Installation Procedure for Cat® Product Link Generation (PLG6x1) {7606, 7610, 7620} Caterpillar

Electric Power Generation

All

Introduction

This Special Instruction provides instructions for installing the Cat^® Product Link Generation (PLG6x1). The PLG6x1 is capable of monitoring electric power assets remotely, while logging critical engine and generator parameters. The PLG6x1 transmits the data off-board into the Cat back-office systems to be viewed in a flexible Caterpillar user interface. The system consists of a module and wiring harness to allow connection to system power, and J1939 data links. Optional Modbus data links and analog/digital inputs are available on the device. The system is proposed for use on all electric power assets, both Caterpillar and competitive brands, providing a fleet solution for equipment owners. This kit is offered as an after-market attachment.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Cat^® Product Link Devices

PLG601 Ethernet Device

The PLG601 records data over the CAN / J1939 and MODBUS data links, and sends the data to the User Interface through a local WAN network.

Illustration 1	g06051386

PLG641 Cellular Device

The PLG641 cellular radio records data over the CAN / J1939 data link, and sends the data to the User Interface through the cellular network or local WAN network. Current GPS location can also be tracked with this device.

Illustration 2	g06051387

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Only persons with training in electrical installations must carry connections to the generator. The generator must be wired correctly. A fire or electrocution could result from wiring that is incorrect. The generator is capable of generating high voltages. Ensure that the generator is not on while the connections are being made. Follow these steps in order to prevent accidental starting: Isolate the machine from all external loads and sources. Shut off the Engine. Disconnect the battery supply lines and tape the leads.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Turn the battery disconnect switch to the OFF position and lockout the battery disconnect switch with a safety lock. Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the start switch and battery disconnect location to inform personnel that the machine is being worked on.

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Improper operation of an access platform could result in injury or death. Operators must carry out their duties properly and follow all instructions and guidelines given for the machine and access platform.

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Do not connect generator to a utility electrical distribution system unless it is isolated from the system. Electrical feedback into the distribution system can occur and could cause personal injury or death. Open and secure main distribution system switch, or if the connection is permanent, install a double throw transfer switch to prevent electrical feedback. Some generators are specifically approved by a utility to run in parallel with the distribution system and isolation may not be required. Always check with your utility as to the applicable circumstances.

Required Parts

Contents Of The 488-0991 Communication Installation Gp (PLG601)

The 488-0991 Communication Installation Gp includes the necessary hardware to install a PLG601 on a generator-set. The PLG601 and engine retrofit harness are included.

Contents Of The 488-0992 Communication Installation Gp (PLG641)

The 488-0992 Communication Installation Gp includes the necessary hardware to install a PLG641 on a generator-set. The PLG641 and engine retrofit harness are included.

Illustration 3	g06052074
90 degree Stub GSM (cell) ant 491-9576 Antenna As

Illustration 4	g06052075
GPS ant, adhesive mount, 4M cable 389-0463 Antenna As

Installation Components Not Included In Kits

Fuse Holder and Fuse

Note: The fuse holder and fuse are not included in the kit but are required for the installation.

Optional Antenna

Illustration 5	g06052080
Dual-mode antenna with isolation mounting kit 499-0689 Antenna As

In areas with reduced cell coverage, it is recommended that the Dual-Mode Antenna assembly kit 499-0689 Antenna As be used to replace the 90 Degree Stub GSM 491-9576 Antenna As and the 4M GPS 389-0463 Antenna As.

When using the Dual mode 499-0689 Antenna As, the antenna should have clear line of site to the sky. If more coax is needed, optional antenna coax extension harnesses can be used, refer to Table 5.

Installation Of The PLG6x1 System

Mounting Hardware

Refer Table 6 for the hardware provided in the kit for mounting the ECM:

Mounting Requirements

The mounting requirements are listed below:

• PLG6x1 must be mounted in a sealed location with no exposure to high-pressure spray or underwater immersion. Exposure to high-pressure spray or underwater immersion will lead to device failure.

• When using the PLG641 with optional dual-mode antenna, the external antenna must be mounted in a horizontal orientation.

• The standard GPS antenna and optional dual-mode antenna must have a clear line of sight to the sky. Usually, the canopy/ container roof will provide an optimal view of the sky with minimal blockages.

• Do not mount the PLG6x1 or antennas in an area with exposure to extreme conditions of heat.

• Locate the antennas so that the connectors are not exposed to high-pressure spray or underwater immersion. Exposure to high-pressure spray or underwater immersion may compromise the connector seals and lead to connection failure.

• Keep a distance of no less than 500 mm (19.6 inch) between the PLG641 radio and other antennas that transmit a radio signal. The lists of radio antennas to maintain a distance from include the citizen band radio, data radio, and commercial communication radios.

• Keep in mind the routing of the coax antenna cable. Route the cable such that the cable is not subject to abrasion or pinching. Do not route the cable near any source of extreme heat (exhaust). Do not mount the cable so that the limitations of temperature −40° C (−40.0° F) and 85° C (185.00° F) are exceeded.

• Route the coax antenna cable with a minimum bend radius of 49.5 mm (1.94 inch). Bend radius depends on the type of cable used. Do not bend the radius any less than ten times the diameter of the cable.

Mounting Instructions

PLG Mounting:

Place the PLG6x1 in the desired mounting location. Take note of accessibility to the backside of the mounting location. This action determines what mounting hardware to use.

Note: Ensure that mounting location does not violate environmental limitations as shown in Table 7.

Standard Mounting

Note: Rubber standoffs must be installed. These rubber standoffs provide both electrical and vibration isolation.

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Illustration 6	g06052138

1. Hold PLG in desired mounting location. Locate the four outer larger holes on PLG6x1 and make a reference mark for drilling.

2. If the backside of the mounting location is accessible, drill four holes using a standard 4 mm (0.15748 inch) sized drill bit. Install a rubber standoff 502-6405 Bushing at each of the four mounting locations using the provided 096-6166 Hard Washer and 8T-2659 Locknut. Then secure the PLG6x1 to the standoffs using the provided 1H-4393 Lockwasher and 095-7930 Screw.

3. If the backside of the mounting location is Not accessible, drill four holes using a standard 3.3 mm (0.125 inch) sized drill bit. Use a M4x0.70 tap to thread all four of the holes. Install a rubber standoff 502-6405 Bushing at each of the four mounting locations. Then secure the PLG6x1 to the standoffs using the provided 1H-4393 Lockwasher and 095-7930 Screw.

   Note: Rubber standoffs must be installed. These rubber standoffs provide both electrical and vibration isolation.

Mounting The Antenna

PLG641 requires an external antenna to communicate over the cellular network. Ensure that the external antennas are mounted at a minimum of 203.2 mm (7.99 inch) away from any metal structures that extend above the mounting plane. Any metal obstruction will create diminished cell and GPS connectivity. Locate a clean dry location where the external antennas can be mounted horizontally with clear line of site to the sky.

Note: Ensure that the cable lengths of the external antennas are long enough to reach the mounted location of the PLG641 cellular radio.

Antenna mounting surface is magnetic but also contains an adhesive cover tab. If adhesive mounting is desired, remove the adhesive cover tab on the back of the antenna as. This process will expose the adhesive mounting surface of the external antenna. Apply the adhesive surface to the previously chosen clean dry surface.

Antenna connects directly to SMA connector labeled "3G/GPRS" on PLG641.

Locate and drill a 25.4 mm (1.0 inch) hole for the 470-1268 Mounting (Isolation Mounting Plate). Remove the nut from the antenna threaded stud (do not discard). To remove nut, follow the below mentioned steps:

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Illustration 7	g06052743

1. Place two cables in the notch and pull opposite connector through. Next, leave one cable in the notch while pulling the next connector through. Finally, pull the remaining connector through.
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   Illustration 8	g06052748

2. In a similar fashion, remove and discard the star washer.
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   Illustration 9	g06052746

3. Add the plastic mounting plate to the bottom of the antenna with the locking features pointing away from the bottom of the antenna.
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   Illustration 10	g06052749

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   Illustration 11	g06052754

4. Feed the antenna cable through the mounting surface hole (Metal plate in picture). Ensure all parts of the locking feature of the plate fit through the hole. Mounting surface must not be thicker than 4 mm (0.15 inch).
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   Illustration 12	g06052758

5. Feed the antenna cable through the plastic shoulder washer. Ensure the locking feature of the shoulder washer and plate are able to interlock. This method will assist with controlling the orientation of the antenna relative to the mounting surface.
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   Illustration 13	g06052762

6. Feed the antenna cables through the flat metal washer and the nut. Tighten the nut to spec: 5 N·m (3.6 lb ft).

7. Route the antenna coax cable or cables back to the location of the PLG641.

Installation Of The Harness

Installation of 492-4281 Control Harness As is used to connect PLG6x1 to the J1939 CAN data link and battery of the generator set.

Note: The Potential Earth (PE) connector should NOT be connected to the chassis. The Potential Earth (PE) connector will not be used in generator set installations.

Follow the below mentioned steps for Installation of the harness:

Power Connections

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Illustration 14	g06052767

1. Insert the two screw terminal connectors from the installation harness to the PLG6x1.
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   Illustration 15	g06052768

2. Insert the appropriate relay into the relay receptacle, for 12 VDC starter systems use 115-1615 Relay As and for 24 VDC starter systems use 231-3930 Relay As.

   Note: Ensure that the equipment power is OFF, and the battery disconnect is engaged when installing the harness.

   Note: During installation, it is important to protect wiring in key locations. Key locations are any area where the wiring could be nicked or cut and come in contact with the chassis. Avoid installation practices where there could be excessive flexing, chafing, or cutting of the wiring.

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   Table 8

   492-4281 Control Harness As Splice Information
   Wire Information	Wire Label (Description)
   105-A1 (Red)	BTRY (+) (Battery positive)
   229-A2 (Black)	BTRY (–) (Battery negative)
   A366-A5 (Blue)	BTRY (–) AFTER DISCONNECT (Battery negative connection after battery disconnect switch)
   N873-A8 (BARE)	CAN SHIELD (Connection to primary CAN 1/CAN A)
   F711-A6 (Yellow)	CAN HI (+) (Connection to primary CAN/ 1CAN A)
   F712-A7 (Green)	CAN LO (–) (Connection to primary CAN 1/CAN A)

3. Direct to battery wiring allows the PLG6x1 to stay powered on and in a reduced power mode when the battery disconnect switch is engaged. Direct to battery wiring enables the PLG641 to send messages, such as GPS locations, even while the battery disconnect is engaged. Refer to Table 8.

4. Connect the black wire labeled "BTRY (–)" directly to the negative post on the starter batteries.

5. Connect the blue wire labeled "BTRY (–) AFTER DISCONNECT" directly to the negative post of the battery disconnect switch/isolator (EMCP/ECU side of switch) or to a terminal block that is located after the battery disconnect switch/isolator.

   Note: If the generator set is not wired with a battery disconnect switch/isolator, connect the blue wire to the same location as black wire directly to the negative post on the starter batteries.

6. Cut a length of red 16AWG wire of sufficient length to reach from the retrofit harness open-end wires to a positive battery source. Examples of a positive battery source could be the positive post on the starter batteries or to a terminal block that has a direct connection to the starter batteries.

   Note: The 304-5284 Fuse Holder must be installed as close to the battery as possible.

7. Splice one end of the 16AWG wire from Step 6 to the red wire on the retrofit harness labeled "BTRY (+)".

8. Splice the opposite end of the 16AWG wire from Step 6 to a 304-5284 Fuse Holder.

9. Cut a length of red 16AWG wire of sufficient length to reach from the 304-5284 Fuse Holder to the positive battery source identified in Step 6.

10. Insert a five amp fuse into the 304-5284 Fuse Holder that was installed in Step 8.

J1939 Network Connections

Illustration 16	g06111553
Typical J1939 communications network layout.

The J1939 communications connection provides a connection between the PLG6x1 and the J1939 network. The J1939 network contains a bus along with wiring to connect the nodes to the bus. The bus is terminated on each end to complete the network. Table 9 shows the parameters for the J1939 network.

Note: When connecting the J1939 / CAN wires from the PLG6x1 to the genset, ensure that they are connected to the J1939 CAN Primary /CAN 1 / CAN A wires on the equipment. Some pieces of equipment will have other connections labeled CAN Accessory / CAN 2 /CAN B. If the Product Link device is connected to the wrong CAN connection, the proper data will not be recorded and sent to user interface.

Connect the yellow wire labeled CAN HI (+), green wire labeled CAN LO (–), and bare wire labeled CAN SHIELD to a tee receptacle or terminal block on the J1939 CAN Primary/CAN 1/CAN A network.

Optional Connections (not included in harness)

More I/O and datalink interfaces are available on PLG6x1 but not included in the standard retrofit harness. Wire ferrules (Cat Part Number: 307-6931 Terminal) on wire ends are recommended when adding to existing connectors. The following optional connections are available:

• RS485 2-wire (half duplex) for connecting PLG6x1 to Modbus RTU supported devices for Modbus data and remotely start-stop of Caterpillar gensets. When wiring PLG6x1 to EMCP 4, reference LEBE0010-01"EMCP 4 SCADA Data Links A&I guide" available on emc.cat.com for proper wiring guidelines, network topologies, and software configuration settings. Before devices will communicate, there are some software configuration steps on the EMCP 4, on the PLG6x1, and perhaps on any other RTU devices.

• RS232 for connecting PLG6x1 to a single Data Communication Equipment (DCE).

• LAN port for connecting PLG6x1 to Modbus TCP/IP supported devices using standard Ethernet cable.

• WAN for connecting PLG6x1 to local wide area network using standard Ethernet cable.

• Analog inputs 1&3 for connecting PT100 sensors. Analog inputs 1-4 for connecting voltage sensors (0-10 VDC) or 0-20 mA current sensors.

• Digital input 2 for connecting PLG6x1 to dry contact input circuits. The digital inputs are of the "dry contact" type which do not require any control voltage and will function with a switch or breaker.

Note: Do not connect a power source to the digital inputs, damage to the unit may occur.

• Relay output for connecting PLG6x1 to other circuits. The relay output must be supplied from an isolating transformer using a secondary listed fuse rated at maximum 3.3 A and minimum 30 VDC.

Installation Of SIM Card (PLG641 only)

Follow the below mentioned steps for installation of SIM card:

1. Make sure that the PLG641 is OFF.

2. Insert the SIM card into the SIM card slot. Ensure that the SIM card has been inserted all the way. Push the SIM card until you hear a click. If necessary, use a small tool insert the SIM card.

PLG6x1 Local Web Configuration Page

The PLG6x1 local web configuration page allows the installer to configure multiple PLG6x1 settings on-site. Some of these settings, such as Modbus, are important to configure on-site while ECU or PLC device settings are accessible. Verify that the software installed on the PLG6x1 is the latest version available on SIS web. If not, update the software locally.

Access Web Configuration Page

To access web configuration page, follow the below mentioned steps:

1. Connect a standard USB to micro USB cable between a computer and PLG6x1 micro USB port. A device driver will install and virtual network card will automatically be created (this process might take a few minutes).

2. Open a web browser and type in the IP address below:
   address/URL field: 169.254.200.200
   
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   Illustration 17	g06065774

3. A login screen will appear. The default username is "admin". The password is the activation code found on the label covering the WAN and LAN ports. Upon removing label, record the activation code for future reference.

   Note: If label is lost and activation code is not recorded, send an E-mail to PLG_Support@cat.com and include System ID/MAC ID of the PLG6x1.

Technical Specifications

PLG6x1 Technical/Environmental Specifications

Illustration 18	g06052837
PLG641

Illustration 19	g06052858
PLG601

PLG6x1 LED Definitions

PLG6x1 Connector Pinouts

PLG641

Illustration 20	g06100790

PLG601

Illustration 21	g06100791