and grounds together to form the extension shown below. 8

Solder the yellow signal wires on the male JR plug end of the servo extension to the Input A 15-pin female D-Sub connector. Clip two sets of servo extension wires to the same length as the other signal wires leading from the male JR connectors to the Input A 15-pin female D-Sub connector. Pull back the power and ground wires all the way to the male JR connector, and clip at the base. These single wires with a male JR connector at one end are to be soldered to the Input A D-Sub connector in the left and right flap nodes. Label each wire near the male JR connectors with the corresponding control surface. See next slide for a picture of the current step. 9

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Solder the throttle modified servo extension signal wires to the Input A and Output D-Sub connectors. The wire at the male JR end goes to the Input A connector, and the female JR end goes to the Output connector. Refer to the Wing Harness wiring diagram. For the gear switch servo wire, take a servo extension and clip the yellow signal wire at the female JR end. Pull the wire back to the same length as the other servo wires leading to the Input A connector, and clip off excess wire length if necessary. Solder the signal wire to the Input A connector, and label the male end with “GEAR”, and the female end with “6V”. The 6V end plugs into the 50 pin harness male JR connector. This powers the receiver. Refer to the Wing Harness wiring diagram, and plug in all of the male JR connectors to their respective slots in the receiver. Tie together groups of wires as necessary to fit nicely inside the aircraft. See next slide for picture of final wing harness. 11

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