Renr8091 04
Renr8091 04
Renr8091 04
November 2008
Systems Operation
Troubleshooting
Testing and Adjusting
PL1000E Communication ECM
SAFETY.CAT.COM
i01658146
Table of Contents
Systems Operation Section
General Information ................................................ 4
Features .................................................................. 4
Electronic Control Module (ECM) .......................... 6
Wiring Harness ....................................................... 7
Quick Start Guide ................................................... 7
Parameter Translation Configuration ..................... 11
Hardware Configuration ........................................ 27
Data Link Configuration ........................................ 28
Data Link Address of Caterpillar Electronic
Control ................................................................ 28
Internet Protocol Configuration ............................. 29
Modbus Configuration ........................................... 30
LAN Network Ethernet Connection ....................... 32
Direct Crossover Ethernet Connection ................. 36
ECM Modbus Interface ......................................... 42
Embedded Web Server ........................................ 56
Custom Web Page ................................................ 63
Modbus Master ..................................................... 68
Hexadecimal Conversion ...................................... 70
Troubleshooting Section
Introduction
General Information .............................................. 72
Service Tools ........................................................ 72
Connector Locations ............................................. 75
Diagnostic Capabilities ......................................... 75
Symptom Procedures
Operational Problems ........................................... 81
Web Browser Problems ........................................ 90
Index Section
Index ..................................................................... 99
4 RENR8091-04
Systems Operation Section
Systems Operation Section The PCL file informs the PL1000E what information
to translate. The PCL file informs the PL1000E which
protocol to output these translations on.
i03326946
The PCL files are created and the PCL files are
General Information modified with the use of the Parameter Translation
Editor (PTE). The PTE is found under the Utilities
SMCS Code: 7610 menu in Caterpillar Communications Tool Kit or Cat
ET version 2007B or higher.
The PL1000E Communication Module is an
Electronic Control Module (ECM). The PL1000E
Communication Module provides the processing i03327180
power, memory, and software in order to integrate
Caterpillar engine data in to multiple applications. The Features
PL1000E Communication Module has the potential
to be upgraded for future applications. SMCS Code: 7610
The 285-1138 Electronic Control Module is The PCL file informs the PL1000E what information
an ECM with no software installed. After the to translate. The PCL file informs the PL1000E which
PL1000E software is installed on the ECM, the protocol to output these translations on.
part number becomes 256-7512 Communication
Electronic Control Module (v4). The 256-7512 The PCL files are created and the PCL files are
Communication Electronic Control Module (v4) modified with the use of the Parameter Translation
can be configured for RS-485 2 wire or 4 wire. Editor (PTE). The PTE is found under the Utilities
The 256-7512 (v4) also supports multi-node menu in Caterpillar Communications Tool Kit or Cat
communications. ET version 2007B or higher.
Cat DataLink (CDL) and J1939 to Modbus The PL1000E 315-0627 Communication Software
Group is required for Modbus Master.
Parameter Translation - Dual Data Link
Feature The PL1000E supports the parameter translations
feature over the following ports:
The CDL and J1939 to Modbus Parameter
Translation feature gathers information from both the RS-232
CDL and the J1939 data links simultaneously.
RS-422
The dual data link feature will translate the CDL and
J1939 data to the industry standard Modbus protocol RS-485, 2 wire (285-1138, 256-7512 v4 and later)
interface.
RS-485, 4 wire
Cat ET version 2007B or later and PL1000E software
release 315-0627 Communication Software Group
J1939 to Modbus Parameter Translation
or later are required in order to use this feature. Cat
ET version 2007B will allow for both CDL and J1939 J1939 to Modbus Parameter Translation provides
objects in the same Parameter Translation Editor
translation of parameter data to and from the J1939
window. Cat ET version 2007B will allow translation
protocol supported in Cat ET to the industry standard
lines to and from a Modbus ECM. Modbus protocol interface. J1939 parameters are
written to or are read from assigned registers. The
Custom Web Pages memory location for the registers are:
Embedded Communications
Adapter (ECA)
The PL1000E Communication ECM provides a
communication adapter for use with standard
Caterpillar service tools such as Cat ET. The
Embedded Communications Adapter (ECA) can be
used in order to configure statistics and to monitor
statistics of the PL1000E. Other devices that are
connected to the CDL data bus may be serviced
and may be flashed. ECA usage is compatible with
Cat ET version 2004B and later. ECA usage is also
g01705933
compatible with Caterpillar Communication Tool Kit Illustration 1
version 2005A or later. PL1000E Communication ECM
i03328480
i02794752
Preparation for Commissioning PL1000E
g01395613
Illustration 3
Sample System Block Diagram
Begin by making a sketch of the system diagram. Note: The PTE file should be located on same
The system diagram should identify each ECM that Compact Disc (CD) with the PL1000E information.
is in the system. The system diagram should identify If the PTE file is not included, then contact local
each ECM communication type. Caterpillar dealer.
Refer to the sample of a system diagram that is Note: For Data Link Addresses information, refer
shown in Illustration 3. Illustration 3 provides an to the System Operation Troubleshooting, Testing
explanation and a description of each electronic and Adjusting, RENR8091, Data Link Address of
control that is used. There is certain information that Caterpillar Electronic Control.
is needed about each device in order to perform the
integration successfully. PL1000E Communication ECM
The system diagram that is shown in Illustration The PL1000E Communication ECM is designed
3 is a generic example that could be used for an specifically for communication translations from
application. Each system may vary depending on the Caterpillar electronic controls.
components and on the interfaces that the system
contains. Required Information and Tools:
Modbus Master Device In order to change from the DHCP setting, refer to
the System Operation Troubleshooting Testing and
This device may be any industry available Modbus Adjusting, RENR8091, PL1000E Communication
communications device so long as it meets the ECM, Internet Protocol Configuration section.
following criteria:
Configure the PL1000E
Capable of Modbus communications over RS-232,
RS-422, RS-485 (4 wire), and RS-485 (2 wire) or The Modbus communications must be configured in
Ethernet the PCL file. The Modbus communications must also
be configured separately in the configuration screen
Modbus Protocol communications designed in of Cat ET.
accordance with Modbus Application Protocol
Specification V1.1a Refer to the Modbus Configuration section of this
document in order to determine the appropriate
Capable of requesting single and multiple Modbus configurations for the system. The ethernet port
registers in the range of 40,001 through 42,000 is used to transfer the PCL file to the PL1000E.
The ethernet port can be configured with Cat ET or
Prepare the PCL File Caterpillar Communication Toolkit.
Use the Caterpillar Communications Tool Kit or If the embedded web server is to be used, then
Caterpillar Electronic Technician (Cat ET) in order to the embedded web server must also be initially
prepare the PCL file as described in this document. configured using Cat ET. Refer to System Operation
Troubleshooting Testing and Adjusting, RENR8091,
Refer to the System Operation Troubleshooting PL1000E Communication ECM, Internet Protocol
Testing and Adjusting, RENR8091, PL1000E Configuration for the appropriate configurations for
Communication ECM, Parameter Translation the system.
Configuration section.
Note: Configuration of the PL1000E Communication
Refer also to the System Operation Troubleshooting ECM and preparation of the PCL file may be
Testing and Adjusting, RENR8091, PL1000E completed prior to the actual installation at the
Communication ECM, Create Parameter system site. The PL1000E Communication ECM
Translation Design section. does not need to be connected to the Caterpillar
electronic controls in the system in order to allow
In the PCL design window, each Caterpillar electronic proper configurations, PCL file creation, or PCL file
control from the system block diagram would be installation.
represented by a CDL or a J1939 ECM Object. Each
Caterpillar electronic control from the system block Install the PCL File onto the PL1000E
diagram will require a PTE file association. The
PL1000E Modbus interface would be represented Note: The PL1000E must be configured before
by a Modbus ECM. The translations are defined installation of the PCL file.
by the Translation Lines. The Translation Lines
are defined by the CDL or J1939 ECM, and by the There are several different methods that can be
Modbus ECM. used in order to install the PCL file, however, all of
the methods must be executed using File Transfer
Contact Network Administrator Protocol FTP over the ECM's ethernet connection.
After the PCL file has been successfully installed
Each network is different. Each network requires on the ECM, the module is ready for installation.
slightly different configurations. The configuration is Also, the module is ready for integration with the
dependent upon the hardware and the software that other Caterpillar electronic controls and the Modbus
is used in order to configure, manage, and maintain master.
the system's servers.
Refer to the LAN Network Ethernet Connection
If the embedded web server of the PL1000E section and to the PL1000E Communication ECM
Communication ECM's is to be accessible over a section of this document for information about
local network, then the local network administrator connection methods.
should be contacted in order to obtain the appropriate
configurations. The factory default setting for the Also, refer to System Operation Troubleshooting
PL1000E is Dynamic Host Configuration Protocol Testing and Adjusting, RENR8091, PL1000E
(DHCP). Communication ECM, Direct Crossover Ethernet
Connection section.
RENR8091-04 11
Systems Operation Section
Install the Necessary Infrastructure to Each process will be discussed in the following
Integrate the PL1000E Into A System sections.
Using either the embedded communication adapter of Parameter Translation Editor (PTE)
the ECM or other external communication adapters,
verify that the service tool can successfully detect all The PTE provides a user interface through which a
Caterpillar electronic controls in the system. user may design and architect the communications
paths within his system. It is a software application
Validate Successful Modbus available as a utility application within Cat ET and the
Communications of the PL1000E to Caterpillar Communications Toolkit.
the Modbus Master
Parameter Translation Editor File (*.pte)
Configure or program the Modbus master to request
The PTE file contains a list of all parameters for a set
any or all of the status and statistics Modbus
of engine models that are available for translation. A
registers from the ECM. In order to retrieve the
standard and statistics Modbus register data, the PTE file is specific to parameters available on either
CDL or J1939. Parameters that are listed within the
ECM Modbus slave address that is defined in the
PTE file may be selected and may be assigned
Modbus configuration through the Cat ET, Caterpillar
Communication Toolkit (the ECM configuration), or a Modbus register through Cat ET or Caterpillar
Communications Toolkit.
embedded web pages must be used.
Alternately, configure or program the Modbus master Note: The registers are not pre-assigned registers
in the PTE file.
in order to request any of the Modbus registers that
are defined in the PCL file for one of the Caterpillar
electronic controls in the system. In order to retrieve Parameter Configuration List (PCL) File
the Modbus registers from the other Caterpillar (*.pcl)
electronic controls in the system, the ECM Modbus
slave address that is defined in the PCL file must be The PCL file is the output of the PTE application.
used. After a user has designed the desired ECM objects
and associated translations in the PTE and chooses
This is the end of Quick Start Guide. to save the file, a *.pcl file will be created. This
file then contains all of the information about the
parameter necessary for translation to Modbus.
i03328544
Properties Window
When a device within the design window (large white
area in the middle of the screen) (5) is selected, the
Properties window will list the information that is
related to that type of object. If no objects exist within
the design window (5) or if the user has clicked on the
white part of the design window, then the properties
window will display the information related to the
overall design. Refer to Illustration 4. The following
sections present information about the objects and
the associated properties that can be displayed.
g01336076
Illustration 5
Address The data link address of the ECM Modbus Slave Address - The Modbus Slave
Object. Electronic controls attached to CDL Address to which all Modbus commands should
and J1939 Data Links must use an address to be addressed to retrieve data as defined in the
communicate on the associated data link. See the parameter translation arrows. This Modbus slave
documentation for the specific electronic control address is not the same address configured
device in order to determine what value must be through Cat ET or Websever.
entered in the address field.
Port - The physical port of the ECM on which
Object Modbus ECM the selected Modbus Slave Device should be
accessible. If multiple ports are needed for each
A Modbus ECM in the design window represents a port, a modbus must be defined. Valid ports are
Modbus interface to the PL1000E Communication RS-232-1, RS-232-2, RS-422, RS-485 (4 wire),
ECM. The characteristics and attributes that are RS-485 (2 wire), or TCP standard.
assigned to this object represent the definition of the
Modbus Slave Device. The Modbus Slave Device Object Translation
will communicate with the Modbus Master Device.
Multiple Modbus ECM Objects may be included in A Translation Object appears on the design window
the design window, but each must be assigned to a as an arrow indicating the direction of data flow.
different physical port of the ECM. Multiple Modbus The direction of data flow indirectly also shows
ECM Objects may not be added to the design window the read/write accessibility of data. In other words,
and assigned the same Port attribute, or the *.pcl if there is a translation arrow pointing from the
file will be unusable by the on board ECM software. CDL ECM Object to the Modbus ECM Object,
Refer to Illustration 7 for an example of the properties this indicates the Modbus Slave Device will only
window for the Modbus ECM object. support register read commands for the parameters
assigned to this translation object. Modbus register
write commands will only be supported in J1939
to Modbus translations. An arrow pointing from
the Modbus ECM Object to the CDL ECM Object
indicates the Modbus Slave Device will only support
register write commands for the parameters assigned
to this translation object.
Parameter The drop down menu contains a list of ECM ID A unique number assigned to the selected
the parameters that are available for assignment to ECM Object. Each ECM Object in the design
the selected Translation Object. When a parameter window must be assigned a unique ECM ID. When
is selected from the drop down menu, the selected a *.pcl file is generated, this number will allow the on
parameter is added to the parameter listing. Also, board software to differentiate between each ECM
a new click here to add row will be added to the Object in the *.pcl file.
properties window.
Description Free form text field that may be
Request Rate Time in milliseconds the PL1000E modified to give a visual indication of what the ECM
will wait before attempting to obtain updated data Object represents within the system being designed.
from the ECM Object from which this data is being
translated. If this time elapses and the PL1000E Refer to Illustration 9 for an example of the properties
is unable to obtain updated information from the window for the WebServer ECM object.
source ECM Object, this data will be considered to
be stale. The minimum valid value for this data is
500 milliseconds.
g01398013
Illustration 10
Set the Default PTE Directory 4. Select the default PTE directory. Press OK.
Before starting the design process, ensure the
Default PTE Directory represents the location of the
desired *.pte files. For this example, all of the *.pte
files have been located in the C:\PL1000E Example\
directory.
g01708273
Illustration 14
g01336162
Illustration 13
The design window will then be updated to reflect the
Click on the Add ECM Object. Refer to Illustration addition of the new CDL ECM.
13. Select CDL from the resulting drop down menu.
Modify the Properties for the New CDL
Note: PTE files are located on CD with PL1000E. ECM Object
Assign the *.pte file to the CDL ECM It is good practice to modify the properties of an ECM
Object object immediately after adding it to the design. This
will aid in distinguishing ECM objects as more objects
Selecting a CDL ECM Object to be added to the are added to the design.
translation design will cause PTE to display an Open
PTE File dialog box as shown in Illustration 11. In Perform the following in order to modify the properties
this dialog select the *.pte file and click on the Open for the new CDL ECM object:
button.
1. Select the new CDL ECM Object.
This step is repeated for each CDL ECM object that
is added to the design in order to define different 2. View the information in the properties window.
ECM applications.
Note: The type should be CDL. The PTE File
Path will display the appropriate path and file name
selected for this ECM Object. For our example it is
C:\PL1000E Example\Sample 36XX.pte.
g01708298
Illustration 16
Note: The following port settings are 3. Select the first parameter that is to be added to
available:RS-231 Port 1, RS-232 Port 2, the translation from the drop down menu.
RS-422, RS-485, and TCP-Standard.
4. Continue to click and add parameters until all
Note: In this example system, the Modbus interface desired parameters have been added to the
is designed to operate over RS-232 Port 1. The PTE translation.
Design window should now look similar to Illustration
16. Note: An Alternate way to add parameters is to
select the icon to add all parameters and then delete
Add Translation Object the unwanted parameters. Refer to Illustration 18 for
the icon location.
Perform the following in order to add the translation
object: Note: Caterpillar does not recommend more than
120 parameters total for all translations.
1. Click on the Add Translation Object button.
Modify Request Rate for All Selected
Parameters
More dynamic parameters should be assigned a
smaller update rate, and less dynamic parameters
should be assigned a larger update rate.
g01336295
Illustration 17
2. Enter the register value. Manually entering the Perform the following in order to save a *.pcl file to
register value is an alternative to allowing PTE to disk.
reassign the Modbus registers.
1. Click on Save.
Note: The operator is able to overwrite other
registers. Note: PTE will display a standard Save PCL File
dialog, which opens the default PTE directory.
3. Click on the view/save parameter list button
to save the modbus register map. This method 2. Select the appropriate path and filename for the
is generally used by an integrator for parameter *.pcl file.
mapping. Refer to Illustration 18, (3) and resolution
of parameters. Refer to Illustration 20. Note: File names are limited to a total length of 33
characters. If a file name is longer than 33 characters,
the on board software will truncate the name to 33
characters while processing the configuration. The
file name may NOT include any spaces.
3. Select Save.
Note: The selected ECM Object will be removed. Select the Source ECM Object
Delete Translation Object The source ECM refers the ECM Object in the design
that the translation arrow is pointing away from. The
Perform the following in order to delete a Translation following illustrations will show that the wizard uses
Object: these terms to assign bi-directional translations. One
will be available for Source to Target ECM and one
1. Select the Translation Object to be removed in for Target to Source ECM.
the PTE Design window.
If a Modbus ECM is selected, the user may also
2. Click on Remove Translation Object or press the define the ECM ID on this screen. refer to Illustration
Delete key on the computer. 22.
4. Click Next.
g01708495
Illustration 23
Click Next.
2. Click Next.
g01708514
Illustration 24
g01709153
Illustration 30
g01709135
Illustration 29
Table 1
Call
Entity Description
Out
Translation from Modbus Slave Represents a translation taking place. In this case the PL1000E is requesting
17
1 to J1939 Engine information from Modbus Slave 1 and writing that information on J1939.
Represents a Caterpillar ECM that the PL1000E, as a Modbus Master, is
18 J1939 ECM
communicating with.
This utility is only available on a translation line from a Modbus Slave ECM to a
J1939 ECM. The basics of this utility are to allow the user to scale their data to
match a public J1939 PGN. For example, a sensor is on Modbus as a slave,
and the user wants to translate the sensor data to J1939 and have it match the
J1939 protocol. The user would simply enter the offset and resolution of the
19 Scale Parameters Utility
data, upload the PCL file to the PL1000E, and the PL1000E would scale the
data from Modbus to match the scaling factors of the parameters to J1939.
NOTE: This utility should only be used for a linear sensor.
An expert should only use this utility. Please contact the dealer technical
communicator for more detailed information.
The rate at which the PL1000E is requesting information from Modbus or
J1939. For example, (4) is requesting information from the J1939 Engine. So
20 Request Rate
the Request Rate in this instance would be how fast the PL1000E is requesting
the specific parameter from the J1939 Engine.
The rate as which the PL1000E is sending the information it requests to the
particular ECM. Take (4) again. The PL1000E is requesting information from
21 Production Rate the J1939 ECM, and then sending it out on Modbus. So the Production Rate
in this case would be the speed that the PL1000E is sending the information
on Modbus.
The register that the PL1000E is either requesting, or writing to, depending on
22 Modbus Register
the translation line that is selected.
Represents a Modbus Slave ECM that the PL1000E, as a Master, is
23 First Modbus Slave ECM
communicating with.
Represents a translation taking place. In this case the PL1000E is requesting
Translation from J1939 Engine
24 information from the J1939 Engine, and writing that information to the Modbus
to Modbus Slave 1
Slave ECM.
Represents a second Modbus Slave ECM that the PL1000E, as a Master, is
25 Second Modbus Slave ECM
communicating with.
When a *.pcl file is opened, the PTE must be able to Note: As an example, the Atmospheric Pressure
locate the *.pte file that was originally used in order parameter has been chosen to be removed.
to create the *.pcl file.
4. Press the delete key that is on the keyboard of
Open the Parameter Control List the computer.
Perform the following in order to open the Parameter Note: The parameter will be removed from the
Control list: Translation Parameter List.
1. Click on Open in the PTE. Add Parameters to the 36XX Engine Cntrl
to PL1000E Interface Translation
Note: An Open dialog will be displayed. Refer to
Illustration 32. Perform the following in order to add parameters
from the 36XX Engine Cntrl to the PL1000E interface
translation:
Note: The PTE will read in the *.pcl file. The PTE
will recreate the Design window objects. The screen
should look similar to Illustration 33.
Note: The PL1000E needs to be configured before Note: If the file was processed successfully, a time
the PCL file is transferred. If needed due to site setup, and date stamp appended to the end of the file name.
then refer to the ECM Configuration, LAN Network
Ethernet Connection, or the Direct Crossover An example of the file name is:
Ethernet Connection section of this manual.
The original file name:
Perform the following in order to initiate configuration 36XX_Sample_PCL_File.pcl
of PL1000E with new PCL file:
The modified file name:
1. Enter xxx.yyy.zzz.aaa in the address field of 36XX_Sample_PCL_File_YYYYMM
the browser. The xxx.yyy.zzz.aaa is the IPv4 DDHHNNSS.pcl
address of the PL1000E which is defined in the
Cat ET configuration screen. Where:
Note: The browser will display the PL1000E Home YYYY = year
Page.
MM = month
2. Navigate to the Configuration/Reset web page
DD = day
3. Select the Reset action.
HH = hour
4. Click Submit.
NN = minute
Note: The user will be prompted for a User Name
and Password for access to reset the PL1000E. SS = second
5. Enter the appropriate User Name and Password. 13. Verify that the appended time and date stamp
reflect the actual time and date of the PL1000E
Note: The browser will indicate the following: warm boot sequence.
The PL1000E device will RESET. This page will
automatically go back to the Home Page. The
i02796160
browser will display the PL1000E Home Page.
i03345200 i03331925
PL1000 #1
PL1000 #2 (Default)
PL1000 #3
Enabled Illustration 35
g01709835
Disabled (Default)
NOTICE
CDL Boost should be enabled only if the wiring lengths
for the harnesses are 30.5 m (100 ft) or greater. If
the wiring lengths for the harnesses are under 30.5 m
(100 ft), then CDL Boost may cause failure.
RENR8091-04 29
Systems Operation Section
IP address:192.168.1.1
Internet Protocol Host Name
Network Mask: 255.255.255.0
The Internet Protocol Host Name (2) is a free form
text field where the host name may be entered. By Default Gateway: 1.0.0.0
default, the IP address is 192.168.1.1.. The address
must be changed if the PL1000E is to be used in a
networked environment. The IP value is limited to
25 characters. The Internet Protocol Host Name is
assigned by the network administrator.
Hardware (CTS/RTS)
None (default)
Reserved
Software (Xon/Xoff)
ModBus #1 Data Size
The ModBus #1 Data Size selections are:
7
g01743935
Illustration 37
8 (default)
ModBus Configuration Details ModBus #1 Parity
ModBus #1 Port Selection The ModBus #1 Parity selections are:
19200 Disabled
38400 Serial Port #1
57600 Serial Port #2
ModBus #2 Echo/No Echo Serial Port #4 (default)
The ModBus #2 Echo/No Echo selections are: ModBus #3 Baud Rate
Echo The ModBus #3 Baud Rate selections are:
7 Echo
8 (default) No Echo (default)
7 i03332863
RS-485 Mode
The RS485 Mode configuration item only appears
on the 285-1138 Electronic Control Modules or
newer. The RS485 Mode selections are as follows:
g01414942
Illustration 38
Note: DHCP is used to allow a network server to Loading the PCL File Using FTP
manage the network node connections dynamically.
Each node needs an IP address, but there are a finite
With a Web Browser
number of addresses. The server can maximize the Perform the following with a standard web browser:
number of addresses available by assigning them
as devices are connected to the network. DHCP
1. In the address field of the browser, type in the IP
requires specialized server software and is not always (IPv4) Address that was noted in Step 7.
available on small networks. In a non-DHCP network
for nodes to communicate through IP dedicated IP
Note: The browser will display the PL1000E
addresses must be assigned to each node. Communication ECM Home Page. This confirms the
connection of the ECM and the PC to the network. If
Perform the following in order to complete a LAN
the user is unable to browse to the ECM Home Page,
network ethernet connection: refer to Troubleshooting, RENR8091.
1. Connect the ECM serial port 3 (ECA) harness
2. In the address field of the browser, enter the
connector to the PC. following: ftp://xxx.yyy.zzz.aaa
2. Apply power to the system and start the service
Note: Where ftp://xxx.yyy.zzz.aaa is the address
tool on the PC. noted in the previous steps, an FTP Folder Error
dialog will appear. The FTP Folder Error is a normal
3. Once connected to the PL1000E, navigate to the
security message that indicates the user has not yet
Configuration screen for IP. logged into the FTP server.
4. Determine whether the network requires support
3. Click OK in this dialog box.
for DHCP or static IP addresses.
4. In the browser menu, select File/Login As.
5. If DHCP support is required, configure the DHCP
Enable Status to Enabled. Note: A login dialog will be displayed prompting for a
User Name and Password. The Default User Name
6. If static IP addressing is required, configure DHCP
is admin, and the Default Password is admin.
Enable Status to Disabled and configure the IP
(IPv4) Address, IP (IPv4) Network Mask, and
5. Enter the appropriate User Name and Password
Network Default Gateway Internet Protocol (IPv4)
and click Login.
Address to the values specified by the network
administrator.
Note: The browser will display the ECM files
and folders on the module's root directory. As a
7. Make note of the IP (IPv4) Address. default, the folders and files displayed are shown in
Illustration 39.
8. Connect the PC and login to the same network as
the PL1000E and start a web browser.
34 RENR8091-04
Systems Operation Section
g01176569
Illustration 40
g01176577
Illustration 41
g01397624 g01402164
Illustration 42 Illustration 44
2. In the Run dialog, type CMD and click OK. 5. At the prompt, type in the user name.
3. At the DOS command prompt, type ftp Note: After entering the user name and password,
xxx.yyy.zzz.aaa. the screen will be similar to the screen in Illustration
44.
Note: xxx.yyy.zzz.aaa is the IPv4 address of the
device. The address of the device is defined in the 8. Set the local directory and remote directory for
Configuration screen in Cat ET. proper transfer of the file.
g01402161
Illustration 43
13. Move the PCL file to the ECM. Using the Put
command, execute the FTP process as shown
in Illustration 49 and Illustration 50, replacing
G3612_Engine.pcl with the name of the PCL file.
g01402168
Illustration 46
10. Since all new PCL files must be loaded into the
New directory, change from the remote directory
to the New directory using the Change Directory Illustration 49
g01402180
New (CD New) command.
14. After the file has been sent successfully, exit the
FTP session using the Bye command. The FTP
session will close, and the screen will return to a
DOS command prompt.
g01402169
Illustration 47
i03332946
g01415005
Illustration 51
PL1000E configuration
Configuring a PL1000E Communication
Module to Work on a Non-DHCP network
Perform the following steps in order to configure
a PL1000E Communication Module to work on
a network that does not have Dynamic Host
Configuration Protocol(DHCP).
g01710895 g01710899
Illustration 53 Illustration 55
5. Select Disabled from the drop down box. 8. Enter the address of the default gateway, if
applicable, in the form of 1.0.0.0 and click OK.
6. Click OK and click Yes to program the ECM.
9. Click Yes to program the PL1000E.
g01710898
Illustration 54
g01710913
Illustration 56
7. Highlight the Network Default Gateway Internet
Protocol (IPv4) Address entry and click Change. 10. Highlight the Internet Protocol (IPv4) Network
Mask entry and click Change.
RENR8091-04 39
Systems Operation Section
g01710914 g01710916
Illustration 57 Illustration 59
11. Enter the Subnet mask value of 255.255.255.0 14. Enter the four parts of the IP address in the four
and click OK. fields according to the information that is provided
by the network administrator. Click OK.
12. Click Yes in order to program the PL1000E.
Note: If a PC is to be connected directly to the
PL1000E via a crossover ethernet cable, then leave
the IP configuration set to the default settings.
g01710918 g01404032
Illustration 60 Illustration 62
4. Select the Connections tab (10). 6. Make a note of the current settings. Uncheck all
checked boxes.
7. Click OK.
g01404026
Illustration 61
g01710921
Illustration 64
g01404064
Illustration 66
g01404040
Illustration 65
Table 2
Function Description Modbus Address
Code Range
3 Read Holding 40001 through 42000
Registers inclusive
6 Preset Single 40001 through 42000
Register inclusive
16 Preset Multiple 40001 through 42000
Registers inclusive
Table 3
Cat Data Link Events
Modbus
Contents Comments
Register Offset
Most Significant Byte (MSB): Count of active events
0 Count of active events
Least Significant Byte (LSB): Maximum table size
MSB: Bit mapped status indicator
Bits 8 through 3: Reserved
Bit 2: 1= table is being updated, 0= table is not being updated
1 Event retrieval status Bit 1: 1= data is stale, 0= data is not stale
Bit 0: 1= overflow, 0= no overflow(1)
LSB: Reserved
MSB: update rate (HI byte)
2 Negotiated update rate LSB: update rate (LO byte). The rate in milliseconds that the
source ECM sends updates of the Event Code table to the
PL1000E.
MSB: Event Identifier 1
3 First Event Identifier (EID)
LSB: Reserved
MSB:
Bits 8 through 4: Reserved
Additional Event Identifier Bits 3 through 1: Warning Category Indicator (WCI)
4
information WCI values: 0 or 1 = Warning, 2 = Service, 3 = Shut Down
LSB: Reserved
(1) Overflow status means that there are more DTCs present than the table can contain.
Table 4
Cat Data Link Diagnostics
Modbus
Contents Comments
Register Offset
Most Significant Byte (MSB): Count of active diagnostics
0 Count of active diagnostics
Least Significant Byte (LSB): Maximum table size
MSB: Bit mapped status indicator
Bits 8 through 3: Reserved
Bit 2: 1= table is being updated, 0= table is not being updated
1 Diagnostics retrieval status Bit 1: 1= data is stale, 0= data is not stale
Bit 0: 1= overflow, 0= no overflow(1)
LSB: Reserved
The minimum update rate at which the source ECM can provide
2 Negotiated update rate diagnostic code updates to the PL1000E in milliseconds. (MSB
first)
MSB: Component Identifier 1
3 First Component Identifier (CID)
LSB: Reserved
MSB
Bits 8 through 6: Warning Category Indicator (WCI)
Additional Component Identifier WCI values: 0 or 1 = Warning, 2 = Service, 3 = Shut Down
4
Information Bits 5 through 1: Failure Mode Identifier (FMI)
LSB: Reserved
(1) Overflow status means that there are more DTCs present than the table can contain.
Table 5
J1939 Diagnostic Trouble Codes (DTCs) and Emissions Related DTCs
Modbus Register
Contents Comments
Offset
Most Significant Byte (MSB): Count of active DTCs
0 Count of active DTC
Least Significant Byte (LSB): Maximum table size
MSB: Bit mapped status indicator
Bits 8 through 4: Reserved
Bit 3: 1 = Non-standard format, 0 = Standard format(1)
1 DTCs retrieval status Bit 2: 1= table is being updated, 0= table is not being updated
Bit 1: 1= data is stale, 0= data is not stale
Bit 0: 1= overflow, 0= no overflow(2)
LSB: Reserved
MSB:
Bits 8-7: Malfunction indicator lamp status
Bits 6-5: Red stop lamp status
Bits 4-3: Amber warning lamp status
2 Lamp status Bits 2-1: Protect lamp status
LSB:
Bits 8-1: Reserved for SAE assignment lamp status
For each pair of bits, the following values represent the associated
status: 00 = Lamp is OFF, 01 = Lamp is ON
MSB (When CM has a value of 1): SPN bits (18 through 11)
First two bytes of the LSB (When CM has a value of 1): SPN bits (10 through 3)
3 first Suspect Parameter
Number (SPN) MSB (When CM has a value of 0): Indeterminate
LSB (When CM has a value of 0): Indeterminate
MSB (When CM has a value of 1):
Bits 8 through 6: SPN bits (2 through 0)
Bits 5-1: Failure Mode Identifier
Lower order bits of the
first SPN LSB (When CM has a value of 1):
4 Failure Mode Identifier (FMI) Bit 8: Conversion Method
Conversion Method (CM) Bits 7-1: Occurrence Count
Occurrence Count (OC)
MSB (When CM has a value of 0):(3) Indeterminate
LSB (When CM has a value of 0): Indeterminate
(1) Non-standard format - ECM's that implement the J1939 DTC transmission method prior to 1996 may format data in any of three
unidentifiable formats. These formats can not be dependably translated for display.
(2) Overflow status means that there are more DTCs present than the table can contain.
(3) For details on implementations of the DTC communication methods where CM is 0, please refer to SAE J1939-73.
Register offsets 3 and 4 are repeated for each SPN PL1000E Communication ECM Default
reported by the source device. The J1939 DTC's Status Modbus Registers
and Emissions Related DTC's Table will hold a
maximum of 20 DTC entries. See explanation in table The PL1000E Communication ECM has been
of overflow in status byte when more than 20 are designed to support a set of default status Modbus
active on a device. Refer to the explanation that is in Registers that can be used to verify initial connectivity
the note of Table 5 for overflow in status bytes when and status of the ECM communications. The registers
more than 20 DTC events are active on a device. and associated data are listed in the table shown in
Table 6.
Note: Some devices may have implemented both
CMs, so some of the DTCs may be in the appropriate
format while some remain indeterminate.
46 RENR8091-04
Systems Operation Section
Table 6
Default Status Modbus Registers
Starting Register Modbus Register Contents Format and Length
ECM Part Number String
40,001
5 registers (10 ASCII bytes)
ECM Serial Number String
40,006
5 registers (10 ASCII bytes)
Personality Module (Software) Part String
40,011
Number 5 registers (10 ASCII bytes)
Module Release Date (Application Date String
Code) string 3 registers (5 ASCII bytes) (MM MY Yx) Where
40,016
MM M is the month (JAN, FEB, etc.) and Y Y is
the last two digits of the year (2005 would be 05)
40,019 Reserved 2 registers (4 bytes)
Module Description String
40,021
13 registers (26 ASCII bytes)
PCL file status (0 = Initializing, 1 = OK, 2 = 1 register (1 byte LSB)
40,034 error or not present) PCL file status (0 = Initializing, 1 = OK, 2 = error
or not present)
ECM Lifetime Clock 2 registers (4 bytes)
40,035
Hours (MSB)
40,037 Reserved 4 registers (8 bytes)
40,041 CDL Received Messages (MSB) 2 registers
40,043 CDL Received Errors (MSB) 2 registers
40,045 CDL transmitted messages (MSB) 2 registers
40,047 CDL transmitted errors (MSB) 2 registers
40,049 Reserved 2 registers (4 bytes)
40,051 J1939 received messages (MSB) 2 registers
40,053 J1939 received errors (MSB) 2 registers
40,055 J1939 transmitted messages (MSB) 2 registers
40,057 J1939 transmitted errors (MSB) 2 registers
40,059 Reserved 2 registers (4 bytes)
RS-232 Port 1 received Modbus - RTU (MSB) 2 registers
40,061
messages
RS-232 Port 1 received Modbus - RTU (MSB) 2 registers
40,063
errors
RS-232 Port 1 transmitted Modbus - RTU (MSB) 2 register
40,065
messages
RS-232 Port 1 transmitted Modbus - RTU (MSB) 2 registers
40,067
errors
40,069 Reserved 2 registers (4 bytes)
RS-232 Port 2 received Modbus - RTU (MSB) 2 registers
40,071
messages
RS-232 Port 2 received Modbus - RTU (MSB) 2 registers
40,073
errors
RS232 Port 2 transmitted Modbus - RTU (MSB) 2 registers
40,075
messages
(continued)
RENR8091-04 47
Systems Operation Section
(Table 6, contd)
RS232 Port 2 transmitted Modbus - RTU (MSB) 2 registers
40,077
errors
40,079 Reserved 2 registers (4 bytes)
RS422/485 Port 4 received Modbus - RTU (MSB) 2 registers
40,081
messages
RS422/485 Port 4 received Modbus - RTU (MSB) 2 registers
40,083
errors
RS422/485 Port 4 transmitted Modbus - (MSB) 2 registers
40,085
RTU messages
RS422/485 Port 4 transmitted Modbus - (MSB) 2 registers
40,087
RTU errors
40,089 Reserved 2 registers (4 bytes)
40,091 Ethernet received Modbus - TCP messages (MSB) 2 registers
40,093 Ethernet received Modbus - TCP errors (MSB) 2 registers
Ethernet transmitted Modbus - TCP (MSB) 2 registers
40,095
messages
40,097 Ethernet transmitted Modbus - TCP errors (MSB) 2 registers
40,099 number of Modbus - TCP connections (MSB) 1 register
40,100 Reserved 100 registers (200 bytes)
ECM Mapping - Number of Entries (30 (MSB) 1 register
40,201
entries or 15 pairs)
40,202 ECM Address (from) (MSB) 2 registers
ECM Type and Port 1 register
40,204
high byte = Type low byte = Port
40,205 ECM Address (to) (MSB) 2 registers
ECM Type and Port 1 register
40,207 MSB = Type
LSB = Port
Personality Module Part Number Refer to Table 6 for the definitions of the possible
data values.
The application software flash file part number
currently programmed into the PL1000E ECM Lifetime Clock
communication module.
An internal timer that indicates the amount of time that
Sample Message: the PL1000E has been in operation over its lifetime.
The ECM lifetime clock is NOT the service meter
Request from Modbus Master 15 03 00 0A 00 05 hours. The ECM lifetime clock is an independent
accumulation of operation hours of the PL1000E
Response from PL1000E Slave 15 03 0A 32 35 device itself.
38 36 38 30 36 2D 30 30
Sample Message:
Data = 2586806
Request from Modbus Master 15 03 00 22 00 02
Application Date Code
Response from PL1000E Slave 15 03 04 00 00
The month and year (last two digits) of the application 00 B2
software flash file release.
Data = 178 hours
Sample Message:
Scale = 1 hour/bit
Request from Modbus Master 15 03 00 0F 00 03
CDL Received Messages
Response from PL1000E Slave 15 03 06 41 55
47 30 38 00 An accumulator that indicates the number of
messages that have been successfully received on
Data = AUG08 CDL. Use this information as an indicator of whether
or not the PL1000E is receiving data on CDL. The
Personality Module Description value is reset each time that the PL1000E has the
power removed and then has the power turned back
Text description of the PL1000E communication on. The accumulator value is not a lifetime total. If
module as it is identified in the Service Tool. This is power to the PL1000E is left on for an extended
the same description seen on the ECM Summary amount of time, then the accumulator value can roll
screen in Service Tool. over and will begin to increment from zero once
again.
Sample Message:
Sample Message:
Request from Modbus Master 15 03 00 14 00 0D
Request from Modbus Master 15 03 00 28 00 02
Response from PL1000E Slave 15 03 1A 50 4C 31
30 30 30 45 20 43 6F 6D 6D 75 6E 69 63 61 74 Response from PL1000E Slave 15 03 04 00 00
69 6F 6E 20 45 43 55 00 50 1D 24
Each time the PL1000E is powered on, it searches An accumulator that indicates the number of errors
for a new PCL file. If the PCL is present in the NEW that have been received on CDL. Received errors
directory, then the PL1000E will process the PCL file can indicate incorrect system wiring or incorrectly
and the PL1000E will assume the configuration that configured parameter translation. The accumulator
is contained within the PCL file. value is reset each time that the PL1000E has the
power removed and then has the power turned back
Sample Message: on. The accumulator value is not a lifetime total. If
power to the PL1000E is left on for an extended
Request from Modbus Master 15 03 00 21 00 01 amount of time, then the accumulator value can roll
over and will begin to increment from zero once
Response from PL1000E Slave 15 03 02 00 01 again.
Note: Data = 01 means PCL File OK. Request from Modbus Master 15 03 00 2A 00 02
RENR8091-04 49
Systems Operation Section
Sample Message:
50 RENR8091-04
Systems Operation Section
Response from PL1000E Slave 15 03 04 00 00 An accumulator that indicates the number of modbus
11 54 errors that have been received on RS-232 Port
1. Received errors can indicate incorrect or faulty
Data = 4436 messages system wiring or incorrectly formatted modbus
messages that are being sent by another modbus
J1939 Transmitted Errors device. The accumulator value is reset each time that
the PL1000E has the power removed and then has
An accumulator that indicates the number of the power turned back on. The accumulator value is
errors that have occurred while the PL1000E was not a lifetime total. If power to the PL1000E is left on
attempting to transmit a J1939 message. Transmitted for an extended amount of time, then the accumulator
errors can indicate incorrect or faulty system wiring. value can roll over and will begin to increment from
The accumulator value is reset each time that the zero once again.
PL1000E has the power removed and then has the
power turned back on. The accumulator value is not Sample Message:
a lifetime total. If power to the PL1000E is left on for
an extended amount of time, then the accumulator Request from Modbus Master 15 03 00 3E 00 02
value can roll over and will begin to increment from
zero once again. Response from PL1000E Slave 15 03 04 00 00
00 00
Sample Message:
Data = 0 errors
Request from Modbus Master 15 03 00 38 00 02
Scale = 1 error message/bit
Response from PL1000E Slave 15 03 04 00 00
00 00 RS-232 Port 1 Transmitted Modbus-RTU
Messages
Data = 0 errors
An accumulator that indicates the number of modbus
Scale = 1 transmit error/bit messages that have been successfully transmitted
by the PL1000E over RS-232 Port 1. The value is
RS-232 Port 1 Received Modbus-RTU Messages reset each time that the PL1000E has the power
removed and then has the power turned back on.
An accumulator that indicates the number of modbus The accumulator value is not a lifetime total. If power
messages that have been successfully received on to the PL1000E is left on for an extended amount of
RS-232 Port 1. Use this information as an indicator time, then the accumulator value can roll over and
of whether or not the PL1000E is receiving modbus will begin to increment from zero once again.
requests on RS-232 Port 1. The value is reset each
time that the PL1000E has the power removed and Sample Message:
then has the power turned back on. The accumulator
value is not a lifetime total. If power to the PL1000E Request from Modbus Master 15 03 00 40 00 02
is left on for an extended amount of time, then the
accumulator value can roll over and will begin to Response from PL1000E Slave 15 03 04 00 00
increment from zero once again. 11 54
RS-232 Port 1 Transmitted Modbus-RTU Errors RS-232 Port 2 Received Modbus-RTU Errors
An accumulator that indicates the number of An accumulator that indicates the number of modbus
errors that have occurred while the PL1000E was errors that have been received on RS-232 Port
attempting to transmit a modbus message over 2. Received errors can indicate incorrect or faulty
RS-232 Port 1. Transmitted errors can indicate system wiring or incorrectly formatted modbus
incorrect or faulty system wiring or incorrect baud messages that are being sent by another modbus
rate settings. The accumulator value is reset each device. The accumulator value is reset each time that
time that the PL1000E has the power removed and the PL1000E has the power removed and then has
then has the power turned back on. The accumulator the power turned back on. The accumulator value is
value is not a lifetime total. If power to the PL1000E not a lifetime total. If power to the PL1000E is left on
is left on for an extended amount of time, then the for an extended amount of time, then the accumulator
accumulator value can roll over and will begin to value can roll over and will begin to increment from
increment from zero once again. zero once again.
RS-232 Port 2 Transmitted Modbus-RTU Errors RS-422 and RS-485 Port 4 Received Modbus-RTU
Errors
An accumulator that indicates the number of errors
that have occurred while the PL1000E was attempting An accumulator that indicates the number of modbus
to transmit a modbus message over RS-232 Port 2. errors that have been received on RS-422 and
Transmitted errors can indicate incorrect or faulty RS-485 Port 4. Received errors can indicate incorrect
system wiring or incorrect baud rate settings. The or faulty system wiring or incorrectly formatted
accumulator value is reset to zero each time that the modbus messages that are being sent by another
PL1000E has the power removed and then has the modbus device. The accumulator value is reset to
power turned back on. The accumulator value is not zero each time that the PL1000E has the power
a lifetime total. If power to the PL1000E is left on for removed and then has the power turned back on.
an extended amount of time, then the accumulator The accumulator value is not a lifetime total. If power
value can roll over and will begin to increment from to the PL1000E is left on for an extended amount of
zero once again. time, then the accumulator value can roll over and
will begin to increment from zero once again.
Sample Message:
Sample Message:
Request from Modbus Master 15 03 00 4C 00 02
Request from Modbus Master 15 03 00 52 00 02
Response from PL1000E Slave 15 03 04 00 00
00 00 Response from PL1000E Slave 15 03 04 00 00
00 00
Data = 0 errors
Data = 0 errors
Scale = 1 transmit error/bit
Scale = 1 error message/bit
RS-422 and RS-485 Port 4 Received Modbus-RTU
Messages RS-422 and RS-485 Port 4 Transmitted
Modbus-RTU Messages
An accumulator that indicates the number of modbus
messages that have been successfully received on An accumulator that indicates the number of modbus
RS-422 and RS-485 Port 4. Use this information messages that have been successfully transmitted by
as an indicator of whether or not the PL1000E is the PL1000E over RS-422 and RS-485 Port 4. The
receiving modbus requests on RS-422 and RS-485 value is reset to zero each time that the PL1000E has
Port 4. The value is reset each time that the PL1000E the power removed and then has the power turned
has the power removed and then has the power back on. The accumulator value is not a lifetime total.
turned back on. The accumulator value is not a If power to the PL1000E is left on for an extended
lifetime total. If power to the PL1000E is left on for amount of time, then the accumulator value can roll
an extended amount of time, then the accumulator over and will begin to increment from zero once
value can roll over and will begin to increment from again.
zero once again.
Sample Message:
Sample Message:
Request from Modbus Master 15 03 00 54 00 02
Request from Modbus Master 15 03 00 50 00 02
Response from PL1000E Slave 15 03 04 00 00
Response from PL1000E Slave 15 03 04 00 50 11 54
1D 24
Data = 4436 messages
Data = 5,250,340 messages
Scale = 1 message/bit
Scale = 1 message/bit
RENR8091-04 53
Systems Operation Section
Ethernet Transmitted Modbus-TCP Errors The following example shows a configuration for a
parameter translation from three ECM's, that are
An accumulator that indicates the number of on Cat Data Link, to a Modbus Master that is
errors that have occurred while the PL1000E was communicating with the PL1000E on RS-232 port 1.
attempting to transmit a modbus message over The PL1000E is configured with a Modbus Slave at
the Ethernet port. Transmitted errors can indicate address of 0x10 on RS232 Port 1.
incorrect or faulty system wiring or incorrect Ethernet
configuration. The accumulator value is reset to Engine Controller (CDL address 0x24)
zero each time that the PL1000E has the power
removed and then has the power turned back on. ICSM#1 (CDL address 0x6D)
The accumulator value is not a lifetime total. If power
to the PL1000E is left on for an extended amount of ICSM#2 (CDL Address 0x6E)
time, then the accumulator value can roll over and
will begin to increment from zero once again. To: Modbus Master on RS-232 Port 1
Sample Message: Note: The default Status Registers and the
Parameter Translation Registers are located at
Request from Modbus Master 15 03 00 60 00 02 different modbus slave addresses on the same
physical port. Refer to the Object - Modbus
Response from PL1000E Slave 15 03 04 00 00 ECM section that is located within the Parameter
00 00 Translation Configuration. The Object - Modbus
ECMsection contains information on assigning the
Data = 0 errors appropriate modbus slave address for Parameter
Translation Registers.
Scale = 1 transmit error/bit
Sample Message:
Number of Modbus-TCP Connections
Request from Modbus Master 15 03 00 C8 00 10
The number of modbus TCP connections that are
currently recognized by the PL1000E. Response from PL1000E Slave 15 03 20 00 24 01
10 00 10 02 20 00 6D 01 10 00 10 02 20 00 6E 01
Sample Message: 10 00 10 02 20 00 00 00 00 00 00 00 00
Table 7
Translation Pair # 1
byte# data 00 24 01 10 (From ECM)
1-2 00 24 ECM Address (Engine Controller MID 0x24)
3 01 ECM Type (Cat Data Link ECM)
4 10 ECM Port (Cat Data Link Port)
byte# data 00 10 02 20 (To ECM)
5-6 00 10 ECM Address (Modbus Slave address 0x10)
7 02
ECM Type (Modbus ECM)
8 20 ECM Port (Modbus-RTU RS232 Port 1)
Translation Pair # 2
byte# data 00 6D 01 10 (From ECM)
9-10 00 6D ECM Address (ICSM#1 MID 0x6D)
11 01 ECM Type (Cat Data Link ECM)
12 10 ECM Port (Cat Data Link Port)
byte# data 00 10 02 20 (To ECM)
13-14 00 10 ECM Address (Modbus Slave address 0x10)
15 02 ECM Type (Modbus ECM)
16 20 ECM Port (Modbus-RTU RS232 Port 1)
Translation Pair # 3
byte# data 00 6E 01 10 (From ECM)
17-18 00 6E ECM Address (ICSM#2 MID 0x6E)
19 01 ECM Type (Cat Data Link ECM)
20 10 ECM Port (Cat Data Link Port)
byte# data 00 10 02 20 (To ECM)
21-22 00 10 ECM Address (Modbus Slave address 0x10)
23 02 ECM Type (Modbus ECM)
24 20 ECM Port (Modbus-RTU RS232 Port 1)
Remaining Bytes
byte# data 00 00 00 00 00 00 00 00 . . .
25-90 00 end of list of mapped ECMs
Note: All of the remaining registers that are requested ECM Address - Any value in the range of 1 through
by the modbus master, that exceed the total number 254. This value will represent either an ECM on
of ECM mapping pairs, are set to zero. a datalink, or a Modbus Slave address that is
assigned to the PL1000E by the system integrator.
ECM Mapping Fields - Valid Values
ECM Type - Refer to Table 8 for definitions of valid
ECM Address values.
Table 8
ECM Type identifier PL1000E Port
0 J1939 ECM
1 Cat Data Link ECM
2 Modbus ECM
Table 9
g01717075
Illustration 69
Diagnostics
Events
RENR8091-04 57
Systems Operation Section
g01717145
Illustration 70
Configuration
The Configuration pages are an alternate means of
setting the ECM Configuration Parameters that are
available in the service tool.
g01720181
Illustration 71
58 RENR8091-04
Systems Operation Section
Default Gateway IP Address If connecting to a All four Modbus locations may be configured at the
network, contact the network administrator for the same time on a single PL1000E module, but no two
appropriate configuration of the Default Gateway IP locations can be set for the same port at the same
Address. If DHCP is not enabled, this will be required time.
for static IP addressing.
The default data link address is 254. The default data
DHCP Dynamic Host Configuration Protocol is link address is also referred to as the Device ID (5)
a process by which a device on a network may and (6) for all Modbus locations, including Modbus
automatically obtain its IP address from a network TCP.
server when the device is powered on or when the
device is reconnected to the network. This process The Device ID (5) and (6) does not need to
enables the use of either the Host Name or assigned be changed unless the system integrator has a
IP address in a standard web browser to view the specific reason for changing the Device ID. All four
device's embedded web pages. Consult with the Modbus locations may use the same Device ID
network administrator for proper configuration of the because each must be on different physical ports.
DHCP enable function. The address, (5) and (6), is only used to access
the Default Status Registers of the PL1000E. The
DHCP Results If DHCP is enabled and executed Default Status Registers contain performance
successfully, the DHCP results will display the statistics of the PL1000E.
assigned IP address, the assigned SubNet Mask,
the assigned Gateway, the assigned Hostname, and The address, (5) and (6), is distinct from the address
the assigned Domain. If DHCP is enabled, then the that is used for the Device ID's that are used by the
information that is typed into the fields above the ECM objects that are defined in the PCL file. The
DHCP area is not in effect. address, (5) and (6), is distinct from the parameters
that are being translated. A Modbus Master device
Modbus Configuration or ECM uses the Modbus Slave addresses that
are defined in the PCL file in order to access the
parameters for the ECM objects that are defined in
the PCL file.
TCP
Cat Data Link Configuration Note: A prompted will appear. The prompt will
request the current password.
PL1000E Module ID (MID)
3. Enter the current password.
The PL1000E Communication Module can be
manually configured to occupy any one of three Reset
distinct source addresses on the Cat Data Link.
This parameter indicates which of the three source Reset Action
addresses the PL1000E should utilize. When multiple
PL1000E Communication Modules are connected to Occasionally, it will be necessary to cause the ECM
the same Cat Data Link network, each must each be to perform either a warm or cold boot sequence,
configured with a unique source address. such as when updating the PL1000E Configuration
Parameters or installing new PCL files. This web
Boost page provides the ability to request the PL1000E to
perform a warm boot function.
The ECM has the capability to extend the physical
harness length limitations of the Cat Data Link Note: The warm boot function feature is protected
network from the standard of 30.5 m (100 ft.) to a by the password. The password is discussed in this
maximum of 305 m (1000 ft.). Enabling the Boost Symptom Procedures section of this document.
function of the PL1000E will allow Cat Data Link
harnessing to which this device is connected to be PL1000E Status Web Pages
run a maximum of 305 m (1000 ft.). See Special
Instructions, REHS2362 for more information related These web pages display the same status information
to harnessing and wiring requirements. that is available in the status screens of the service
tool and can be used for communication verification
Note: CDL boost that is available for the PL1000E, and troubleshooting.
256-7512 Communications ECM (v3) , that uses the
258-4548 ECM, is enabled through a configuration
parameter in Cat ET or through the embedded web
page.
NOTICE
CDL Boost should be enabled only if the wiring lengths
for the harnesses are 30.5 m (100 ft) or greater. If
the wiring lengths for the harnesses are under 30.5 m
(100 ft), then CDL Boost may cause failure.
Password Configuration
Change Password g01720755
Illustration 74
The PL1000E Write Access Password may be
modified from this interface. The current password is Access the status web pages using the left navigation
required to authorize updating to the new password. menu shown in Illustration 74. The following sections
explain the ECM Summary and ECM Mapping
Perform the following in order to change the screens and their contents.
password:
2. Click on Submit.
60 RENR8091-04
Systems Operation Section
g01720774 g01720933
Illustration 75 Illustration 76
PL1000E Summary Screen ECM Mapping Screen
ECM Serial Number Hardware serial number of The ECM Mapping screen displays a tabular overview
the PL1000E Communication ECM. The ECM Serial of the ECMs that are programmed into the device for
Number can be used in order to verify which ECM parameter translations as defined in the PCL file. The
web pages are being viewed when multiple PL1000E table is separated into two sections of three columns.
devices are integrated into the same network. The ECM#, Type, and Port in each section combine
to describe an ECM in the translation. The group of
Personality Module Description The text three columns on the left represent the From ECM,
description of the PL1000E Communication ECM as and the group of three columns on the right represent
it is identified in the service tool data base. This is the the To ECM. This From and To relationship describe
same description seen on the ECM Summary screen the ECMs and direction of data translation relative to
in the service tool. the communication ports and protocols.
Statistics Physical
g01720953
Illustration 78
Total Number of Receive Errors (Rx Errors) The Total Number of Messages Received (Rx
total number of errors that have been identified by Messages) The total number of valid properly
the PL1000E while attempting to receive data on formatted Modbus messages successfully received
the physical port. These errors can be caused by on the communications port.
incorrect baud rate or other port configurations. The
lack of receive errors does not necessarily indicate Total Number of Messages Transmitted (Tx
that protocol communications are successful. It Messages) The total number of messages
simply indicates that all individual bytes are being successfully transmitted by the PL1000E on the
received successfully. Successful communications communications port.
still depends on the communication protocols and the
transmitting devices adherence to the same. Total Number of Receive Errors (Rx Errors) The
total number of errors identified by the PL1000E
Total Number of Transmit Errors (Tx Errors) while attempting to receive Modbus messages on the
The total number of errors that have been identified communications port. These errors can be caused
by the PL1000E while attempting to transmit data by incorrectly formatted messages being transmitted
on the physical port. These errors can be caused by by the Modbus Master or another Modbus Slave
incorrect baud rate and other port configurations, connected to the communications port.
faulty wiring, or incorrect ECM configuration. The
lack of transmit errors does not necessarily indicate Total Number of Exceptions Transmitted (Tx
that protocol communications are successful. Exceptions) The total number of exception
It simply indicates that the PL1000E is able to messages successfully transmitted by the PL1000E
successfully transmit the individual bytes. Successful on the communications port. The PL1000E generates
communications still depends on the communication exceptions in response to requests for invalid Modbus
protocols and the receiving device's adherence to registers or unsupported Modbus Function Codes.
the same.
Total Number of Transmit No Response
Modbus Occurrences (Tx No Rsp) Every time the
PL1000E receives a valid properly formatted Modbus
The Modbus communication statistics page displays message, the ECM increments this counter. Each
the Total Number of Messages Received, Total time the PL1000E transmits a Modbus Message,
Number of Messages Transmitted, Total Number the ECM decrements this counter. The increment
of Receive Errors, Total Number of Exceptions and decrement actions occur within milliseconds
Transmitted, Total Number of Transmit No Response and are typically not viewable on the web page.
Occurrences, and Total Number of Connections (only However, if this value is other than zero it indicates
applicable to Modbus-TCP). These totals represent the PL1000E is receiving Modbus messages and not
the total accumulations since the last warm or cold responding. The PL1000E configuration should be
boot sequence of the ECM. These are NOT lifetime verified and the PCL file should be reviewed to insure
totals. the desired parameters and Modbus communications
are configured appropriately.
Protocol
i03341123
Overview
PCL, Extensible Markup Language (XML), Extensible
Stylesheet Language (XSL), and Cascading Style
Sheet (CSS) files all reside on the PL1000E web
server. These files work together to provide a
customized view of data gathered by the PL1000E.
Illustration 81 displays the relationship between the
file types.
g01721055
Illustration 80
g01214643
Illustration 81
The PCL file contains configurations that translate Creating Custom XML Pages
parameters in a web-based solution. The XML
custom page file consists of a select group of Custom Pages allow user-selected parameters to be
parameters to monitor and view together gathered monitored through a web browser. A Custom Page
from the larger list in the PCL file. The XML, XSL, is configured using an XML file that is published to
and CSS files are read by the browser to provide the the PL1000E Web Server.
user with the view of their data.
To create a custom page:
Understanding the XSL File 1. Copy the CSPL1000E_Custom_Page.xml
template. The template is located on the CD that
The XSL file is a stylesheet for the XML file. The .XSL
was included with the ECM to a PC with a text
file calls the CSS file to use for the web page, places
elements on the page, and associates error strings editor.
with certain values gathered from the ECM.
Throughout this section of the document, there
The style sheet must be indicated in the XML file. The are references to a Parameter Translation Editor
(PTE) .
style sheet controls the format of the data as it will be
displayed on the page. The programmer associates
an XML file with a specific XSL file in the .xsl?> tag
with the filename for the XSL file.
g01721356
Illustration 82
66 RENR8091-04
Systems Operation Section
g01717224
Illustration 83
Table 10
Number Tag Name Description
Contains the Custom Page title (see Illustration 83). Unique titles for custom pages
1 <Title>
allow better organization when analyzing larger or more complex systems.
Each parameter is represented by an item element containing the attributes of that
2 <Item>
parameter.
A unique identifier for a parameter used in a web server translation. The UID
contained in the XML file will be converted to the decimal equivalent value of the UID
3 <UID> included in the PTE file as a hexadecimal value. Refer to Converting a Hexadecimal
Number to a Decimal Number for more information on converting the hexadecimal
number to a decimal value.
The same unique number that is assigned for the ECM ID in the Parameter
Translation Editor for the PCL file. Refer to Modify the properties for the New CDL
4 <ECMUID>
ECM object in the Manual Parameter Configuration List Creation section to identify
the ECM ID.
Contains a label created by the user to describe the ECM from which the parameter
was obtained. This description is free form text and can be customized to clearly
5 ECM Description describe the ECM from which data is being collected. It may be helpful to identify this
ECM with the same description as was used in the PCL file creation, but it is not
necessary. These two descriptions may be different.
Contains a label chosen by the user to describe the parameter that is to be
monitored. This description is free form text and can be customized to clearly
6 UID Description
describe the parameter being displayed. It may be helpful to identify this Parameter
with the same description as viewed in the PCL file creation, but it is not necessary.
The value of the parameter being monitored. The OSEFUNC tag is formatted as:
7 Value /ssi/getparm/X,Y where X is the ECM ID, and Y is the UID. Refer to the
description for item 4 for more information on the ECM ID
8 Decimals The number of decimal places to apply to the value of the parameter to be monitored.
9 Unit The units of measure used for the parameter to be monitored.
10 Type Always set to Zero.
g01721400
Illustration 84
Note: If the page does not appear to reflect the Note: If parameters used in the XML file do not
changes, force the browser to execute a refresh. If appear on the page, make sure that the parameters
the page still does not appear to reflect the changes, were added to the web translation object in the PTE
then close the browser and start the browser again. when the PCL file associated with the page was
created.
Viewing Custom XML Pages Using
a Browser i02836787
Perform the following in order to view the list of Limited Modbus Master
Custom Pages:
The PL1000E can act as a Modbus Master in a
1. Click the Custom Pages tab on the navigation limited fashion. As a Modbus Master, the features
menu. of the PL1000E are limited to translating data from
CDL or J1939 to Modbus. The PL1000E cannot act
2. Click the link in the navigation menu or the link on as a full Modbus Master.
the Custom Pages web page to view the desired
Custom Page. Considerations for Designing a Robust
System
Modbus is a Point-to-Point protocol. Therefore, the
PL1000E will send a request message on Modbus
and then will wait for a response. In a Point-to-Point
protocol system that operates properly, the process
to send a request and wait for a response is not an
issue. If the PL1000E does not receive a response,
the PL1000E will wait for 250ms, and then move on
to the next request. If some slaves do not respond to
the requests of the PL1000E, then system operation
will slow due to the wasted time. If this happens
with too many messages, then the data may not be
received in a timely fashion.
g01721413
Illustration 85
There is another issue that must be considered with
the Point-to-Point protocol. If too many parameters
are being requested within a given time period, there
is possibility that the transmit buffer on the PL1000E
may become full. If the transmit buffer becomes
full, then transmit messages may be dropped. The
equation below is a guideline in order to determine
the load on the Modbus Link. The equation calculates
the total time the system takes to send one request
and receive one response.
g01721414
Illustration 86
g01412383
Illustration 87
LengthReqBit = Total Length of the Request Message in Bits.
BaudRate = The Baud rate you system configured.
TotalPropagationTime = Time that it takes the message to reach the destination.
SlaveResponseTime = Time it takes the Modbus slave to respond to the request from PL1000E.
LengthRespBits = Total Length of the Response Message in Bits.
g01412389
Illustration 88
The total time that is required in order to send one In summary, make sure that the system design
request and receive one response from the system is makes sense. Make sure that high request rates of
110.8ms. In theory you should be able to request 9 the data do not say rates of speed because they
messages per second. In the example, 20 requests a are the inverse of each other.
second are being sent to the transmit buffer, but only
9 messages per second can be sent out. The buffer
for the PL1000E will eventually become full because
the amount of messages that are being queued per
second is more than what is being sent out.
70 RENR8091-04
Systems Operation Section
Table 11
Translation PL1000E as Modbus Slave PL1000 as Modbus Master
The PL1000E requests data on CDL and holds PL1000E requests data on CDL, then writes
CDL to Modbus the data in a Modbus register waiting for a the data to a Modbus Slave.
register request from a Modbus Master
The PL1000E waits for data to be written to it
Modbus to CDL from a Modbus Master, then the PL1000E Not Supported
writes the informationon CDL.
The PL1000E requests data on J1939 and The PL1000E requests data on J1939 and
J1939 to Modbus holds the data in a Modbus register waiting for writes the data in a Modbus Slave.
a register request from a Modbus Master.
The PL1000E waits for data to be written PL1000E requests information from a Modbus
Modbus to J1939 to it from a Modbus master, then writes the slave, then the PL1000E writes the information
information on J1939. on J1939.
The PL1000E requests data on CDL, then
CDL to Webserver Not Supported
pases the data to the webserver.
The PL1000E requests data on J1939, then
J1939 to Webserver Not Supported
pases the data to the webserver.
4. Configure the serial ports that are on the PL1000E. 2. Click Programs.
g01747434 g01721454
Illustration 89 Illustration 91
g01721453
Illustration 90
72 RENR8091-04
Troubleshooting Section
Table 13
Service Tool Capability
Service Tool Feature Caterpillar Electronic Technician Caterpillar Communication Tool Kit
PL1000E ECM Summary Yes Yes
PL1000E ECM Configuration Yes Yes
PL1000E ECM Status Yes Yes
PL1000E ECM Totals Yes Yes
g01721458
Illustration 93
g01721457
Illustration 92
g01721459
Illustration 94
Note: Items (3), (4), and (5) are part of the 171-4400
Communication Adapter Gp.
SMCS Code: 7553-546-WW The failures of the ECM system are displayed.
The location of the service tool connector will vary The status of most of the inputs and the outputs
between applications. Cat ET can be connected to are displayed.
the system as follows:
The settings for the ECM are displayed.
By using the 7X-1700 Comm Adapter
Display the status of the input and output
By using the 171-4400 Comm Adapter II parameters in real time.
Through the embedded com adapter within the Display the clock hour of the internal diagnostic
PL1000E Communication ECM (pins 62, 63, and clock.
64). In order to use the embedded communications
adapter, a custom built service cable must be Load new FLASH software.
connected between the RS-232 port of the PC and
the RS-232 Serial Port 3 of the PL1000E.
Status Groups For The Electronic The second of these screens displays the
Technician communication statistics for serial port 4 which is
the RS-422 and 485 port. For each serial port, the
Cat ET is used as the primary reference in the physical layer bytes that are received, physical
discussion and Illustrations that follow. The reference layer bytes that are transmitted, the physical layer
to the Cat ET also implies a reference to the receive errors, and the physical layer transmit errors
Caterpillar Communication Tool Kit when features are are displayed. This information represents the
common between the two. communication statistics of the physical port and may
include counts of bytes received or transmitted from
Status Group 1 - Serial Port Statistics various protocols on the same physical port. The
physical communication statistics is a good tool to
use to verify the ECM is successfully receiving data
at the most basic level. The communication statistics
on this page are automatically updated by the ECM
every 1 second. These totals are the accumulated
totals since the last warm boot sequence or cold
boot sequence of the ECM (Keyswitch or power
cycle). These totals are not Lifetime totals and will
be reset with each boot sequence of the ECM. The
Clear Counters button (password protected) simply
forces these values to all zeros without the need for a
warm boot or cold boot.
Status Group 2- Modbus Statistics Modbus RTU Receive Errors The total number
of errors identified by the ECM while attempting to
receive Modbus messages on the communications
port. These errors can be caused by incorrectly
formatted messages being transmitted by the
Modbus Master or another Modbus Slave
connected to the communications port. Additionally,
these errors may be caused by requests for registers
or Modbus Function Code not supported by the
ECM.
g01397805
Illustration 97
Modbus Statistics screens 1 and 2
Modbus TCP Receive Errors The total number Modbus RTU packets transmitted The total
of errors identified by the ECM while attempting to number of Modbus RTU messages transmitted
receive Modbus TCP packets on the Ethernet port. successfully by the ECM. These totals represent
These errors can be caused by incorrectly formatted all Modbus RTU messages transmitted on all
messages being transmitted by the Modbus Master configured Modbus ports. The ports are RS-232
or another Modbus Slave connected to the Ethernet Port 1, RS-232 Port 2, and the RS-422/485 Port.
port. Additionally, these errors may be caused by The ECM does not include any message counts
requests for registers or Modbus Function code not from Modbus TCP messages transmitted on the
supported by the ECM. Ethernet port.
Modbus TCP packets transmitted The total Modbus RTU transmit errors The total number
number of Modbus TCP packets successfully of Modbus RTU exception messages transmitted
transmitted by the ECM on the Ethernet port. by the ECM. These totals represent all Modbus
RTU exception messages that are transmitted on
Modbus TCP transmit errors The total number all configured Modbus ports. The ports are RS-232
of errors identified by the ECM while attempting to Port 1, RS-232 Port 2, and the RS-422/485 Port.
transmit Modbus messages on the communications The ECM does not include any message counts
port. from Modbus TCP exception messages transmitted
on the Ethernet port. An exception message will be
Modbus TCP no responses Every time the transmitted under the following conditions:
ECM receives a valid, properly formatted Modbus
message, the ECM increments this counter. Each The ECM receives a Modbus function code it
time the ECM transmits a Modbus message, the does not support. The ECM supports the following
ECM decrements this counter. The increment and function codes: 3 = Read Holding Register, 6 =
decrement actions occur within milliseconds and Write Single Register, 8 = Diagnostics, 16 =
are typically not viewable on the status screen. Write Multiple Registers.
However, if this value is other than zero this would
indicate the ECM is receiving Modbus messages The ECM receives a Modbus request for a register
and not responding. The ECM configuration should outside of the supported register ranges. The ECM
be verified and the PCL file should be reviewed in supports registers in the range of 40,001 to 42000.
order to insure the desired parameters and Modbus
communications are configured appropriately. Modbus RTU no responses The total number
of Modbus RTU messages received successfully
Modbus TCP connections The total number of by the ECM for which the ECM has not transmitted
Active Modbus TCP connections identified and a response. These totals represent all Modbus no
being serviced by the ECM on the Ethernet port. The responses on all configured Modbus ports. The
ECM is capable of supporting up to 10 Modbus TCP ports are RS-232 Port 1, RS-232 Port 2, and the
connections at the same time. RS-422/485 Port.
Status Group 3- Cat Data Link (CDL) Statistics Status Group 3- J1939 Statistics
g01721475 g01721476
Illustration 99 Illustration 100
CDL Statistics screen. J1939 Statistics screen.
CDL packets received The total number of J1939 packets received The total number of valid
valid properly formatted messages successfully properly formatted messages successfully received
received on Cat Data Link (CDL) by the PL1000E on J1939 by the PL1000E Communication ECM.
Communication ECM.
J1939 receive errors The total number of errors
CDL receive errors The total number of errors identified by the ECM while attempting to receive a
identified by the ECM while attempting to receive J1939 message. An increment of this number can
a CDL message. An increment of this number can indicate improper J1939 harnessing. J1939 harness
indicate improper CDL harnessing. CDL harness pin-outs and total bus length should be analyzed.
pin-outs and total bus length should be analyzed.
J1939 packets transmitted The total number of
CDL packets transmitted The total number of messages successfully transmitted on J1939 by the
messages successfully transmitted on CDL by the ECM.
ECM.
J1939 transmit errors The total number of errors
CDL transmit errors The total number of errors identified by the ECM while attempting to transmit a
identified by the ECM while attempting to transmit J1939 message. An increment of this number can
a CDL message. An increment of this number can indicate improper J1939 harnessing. The harness
indicate improper CDL harnessing. The harness should be analyzed and repaired.
should be analyzed and repaired.
80 RENR8091-04
Troubleshooting Section
g01180273
Illustration 101
RENR8091-04 81
Troubleshooting Section
SMCS Code: 7610-035 1. Use Cat ET in order to confirm the Internet Protocol
configuration. Confirm that the IP settings are set
appropriately for direct cross over connections.
Symptom Procedures Refer to the System Operation Troubleshooting
Testing and Adjusting, RENR8091, Internet
Problem - Unable to Browse to the Protocol Configuration section in order to help
PL1000E Home Page - Network determine the appropriate settings.
Connection 2. Confirm that the cable being used is a cross over
cable.
Probable Cause
3. Confirm the PC settings. Refer to the Configuring
1. Using Cat ET, confirm the Internet Protocol
a Non-networked Windows-based PC to Access
configuration. Confirm these settings with the
the PL1000E Communication Module section.
network administrator.
Any deviation from the required settings may
prevent browser access to the PL1000E
2. Confirm the PL1000E Communication ECM is
Communication ECM embedded web pages.
properly connected to power, ground, and key
switch inputs in the system.
4. At the command prompt, type the following
command and press the enter key. Where
3. If the ECM Internet Protocol configurations are
xxx.yyy.zzz.aaa is the IP address or domain
configured properly, try using a DOS shell window
name of the module.
to ping the ECM.
Table 15
Error Probable Cause Remedy
Use the Parameter Transltion Editor
Error: Rolling Reset The PCL file is of an incompatible format
to re-create the PCL file and review
315-0627 Communication Software or there is an invalid configuration
the configuration parameters for any
Group and earlier software parameter causing the reset condition.
invalid data
Indicates that the application software No Remedy, since this is just an
Application Started
initialized properly. informational message.
Unable to create the log_config.txt file
Error: Creating File : log_config.txt indicating the module is out of available Delete older files from Archive folder.
RAM space for file storage.
Use the Parameter Transltion Editor
to re-create the PCL file and review the
configuration parameters for any invalid
data. If problem persists, contact the
Unable to create socket at port 502 or
Error initializing TCP socket product support representative and be
PCL file is of an invalid format.
prepared to provide a copy of the PCL
file and any log status messages to
the product support representative for
analysis.
Contact the product support
representative. Be prepared to
Error initializing PX language Potential Operating System error provide a copy of the PCL file and any
messages from the log status files to
the product support representative.
Obtain latest copy of service tool and
re-create the *.pcl file from scratch.
Error validating file PCL file formatted incorrectly
There may be a version issue between
the service tool and PL1000E software.
Indicates no *.pcl file found in the New
Error reading file Unable to open and process *.pcl file or Current directory. Load the *.pcl file
into the New directory.
RENR8091-04 85
Troubleshooting Section
Table 16
Error Probable Cause Remedy
Error initializing Modbus stack The PCL file was created containing Open and modify the PCL file to change
Bodbus communications defined for the RS-422 or RS-485 connection
both RS-422 and RS-485. The PL1000E definitions so that there is only one or
cannot support these communications the other defined.
simultaneously, as they occupy the
same physical serial port.
Error initializing software Indicates some low level initialization Power down the unit for approximately
failed during application software startup 10 seconds and attempt to start it up
sequence. again. If the problem persists, flash
the module with undated application
software.
Status: Valid - .pcl file loaded PCL file was validated and processed No remedy, since this is just an
successfully successfully informational message.
Unable to create Current directory During initializing, the software was Power down the unit for approximately
unable to successfully create the Current 10 seconds and attempt to start it up
directory. again. If the problem persists, flash
the module with undated application
software.
Unable to create New directory During initializing, the software was Power down the unit for approximately
unable to successfully create the New 10 seconds and attempt to start it up
directory. again. If the problem persists, flash
the module with undated application
software.
Unable to create Archive directory During initializing, the software was Power down the unit for approximately
unable to successfully create the Archive 10 seconds and attempt to start it up
directory. again. If the problem persists, flash
the module with undated application
software.
Unable to create Error directory During initializing, the software was Power down the unit for approximately
unable to successfully create the Error 10 seconds and attempt to start it up
directory. again. If the problem persists, flash
the module with undated application
software.
86 RENR8091-04
Troubleshooting Section
Table 17
Error Probable Cause Remedy
Error: Multiple .pcl files found in the Indicates that multiple *.pcl files were Delete the directory before resetting
Current directory. found in the New or Current directory the PL1000E. Browsers sometimes
Multiple .pcl files found in the New during initialization and the software did cache the names of the files in the New
directory. not know which one to process. and Current directories. Go to Menu,
View, and click Refresh in order to
force the browser to display the most
recent list.
Status: Moved the .pcl from the Current PCL file was successfilly moved from When a file is moved to the error
directory to the Error directory. the Current to the Error directory. directory, it indicates an error in the file
content or format. The latest service
tool should be used in order to create
a new file.
Error: pcl file not found in the Current No PCL file exists in the Current The module first determines if a PCL
directory. directory. file is loaded into the New directory,
and if not, then searches for a PCL file
in the Current directory. Lod a new PCL
file into the New directory and power
cycle the unit.
Error: Unable to set the RW permission Potential operating system error Contact the Technical Communicator
on the Current directory. (TC) and be prepared to provide a copy
of the PCL file and any messages from
the log status files.
Error: Unable to move the .pcl from This error indicates the module is out of Delete older files from the Archive
the Current directory to the Archive available file space for storage. folder.
directory.
Error: .pcl file name truncated to 33 The maximum length for PCL file names No action is necessary unless a
characters. is 33 characters. different file name is desired. If a
different file name is desired, then
load the newly named file in the New
directory observing the maximum
character limitation of 33 characters.
RENR8091-04 87
Troubleshooting Section
Table 18
Error Probable Cause Remedy
Unable to move the .pcl file from the Unable to move the .pcl file indicates Delete the older files from the Archive
New directory to the Current directory. the module is out of available file space folder.
for storage.
Unable to set the RW permission on the Potential operating system error Contact the Technical Communicator
Current directory. (TC) and be prepared to provide a copy
of the PCL file and any messages from
the log status files.
Invalid .pcl file in the New directory. Invalid PCL file format. Obtain the latest copy of the service
tool. Recreate the *.pcl file from
scratch. There may be a version issue
between the service tool and the
PL1000E software.
Status: Invalid .pcl file in the Current Invalid PCL file format Obtain the latest copy of the service
directory. tool. Recreate the *.pcl file from
scratch. There may be a version issue
between the service tool and the
PL1000E software.
Status: Unable to read the .pcl file into This is a general status message that Obtain the latest copy of the service
the memory. indicates there was and error parsing tool. Recreate the *.pcl file from
the .PCL file into the PL1000E memory. scratch. There may be a version issue
The specific error should also be logged. between the service tool and the
PL1000E software.
On-board file header
On-board file header ID !=0xB100
On-board file header Version !0x0002
On-board file header File Contents Type
!=0xC480
Config Data Record block
On-board file header Recblock
!=0xC480
Config Data Record ID !=1
Software Config Data
Software Config Data BlockID !=0xC490 Obtain the latest copy of the service
tool. Recreate the *.pcl file from
.pcl file Base Config Invalid PCL file format scratch. There may be a version
.pcl file Revision issue between the service tool and
the PL1000E software.
Invalid size
Checksum position
Checksum not found
File seeking pk_OnboardFileHeader_t
????? File seeking
pk_CfgDataRecBlock_t
File seeking
File seeking pk_PX_Baseconfig_t
File seeking builderBaseBlobSize
Allocating memory for the tables
88 RENR8091-04
Troubleshooting Section
Table 19
Error Probable Cause Remedy
This is a general error message that indicates
Error reading the
there was and error parsing the .PCL file into the
configuration tables
PL1000E memory. The specific error should also
into memeory Obtain the latest copy of the service tool.
be logged.
Recreate the *.pcl file from scratch. There
Error reading data Specific error message for reading the may be a version issue between the service
link table configuration tables into memeory. tool and the PL1000E software.
Error reading ECM Specific error message for reading the
table configuration tables into memeory.
The PCL file specifies that a serial port for Modbus Use the service tool in order to configure the
Modbus port not communications that has not been properly appropriate Modbus communications serial
configured configured on the PL1000E configuration screen port to match that is defined in the PCL file.
in ET
The PL1000E will not accept a Modbus slave Modifiy the Modbus slave address to a value
Illegal Modbus address
address of zero. between 1 and 254.
The slave address that is defined in the PCL file
for RS-232 port 1 is the same as the Modbus
slave address that is defined in the service tool
configuration. These two slave addresses must be
Use the service tool in order to change the
Modbus slave address different. The Modbus slave address that is defined
slave address for the configuration that is
conflict RS-232 port 1 in the PCL file is used to access data that is defined
associated to the RS-232 port 1.
in the PCL file. The Modbus slave address that is
defined in the service tool configuration screen is
used to access communication statistics and ECM
information from the PL1000E.
Table 20
Error Probable Cause Remedy
Error reading the tag table
Error reading the DSWrite table
Error reading the DSRead table Obtain the latest copy of the service
tool. Recreate the *.pcl file from
Specific error message for Error reading
Error reading the Enum lookup table scratch. There may be a version issue
the configuration tables into memeory.
between the service tool and the
Error reading the Unit Conversion table PL1000E software.
Error reading the language table
Error reading the string index table
Table 21
Error Probable Cause Remedy
Error reading string blob
Error validating Base Config
Error validating Data Link Types Obtain the latest copy of the service
tool. Recreate the *.pcl file from
Specific error message for Error reading
Error validating ECM table scratch. There may be a version issue
the configuration tables into memeory.
between the service tool and the
Error validating Tag table PL1000E software.
Error validating DSWrite table
Error validating DSRead table
Table 22
Error Probable Cause Remedy
Error validating Enum table
Error validating
Error validating
Obtain the latest copy of the service
lfp tool. Recreate the *.pcl file from
Specific error message for Error reading
scratch. There may be a version issue
Error fread !=readSize the configuration tables into memeory.
between the service tool and the
PL1000E software.
Invalid source path/file name
Invalid destination path/file name
Error writing to destination file
90 RENR8091-04
Troubleshooting Section
Q: Why does the browser not show the changes 2. Click Status.
made on the pages that were just uploaded to the
web server? 3. Click ECM Mapping.
A: The issue may be that the browser still has old Note: Two tables will be displayed. Look at the bottom
data cached within the memory set aside for this table which contains a summary of translations in the
purpose. Select the web page within the web browser PCL file. At least one of the translations must be a
by clicking within the page but not on a link. Click the CDL to Web translation. If not, create a CDL to web
Refresh button on the tool bar of the browser or use translation for each desired parameter.
the Refresh function for the browser. If this process
does not work, browse off of the page and clear the 4. Save the PCL file.
cache of the browser according to the instructions of
the browser. Then try to browse the page again. 5. Republish the PCL file.
Q: Why does the message Parameter Unavailable 6. Cycle the power to the ECM.
appear for a parameter that is on the custom page?
7. Browse to the custom page in order to confirm that
A: If the custom page displays the message the changes are updated.
Parameter Unavailable in the value part of the table,
then the parameter either does not exist in the PCL
file on the PL1000E web server or there is an error in
the coding of the XML file.
g00820688
Illustration 102
(1) Correctly Routed Harness (3) Incorrectly Routed Harness
(2) Correctly Inserted Plug (4) Incorrectly Inserted Plug
g00690571 g00828600
Illustration 103 Illustration 104
Proper Installation of Plug DT Type sealing plug
The 8T-8729 Connector Pin (2) and the 8T-8730 Connector
Socket (1) is designed to accept only one 16/18 AWG wire. Do not
insert multiple wires of a smaller wire size. An incorrect method
would be using two 24 AWG wires. The 9W-0852 Connector Pin
and the 9W-0844 Connector Socket is designed to accept only one
14 AWG wire. Do not insert multiple wires of a smaller wire size. An
example of an incorrect method is the use of two 20 AWG wires.
a. Ensure that the connector is properly locked. a. Each connector contact should withstand 45 N
Also, ensure that the two halves of the (10 lb) of pull. Each wire should remain in the
connector can not be pulled apart. connector body. This test checks whether the
wire was properly crimped in the contact and
b. Verify that the latch tab of the connector is whether the contact was properly inserted into
properly latched. Verify that the latch tab of the the connector.
connector is fully latched.
b. The DT connectors use an orange wedge to
Expected Result: The connector will securely lock the terminals in place.
lock. The connector and the locking mechanism
are without cracks or breaks. c. Check in order to ensure that the orange wedge
is not missing and that the orange wedge is
Results: installed properly on the DT connectors.
OK The connector will securely lock. The Note: A Crimp Tool should ALWAYS be used in order
connector and the locking mechanism are to crimp wires on connector contacts. Do not solder
without cracks or breaks. Proceed to test step the terminals. Use the proper Crimp Tool.
2.
Expected Result: Each connector contact
NOT OK A problem exists with the connector. should withstand 45 N (10 lb) of pull. Each wire
remains in the connector body.
Repair: Repair the connector or replace the
connector, as required. Results:
Results:
94 RENR8091-04
Testing and Adjusting Section
c. Thoroughly inspect ECM connectors for Expected Result: The contacts are properly
evidence of moisture entry. If moisture or aligned and the contacts appear undamaged.
corrosion is evident in the connector, the
source of the moisture entry must be found Results:
and the source of the moisture entry must be
repaired. If the source of the moisture entry is OK The contacts are properly aligned and
not repaired, the problem will reoccur. Simply the contacts appear undamaged. Proceed to
drying the connector will not fix the problem. test step 7.
Likely paths for the entrance of moisture are
from missing seals, improperly installed seals, NOT OK A problem exists with the connector
nicks in exposed insulation, and improperly contacts.
mated connectors.
Repair: Repair the contacts and wiring and/or
Note: Moisture can also travel from one connector replace the contacts and wiring.
through the inside of a wire to the ECM Connector. If
moisture is found in the ECM connector, thoroughly STOP.
check all connectors and wires on the harness that
connect to the ECM. The ECM is not the source of 7. CHECK THE FIT OF THE CONTACTS.
the moisture. Do not replace an ECM if moisture is
found in either ECM connector.
STOP.
i02815873
Results:
96 RENR8091-04
Testing and Adjusting Section
i02815888 i03342206
Electrical problems are often caused by failed The PL1000E is flashed in order to upgrade the
electrical wires that have either an open circuit or a software. Flash programming of the ECM must
short circuit. If one part of the circuit contacts another also be done if the ECM has been replaced. The
part of the same circuit, the flow is diverted from the Caterpillar Electronic Technician (ET) contains the
desired path. This would be a short circuit. program WinFlash. WinFlash is used in order to load
software into an ECM.
Perform the following in order to test for a short
circuit: Three communications adapters are available in
order to flash electronic control modules:
Test for a short circuit.
7X-1700 Communication Adapter Gp
1. Turn the battery disconnect switch key and the
key start switch to the OFF position. 171-4400 Communication Adapter Gp
2. Disconnect both ends of the wiring harness. Embedded Communications Adapter (ECA) is
available on serial port 3 of the ECM. The ECA
3. Turn the multimeter dial to the 200 ohm range and feature supports ECM flashing functionality when
measure the electrical resistance. application software is installed on the ECM. If a
Blank Box condition occurs due to connection
4. Turn the multimeter probe in order to make related probems or due to power lost during the
contact with the connector of the suspected faulty flashing procedure for the PL1000E, then use of
electrical wire. the 171-4400 Communication Adapter Group will
be necessary in order to flash the PL1000E.
5. Use the other probe from the multimeter to check
for continuity across all electrical wires in the same Perform the following procedure in order to flash
wiring harness and check all wires for continuity program the PL1000E:
across the frame to ground.
1. Connect the appropriate data link cable between
6. If there is continuity between any of the electrical the communication adapter and the personal
wires, the multimeter will have a reading of less computer (PC) that contains Cat ET software.
than 5 ohms. Continuity between any other wires When using the ECA, the data link cable is a serial
in the wiring harness indicates that there is a short connection directly between the PC and serial port
between those wires. The wiring harness must be 3 of the ECM .
repaired or replaced.
2. When the ECA is not used, connect the data link
7. Use the multimeter in order to test for continuity cable between the communication adapter and
across the frame or ground. If there is continuity the diagnostic connector of the engine. If the ECA
between any of the electrical wires, the multimeter is used, the ECA is already connected to the
will have a reading of less than 5 ohms. If there system by the use of the standard Cat DataLink or
is continuity between any of the wires and the J1939 connection.
frame, there is a short circuit between the wire
and the frame. Identify the wire that has a short to 3. Use WinFlash in order to load the software.
the frame.
i03346220
Reference: In order to determine if the wire is a part
of the ground circuit, refer to the Electrical System
Schematic section of this document.
Electronic Control Module
(ECM) - Configure
If the wire is a part of the ground circuit and the wiring
harness is damaged, the wiring harness must be SMCS Code: 7610-025
repaired or replaced.
Cat ET or Caterpillar Tool Kit is required in order to
configure the PL1000E Communications ECM.
RENR8091-04 97
Testing and Adjusting Section
Once Cat ET is connected and the PL1000E 6. Verify that the ECM operates correctly.
Communication ECM has been selected, the user
can navigate to the configuration screen through the
i03342500
use of the service tool menus.
System Schematic
SMCS Code: 7566
g01721477
Illustration 106
i02811340
g01717876
Illustration 107
RENR8091-04 99
Index Section
Index
C I
F
P
Features .................................................................. 4
CDL Boost............................................................ 6 Parameter Translation Configuration...................... 11
Embedded Communications Adapter (ECA) ....... 6 Create *.pcl File Using the PCL Wizard ............. 21
Embedded Webserver ......................................... 6 Create a Modbus Master PCL File..................... 23
PL1000E configured as a Limited Modbus Create Parameter Translation Design ................ 11
Master ................................................................ 5 Familiarization with the Parameter Translation
PL1000E configured as a Modbus Slave............. 4 Design Interface ............................................... 12
Initiate Configuration of PL1000E with New PCL
File ................................................................... 26
G Installation of PCL File to PL1000E ................... 26
Manual Parameter Configuration List Creation.. 15
General Information........................................... 4, 72 Open an Existing *.pcl file for Modification......... 24
Parameter Translation Files and Configuration
Tools.................................................................. 11
H
Hardware Configuration......................................... 27
ECM Configuration............................................. 27
Hexadecimal Conversion....................................... 70
Q
Table of Contents..................................................... 3
Testing and Adjusting ............................................ 91
Testing and Adjusting Section ............................... 91
Troubleshooting Section........................................ 72
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