- Electric Power Generation: All
- Engine:Industrial, Marine, and Generator Set that Use Flash Programming All
Introduction
This Special Instruction provides information for the installation of the 256-7512 Communication Electronic Control Module (PL1000E). Refer to Systems Operation, RENR8091 for more information about the 256-7512 PL1000E Communication ECM .
Do not perform any procedure that is outlined in this special instruction, or order any parts until the entire special instruction has been read and understood.
Refer to Special Instruction, REHS4498 for the required procedures to configuring and to programming the PL1000E.
Required Tools
The following tools will be required to install the 256-7512 PL1000E Communication ECM . The list below contains the recommended Caterpillar service tools.
| Part Number | Description |
| Laptop Computer | |
| JERD2124 | Caterpillar Electronic Technician (Cat ET) Version 2007B or later |
| JERD2129 | Date Subscription for all engines and machines |
| EERP1000 | Caterpillar Tool Kit Version 2007B or later |
| 171-4400 | Communication Adapter Gp (Cat ET TO ECM INTERFACE) (optional) (1) |
| 9U-7330 | Digital Multimeter |
| 7X-1710 | Multimeter Probe |
| 1U-5804 | Crimp Tool (12-AWG TO 18-AWG) |
| 175-3700 | Connector Repair Kit (DT) |
| Two short jumper wires (2) | |
| Long extension wire (3) | |
| 4 mm (5/32 inch) Allen wrench |
| ( 1 ) | The 7X-1700 Communication Adapter Gp or the embedded communication adapter of the ECM may also be used. |
| ( 2 ) | Two short jumper wires are needed to check the continuity of some wiring harness circuits by shorting two adjacent terminals together in a connector. |
| ( 3 ) | A long extension wire may also be needed to check the continuity of some wiring harness circuits. |
Parts List
| Required Parts | ||
| Quantity | Part Number | Description |
| 10 | 7K-1181 | Cable Strap |
| 4 | 8C-5608 | Spacer |
| 4 | 8C-8451 | Bolt |
| 8 | 9X-6165 | Washer |
| 8 | 9X-9896 | Isolation Mount |
| 4 | 117-1660 | Rubber Bumper (1) |
| 4 | 129-3178 | Locknut |
| 1 | 256-7512 | PL1000E Communication ECM with Flashed application software |
| 1 | 276-0785 | Harness Assembly |
| 1 | 228-6559 | Harness Assembly |
| ( 1 ) | The rubber bumper has an adhesive back. The rubber bumper is applied to the bottom of the ECM when shock mounting is not required. The rubber bumper is for use when mounting the ECM on a table or desk only. |
Additional Parts that may be needed
For most applications, the 276-0785 Harness Assembly will require additional wiring. Table 3 lists optional components that may be needed in order to complete the wiring for the intended application.
| Additional Wiring Components | ||
| Quantity | Part Number | Description |
| 1-70 | 9X-3402 | Connector Socket (16 AWG to 18 AWG) |
| 1-70 | 126-1768 | Connector Socket (14 AWG) |
| 1-3 | 163-5620 | Plug Assembly (DB-9 Style) |
| 1-3 | 163-6484 | Receptacle Assembly (DB-9 Style) |
| 1-3 | 162-1722 | Plug Assembly (DB-15 Style) |
| 1-2 | 163-5618 | Plug Assembly (DB-25 Style) |
| 1-2 | 163-5619 | Receptacle Assembly (DB-25 Style) |
| 1-4 | 5N-4988 | Isolation Diode (Single) |
| 1 | 7C-2668 | Isolation Diode (4 Pack) |
| 1-2 | 134-2540 | Receptacle Assembly (J1939 Terminating Resistor) |
| 199-9785 | Wire Assembly (Splice) | |
| 207-3814 | Wire Assembly (Splice) | |
| 115-8109 | Wire Splice (Single Sealed) | |
Some installations may require additional mounting hardware to secure the ECM to a mounting surface. The methods for installation are detailed in the ""Installation of the ECM Module" " section. Table 4 lists the optional components for mounting the ECM.
| Additional Components for Mounting the ECM | ||
| Quantity | Part Number | Description |
| 4 | Various | M6 X 1 bolt or weld stud (length varies depending on mounting method) |
| 4 | Various | M6 X 1 weld boss, nut, or similar fastener |
Considerations for Mounting the ECM
Identify a mounting location for the ECM. Measure the location in order to ensure correct spacing for the ECM "footprint" and the harness routing.
Keep in mind the mounting location of the PL1000E.
The PL1000E 256-7512 Communication Electronic Control Module v4, must be mounted in a location that will not expose the PL1000E to temperatures above 85 °C (185 °F). If the temperature at the location is unknown, mount the PL1000E in a location that can be properly ventilated.
The PL1000E 256-7512 Communication Electronic Control Module v3, must be mounted in a location that will not expose the PL1000E to temperatures above 70 °C (158 °F). If the temperature at the location is unknown, mount the PL1000E in a location that can be properly ventilated.
Determine the appropriate mounting method for each specific application. The mounting can be a shock mount or a desk mount.
| NOTICE |
|---|
For mounting applications where the ECM may be subjected to shock or vibration, use the shock mounting method. Use the desk mounting method for mounting applications where the ECM will not be exposed to shock or vibration. When mounting the ECM, orient the ECM so that the ECM connector is not subjected to high pressure spray or underwater submersion. Exposure to high pressure spray or underwater submersion may compromise the connector seal and lead to connection failure. When mounting the ECM, orient the ECM so that the ECM is not used as a "boot step" or a fulcrum point. The ECM is made of a high strength cast aluminum, but can still be damaged. |
Installation of the ECM Module
Desk Mounting Method
- When mounting the ECM on a stable surface such as a table or desk, assemble four of the 117-1660 Rubber Feet to the bottom side of the ECM. One rubber foot must be installed at each corner of the ECM. The bottom side of the ECM is the side opposite of the ECM connector.
- Place the ECM in the desired location on a flat level surface.
Shock Mount Method
There are several different methods in order to shock mount the ECM. Select a method that is appropriate for the intended application and environment.
Preferred Shock Mounting Method using weld bosses or weld studs
The preferred method in order to shock mount the ECM requires the use of weld bosses or weld studs. Refer to Illustrations 1 and 2.
- Locate the ECM template. Place the template in the desired location in order to mount the ECM. The ECM template is located in the "ECM Template" section that is located at the end of this publication. The ECM template is Illustration 18.
- Mark the location for each of the mounting holes.
- Remove the template.
- Weld the bosses or studs at the marked locations.
- Mount the ECM as shown in Illustration 1 or Illustration 2.
- Tighten each of the fasteners to 12 N·m (9 lb ft).
 | |
| Illustration 1 | g01111540 |
Example of the Shock Mount that Uses Bolts and Weld Bosses (1) M6 x 1, 43 mm (1.75 inch) bolt (2) 9X-6165 Washer (3) 9X-9896 Mount (4) 8C-5608 Spacer (5) 256-7512 PL1000E Communication ECM (6) M6 x 1 Weld Boss, Weld Nut, or Similar Fastener (7) Mounting Plate | |
 | |
| Illustration 2 | g01111773 |
Example of the Shock Mount that Uses Weld Studs (1) 256-7512 PL1000E Communication ECM (2) M6 x 1 Locknut (3) 9X-6165 Washer (4) 9X-9896 Mount (5) M6 x 1, 43 mm (1.75 inch) weld stud (6) 8C-5608 Spacer (7) Mounting Plate | |
Shock Mounting that Uses Bolts and Threaded Holes for Mounting
Shock mounting an ECM that use threaded holes will require the use of drilled and tapped holes to mount the ECM. Refer to Illustration 3.
- Locate the template for the ECM. Place the template in the desired mounting location. The template is located in the "ECM Template" section that is located at the end of this publication. The template is Illustration 18.
- Mark the location for each of the mounting holes.
- Remove the template.
- Drill a 4 mm (11/64 inch) hole at each marked location.
- Tap each hole with a M6 x 1 tap in order to provide the threaded holes for the M6 x 1 bolts.
- Mount the ECM as shown in Illustration 3.
- Tighten the bolts to 12 N·m (9 lb ft).
 | |
| Illustration 3 | g01111821 |
Example of the Shock Mount that Uses Threaded Mounting Holes (1) M6 x 1, 43 mm (1.75 inch) bolt (2) 9X-6165 Washer (3) 9X-9896 Mount (4) 8C-5608 Spacer (5) 256-7512 PL1000E Communication ECM (6) Mounting Plate | |
Shock Mount the ECM with the Use of Bolts and Through Holes
Shock mounting the ECM by use of through holes will require drilling four clearance holes. Refer to Illustration 4.
- Locate the template for the ECM. Place the template in the desired mounting location. The template is located in the "ECM Template" section that is located at the end of this publication. The template is Illustration 18.
- Mark the location for each of the mounting holes.
- Remove the template.
- Drill a 6.35 mm (0.25 inch) hole at each marked location.
- Mount the ECM as shown in Illustration 4.
- Tighten the bolts to 12 N·m (9 lb ft).
 | |
| Illustration 4 | g01111894 |
Example of a Shock Mount with the Use of Through Holes (1) 256-7512 PL1000E Communication ECM (2) M6 x 1 Locknut (3) 9X-6165 Washer (4) 8C-5608 Spacer (5) 8C-5607 Mount (6) Mounting plate (7) M6 x 1, Bolt minus the Length = 43 mm plus the Mounting Plate Thickness | |
Wiring Requirements and Installation
The purpose for the 276-0785 Harness Assembly is to provide basic power and communications capability with the 256-7512 PL1000E Communication ECM . The harness connectors are shown in Table 5.
| Connector | Part Number | Description |
| ECM | 160-7690 | 70 pin AMP rectangular plug. Provides the connection to the PL1000E Communication ECM. |
| Power | 3E-3376 | 4 pin Duetsch (DT) style rectangular receptacle. The connector provides ready access to the battery and key switch connections on the PL1000E Communication ECM. |
| Service Tool | 8T-8735 | 9 pin Duetsch HD-10 style round plug. The connector is the standard service tool connector found on most Caterpillar machine and engine connections that are for use with the 171-4400 Communications Adapter II or similar communications device. The communications device is connected to a PC serial port or parallel port allowing the PC to communicate with the Cat Datalink network or the J1939 No. 1 network using standard Caterpillar tools such as Cat ET. |
| Embedded Comm Adapter | 257-2719 | 9 pin AMP DB plug. The connector provides a similar function as the Service Tool connector expect that the connector can plug directly into a PC rather than must go through a 171-4400 Communications Adapter II or similar device. Refer to the section "Embedded Comm Adapter Connection Group" in Table 6 for more information. |
| NOTICE |
|---|
The technician must provide additional wiring in order to complete the installation of the ECM into a custom communication system. The 276-0785 Harness Assembly electrical diagram is shown in Illustration 5. The wiring of individual power and communications circuits is detailed in subsequent sections. |
ECM Connector and Wiring Harness Connections
 | |
| Illustration 5 | g01416941 |
Note: The 258-4548 Electronic Control Module is an ECM with out any software installed. After the software is installed that is used for the PL1000E, the part number becomes 256-7512 Communication Electronic Control Module (v3). The 256-7512 Communication Electronic Control Module (v3) can not be configured for RS-485 2 wire.
Note: The 285-1138 Electronic Control Module , Multi node v4, is an ECM with out any software installed. After the software is installed, that is used for the PL1000E, the part number becomes 256-7512 Communication Electronic Control Module (v4). The 256-7512 Communication Electronic Control Module (v4) can be configured for RS-485 2 wire or RS-485 4 wire.
Refer to Illustration 5 for possible connections that can be made to the 256-7512 PL1000E Communication ECM for specific applications. The connection groups that are shown in Illustration 5 are described in Table 6. Use only the connection groups that are necessary for the specific application.
Note: Most of the connection groups require special configurations of the 256-7512 PL1000E Communication ECM . In order to make the changes, use Cat ET 2007B or higher or Cat Toolkit 2007B or higher as shown in Table 1. Refer to System Operation, RENR8091 for specific information about these special configurations.
| Applications for the Connection Groups | |
| System Power Connection Group | The system power connection group provides a standard electronic control power connection between system power and the ECM. Refer to the section ""System Power Wiring Requirements" " for specific wiring requirements. |
| Cat Datalink (CDL) Connection Group | The Cat Datalink group provides a standard Cat Datalink connection. This connection must be used when using the PL1000E Communication ECM's Embedded Communications Adapter (ECA) feature to service a CDL compatible device using standard Caterpillar service tools, such as Cat ET. Refer to the ""Cat Datalink Communications Wiring Requirements" " section for specific wiring requirements. |
| J1939 Network Connection Group | The J1939 network connection group provides a standard "CAN" bus connection operating at a 250,000 baud rate. The J1939 network connection group must be connected in order to implement the PL1000E Communication ECM's J1939 to Modbus feature. Additionally, the J1939 network connection group may also be connected in order to facilitate connections to the J1939 compatible devices using the PL1000E Communication ECM's embedded communications adapter feature for standard Caterpillar service tools, such as Cat ET. Refer to "SAE J1939-11", "SAE J1939-15", and the ""J1939 Communications Wiring Requirements" " section for specific wiring requirements. |
| RS-485 Network Connection Group | The RS-485 Connection Group is capable of providing a RS-485 (4 wire or 2 wire or RS-422 connection that can be used for Modbus communications. The PL1000E Communication ECM must be configured for the appropriate protocol and baud rate. Refer to the System Operation Test and Adjust, RENR8091, "ECM - Configure" for available configuration values. |
| RS-232 Serial Connection Group 1 & RS-232 Serial Connection Group 2 |
The RS-232 serial connection groups provide a standard RS-232 serial interface programmable to operate in the range of 4800 to 115200 baud rate. The serial connection groups correspond to the PL1000E Communication ECM serial ports 1 and 2. Refer to the ""RS-232 Communications Wiring Requirements" " section for specific wiring requirements. |
| Embedded Communications Adapter Connection Group | The embedded communications adapter connection group provides a standard RS-232 serial interface. The interface can operate within a baud rate range from 9600 to 115000. The embedded communications adapter connection group must be connected in order to make use of the PL1000E Communication ECM's embedded communications adapter feature. The embedded communications adapter feature allows standard Caterpillar service tools, such as Cat ET to interface with a CDL device or a J1939 device. |
| Ethernet Connection Group | The Ethernet connection group provides an interface for use with the Modbus TCP, embedded web pages, and the FTP. This connection group may be installed for either a network connection or a cross over direct connection. |
Requirements for the System Power Wiring
The power connector in the 276-0785 Harness Assembly provides a direct connection to the switched power inputs and the power inputs that are not switched.
| NOTICE |
|---|
The 276-0785 Harness Assembly contains 218-4935 Arc Suppressors to protect the internal circuitry of the 256-7512 PL1000E Communication ECM from high voltage transients. DO NOT remove these transient devices from the 276-0785 Harness Assembly . DO NOT rewire the system to avoid the transient devices. If the transient devices are removed or if the system is rewired in order to avoid the transient devices, then the warranty for the 256-7512 PL1000E Communication ECM will be voided. |
The parameters for the basic power connections are shown in Table 7. Basic electrical connections are shown for single power sources in Illustration 6. Basic electrical connections are shown for multiple power sources in Illustration 7.
| Parameters for the Basic Power Connections | |||
| Parameter | Value | ||
| Min | Nominal | Max | |
| Voltage between BATT+ and BATT- | 9 DCV | 12 DCV or 24 DCV | 32 DCV |
| Current Draw (1) | 0.5A | 5A | |
| ( 1 ) | Provide fuse protection for the BATT+ and KEYSW to not allow the current to exceed 5 amps |
 | |
| Illustration 6 | g01145213 |
Example of the Connection for a Single Power Source | |
 | |
| Illustration 7 | g01145216 |
Example of the Connections for Multiple Power Sources | |
Additional information for power connections that must be considered:
- Minimum 18 AWG wire should be used for the KEYSW, BATT+, and BATT- connections and harnessing.
- The key switch connection "activates" the PL1000E. If a key switch does not exist in the electrical system, or if it is desired to have the PL1000E powered at all times, then connect the KEYSW connection directly to BATT+.
- The power supply that has the BATT- tied to a common ground for the system components that are used for a particular circuit, must also supply the power for the system components that are tied to that same circuit. Grounding requirements may vary from one application to another application. Consult the system schematics and other system documentation for grounding requirements.
- Provide fuse/circuit protection for BATT+ and KEYSW. The fuse protection must not allow the current to exceed 5 amps.
- Provide diode isolation in circuits that have multiple power sources. The diodes isolate the power sources and allow the PL1000E to remain powered if at least one power source is operational.
- Use good wire routing practices and wire securing practices in order to avoid damage to the cable.
- Route the cable in order to avoid inducing electrical noise into the cable from high power and sources of high frequency.
- Install the 8T-8737 Seal Plugs into any unused sockets at the rear of the connector.
Requirements for Wiring Cat Datalink Communications
The Cat Datalink communications connection provides a connection between the PL1000E and the Cat Datalink network.
The use of "Boost Disabled" or "Boost Enabled" can determine the physical location for installation of the PL1000E.
The PL1000E can be installed close to the system with the use of "Boost Disabled" as long as the total network wiring length of 30.5 m (100 ft) is not exceeded.
The PL1000E can be installed at further distances away from the system with the use of "Boost Enabled" as long as the total network length of up to 305 m (1000 ft) is not exceeded.
The distances for wiring are dependent on wire gauge, wire resistance, and capacitance of the cable. Refer to Table 8 for specific requirements for wiring and basic parameters. Basic electrical connections are shown in Illustration 8 and Illustration 9.
Note: This note applies to the 256-7512 Communication Electronic Control Module v3, 258-4548 Electronic Control Module v2, and to earlier versions. If the PL1000E is to be removed from system power, the CDL Boost function must be disabled in order to prevent internal backup battery drain. If the PL1000E is removed from system power with CDL Boost enabled, the PL1000E internal backup battery will be depleted in as little as 24 hours.
| Port Characteristics for Cat Datalink | |||
| Parameter | Value | ||
| CDL Boost Disabled | CDL Boost Enabled | ||
| Maximum Cable Length (1) | 30 m (100 ft) 16 AWG wire |
300 m (984 ft) 18 AWG wire |
|
| Maximum Capacitance of the Cable (2) | Conductor to Conductor | .0023 µF | .035 µF |
| Conductor to Shield | .0044 µF | .006 µF | |
| Maximum resistance of the cable for a single conductor (3) | 0.43 Ω | 6.5 Ω | |
| Maximum number of devices (4) | 11 | 11 | |
| ( 1 ) | This length is the total length of all wiring in the Cat Datalink network, including the wiring for the ECM. Refer to Illustration 10 for an explanation in order to properly calculate cable length. |
| ( 2 ) | In order to measure the capacitance of the cable, disconnect all of the devices from the network at the connection for the device. The wires for the network must be open between the two conductors. Measure the capacitance between the two wires. |
| ( 3 ) | In order to measure the resistance of the cable, disconnect all devices from the network at the connection for the device. The wires for the network must be open between the two conductors. Short the wires together at the PL1000E. Measure the resistance between the two wires at all of the connections of the other devices. For the maximum reading taken, divide the resistance measurement by 2 and then compare to the value that is shown in this table. |
| ( 4 ) | This is the number of devices on the network including the PL1000E Communication ECM. |
 | |
| Illustration 8 | g01777158 |
Example of Typical Wiring for Cat Datalink Communications that Use the Service Tool Connector | |
 | |
| Illustration 9 | g01777174 |
Typical Cat Datalink Wired to a 276-0785 Harness Assembly . | |
 | |
| Illustration 10 | g01157209 |
Additional Cat Datalink connection information to consider:
- Connecting to the Cat Datalink network is NOT necessary for operation of the PL1000E Communication ECM.
- Connecting multiple Cat Datalink networks together, without properly configuring the ECM's that are on the networks, may cause communications conflicts among the ECM's and may cause possible shutdown of the engines or other devices controlled by the ECM's.
- If connecting to a Cat Datalink network, then connect to only one network .
- 16 AWG or 18 AWG common harness wire should be used for wiring the Cat Datalink network as a twisted pair with 1/3 to 1 full twist per inch.
- Use good wire routing and wire securing practices in order to avoid damage to the cable.
- Run cable away from high power and sources of high frequency in order to avoid inducing electrical noise into the wiring.
- Each ECM that is installed on the Cat Datalink network must have power system connections that share a common ground (BATT-).
- Install the 8T-8737 Seal Plugs into any unused sockets at the rear of the connector.
J1939 Communications Wiring Requirements
The J1939 communications connection provides a connection between the PL1000E Communication ECM and the J1939 network. The J1939 network contains a bus along with wiring in order to connect the nodes to the bus. The bus is terminated on each end in order to complete the network. Table 9 shows the parameters for the J1939 network and Illustration 11 shows a typical J1939 network layout. Illustration 12 and Illustration 13 show electrical connection methods for J1939.
| J1939 Port Characteristics | ||
| Parameter | Value | |
| Shielded (SAE J1939-11) | Unshielded (SAE J1939-15) | |
| Maximum Nodes (n) | 30 | 10 |
| Maximum Length of the Bus (1) (L) | 40 m (132 ft) |
|
| Maximum Length of Stub Wire (2) (S) | 1 m (3.3 ft) |
3 m (9.8 ft) |
| Node Distance (d) | 0.1 m (0.3 ft) to 40 m (131 ft) |
|
| Minimum distance to terminating resistor (d0) | 0.0 m | |
| Terminating Resistors (RT) | 120 Ω, 0.5 Watt | |
| ( 1 ) | Do not include cable stubs in the calculations. |
| ( 2 ) | Subtract 0.33 meters if the cable stub is for a service port connector. |
 | |
| Illustration 11 | g01157211 |
Typical J1939 Communications Network Layout | |
 | |
| Illustration 12 | g01157214 |
J1939 Communications Wiring that Uses Service Tool Connector | |
 | |
| Illustration 13 | g01157218 |
J1939 Communications Wiring - Alternate Routing of 276-0785 Harness Assembly | |
Additional J1939 connection information to consider:
- A terminating resistor must be connected to both ends of the J1939 communications bus for proper operation of the network.
- 16 AWG or 18 AWG common harness wire should be used for wiring the J1939 network as a twisted pair with 1 full twist per inch.
- Use good wire routing and wire securing practices in order to avoid damage to the cable.
- Run cable away from high power and sources of high frequency in order to avoid inducing electrical noise into the wiring.
- Each device that is installed on the J1939 network must have power system electrical connections that share a common ground (BATT-).
- Install sealing plugs ( 8T-8737 ) into any unused sockets at the rear of the connector.
RS-485 and RS-422 Harness Requirements
The RS485/422 connection that is on the PL1000E allows for the communication of the Modbus protocol. The basic parameters are shown in Table 10. Basic electrical connections are shown in Illustrations 14 and 15.
| RS-485 Port Characteristics | |
| Parameter | Value |
| Maximum Cable Length | 305 m (1000 ft) |
| Maximum Capacitance of the Cable from one Conductor to another Conductor (1) | .022 µF |
| Maximum Resistance of the Cable for a single Conductor (2) (3) | 39 Ω |
| ( 1 ) | In order to measure the capacitance of the cable, disconnect all of the devices from the network at each device. The wires for the network must be open between the two conductors. Measure the capacitance between the two wires. |
| ( 2 ) | In order to measure resistance of the cable, disconnect all devices from the network at each device. The wires for the network must be open between the two conductors. Short the wires together at the PL1000E Communication ECM. Measure the resistance between the two wires at all of the other connections for each device. For the maximum reading taken, divide the resistance measurement by 2. Compare the measured value to the value that is shown in this table. |
| ( 3 ) | 256-7512 v3 and earlier hardware requires a 120 ohm impedance matching resistors at each end. |
 | |
| Illustration 14 | g01416718 |
 | |
| Illustration 15 | g01416723 |
Additional information for the RS-485 connection that must be considered:
The PL1000E part number 256-7512 (v4) and beyond support RS-485 2 wire. Previous versions do not support Rashly 2 wire.
- 16 AUG. or 18 AUG. common harness wire should be used for wiring the Rashly network.
- Use good wire routing and wire securing practices in order to avoid damage to the cable.
- Route the cable away from high power and sources of high frequency in order to avoid inducing electrical noise into the wiring.
- Each device that is installed on the Rashly network must have power system connections that share a common ground (BATT-).
- Install sealing plugs ( 8T-8737 ) into any unused sockets at the rear of the connector.
RS-232 Wiring Requirements
The RS-232 communications connection provides a connection between the PL1000E and RS-232 devices. The connection conforms to EIA RS-232 standards. The connection will work with any RS-232 devices that also conform to the EIA RS-232 standards. Table 11 shows the parameters for connections for a RS-232 device. Illustration 16 shows a typical electrical connection to RS-232 devices.
| RS-232 Port Characteristics | |
| Parameter | Value |
| Maximum Length of the Cable | 30.5 m (100 ft) |
| Maximum Capacitance for the Cable from one Conductor to another Conductor (1) | .002 µF |
| Maximum Resistance of the Cable for a single Conductor (2) | 25 Ω |
| ( 1 ) | In order to measure capacitance of the cable, disconnect all devices from the network at the device. The wires for the network must be open between the two conductors. Measure the capacitance between the two wires. |
| ( 2 ) | In order to measure the resistance of the cable, disconnect all devices from the network at the device. The wires for the network must be open between the two conductors. Short the wires together at the PL1000E Communication ECM device. Measure the resistance between the two wires at each of the other devices. For the maximum reading taken, divide the resistance measurement by 2 and compare to the value shown. |
 | |
| Illustration 16 | g01157224 |
Additional RS-232 device connection information to consider:
- Either 16 AWG or 18 AWG wire should be used for all RS-232 serial port connections and harnessing.
- Use good wire routing and wire securing practices in order to avoid damage to the cable.
- Route the cable away from high power and sources of high frequency in order to avoid inducing electrical noise into the wiring.
- Each device that is installed must have power system connections that share a common ground (BATT-).
- Install sealing plugs ( 8T-8737 ) into any unused sockets at the rear of the connector.
Wiring Requirements for Ethernet
The Ethernet communications connection provides a connection between the PL1000E and Ethernet devices. The connection must conform to EIA 568-A standards. The connection must be able work with any Ethernet device that also conforms to EIA 568-A standards.
A minimum of "Category 5" Ethernet cable that meets ANSI/EIA/TIA-568-A building wiring standards must be used when connecting to PL1000E. The "CAT 5" rating will be printed on the jacket of the cable. A "Category 5" cable will meet specified requirements regarding loss and induction of undesired signals. There are restrictions on the maximum cable length for both 10 and 100 Mbits per second networks.
The following list is additional information that must be considered for connection of the Ethernet devices:
- Use good wire routing and wire securing practices in order to avoid damage to the cable.
- Route the cable away from high power and sources of high frequency in order to avoid inducing electrical noise into the wiring.
- Each device that is installed must have power system connections that share a common ground (BATT-).
- Install sealing plugs ( 8T-8737 ) into any unused sockets at the rear of the connector.
Building the Custom Harness Assembly
 | |
| Illustration 17 | g01112044 |
Connector Details for the ECM Harness (1) 160-7690 Connector (2) Allen Head Bolt (3) 8T-8737 Seal Plug (4) 126-1768 Connector Socket (14 AWG) or 9X-3402 Connector Socket (16-18 AWG) (5) Wire showing stripped length | |
- Refer to Illustration 17 and Illustration 5 to match the correct wires on the harness to the correct socket positions on the connector.
- Locate the sealing plugs that will need to be removed from the connector. Use a fully insulated piece of 18 AWG wire as a tool in order to push the sealing plugs through the connector body from the front side of the connector.
- Strip 7 mm (0.275 inch) of insulation from the end of each wire that is to be installed into the connector.
Note: Ensure that the wires are the correct gauge for the intended application.
- Crimp a socket onto the end of each stripped wire.
- Locate the correct position on the connector, then push the socket, with attached wire, into the connector body from the rear of the connector until fully seated.
- Repeat Step 5 for each wire and socket that is to be installed into the connector.
Connecting the Harness Assembly to the PL1000E Communication ECM
- Place the 160-7690 Connector Plug As , a 70 pin connector, of the harness assembly onto the ECM connector.
- Tighten the connector bolt with a 4 mm (5/32 inch) Allen wrench.
Connecting the Custom Harness to the System
Consult the system schematics for the specific application for information which will aid in the connection of the custom harness into the system.
ECM Template
 | |
| Illustration 18 | g01112325 |