1. Ethernet Cable Installation and Troubleshooting
Brian Shuman, RCDD
November 2003

2. Design Considerations Copper Cable Installation Guidelines
Agenda
Introduction
Design Considerations
Copper Cable Installation Guidelines
Troubleshooting
Standards Update
Summary

3. Design Considerations
Environmental Evaluation
Temperature (max & min)
Moisture (humidity, wash down)
Chemicals, oils, etc.
EMI (sources and severity)

4. Design Considerations (cont)
Distances
Keep copper runs to 100 meter max total channel length
Reduce length for elevated temp or use high temp cable
Limit patch length to 10 meters if 90 meters of horizontal is used
Use fiber optic cabling for longer runs

5. Design Considerations (cont)
Component Selection
Cat 5e minimum
Industrial grade cable jackets
Sun Res
Oil Res
Special jackets for unique applications, just ask!
Upjackets for added robustness
Armor for even more robustness

6. Design Considerations (cont)
Component Selection (cont)
Sealed connectors
IP67 rating for wash down
Not intended for submerged applications
Shielded components for high EMI applications

7. Design Considerations (cont)
Component Selection (cont)
RJ-45 vs M12-4
RJ-45 is commercial standard
M12-4 is sealed has a smaller footprint than sealed RJ-45s
Must use Ethernet M12-4 (D-coded)

8. Design Considerations (cont)
Pathways & Spaces
Tray or conduit where needed
Route cabling away from potential noise sources (drives, welders, power lines, etc.)
Cross power lines perpendicularly

9. Copper Cable Installation Guidelines
Pulling Cable
Minimize pull force
Commercial cables stretch easily!
Lay cable into tray where possible

10. Copper Cable Installation Guidelines
Terminating
Minimize jacket removal
Pairs should not be exposed outside of the connector
Minimize pair untwist length
TIA 568-B recommends ¼” max
1/8” or less is achievable
Pre-terminated, pre-certified assemblies for “plug and play” installation
Keep spares “just in case”

11. Copper Cable Installation Guidelines
Terminating
RJ-45 “pin-out”
T568B most common
M12-4 pin-out

12. RJ-45 Wiring Diagram - T568A W-G G W-O BL W-BL W-BR BR O 1 2 3 4 5 6 7
Pair 1
Pair 3
Pair 2
Pair 4

13. RJ-45 Wiring Diagram - T568B W-O O W-G BL W-BL W-BR BR G 1 2 3 4 5 6 7
Pair 1
Pair 3
Pair 2
Pair 4

14. M12 - 4 D Pin Out RX- Receive Data - 4 RX+ Receive Data + 2 TX-
Transmit Data - 3
TX+
Transmit Data + 1
Signal
Name
Pin

15. Administration
TIA 606 Standard describes commercial cabling administration
Document methodology
What do the labels mean?
Keep duplicate copies
Labeling software & label printers are available

16. Testing & Certification
Handheld Testers vs. Multimeters
Need to measure RF parameters
Insertion loss (attenuation), NEXT, Return Loss, ELFEXT, Delay, Skew, etc.
Basic continuity check not sufficient!

17. Testing & Certification
Channel vs. Link Requirements
Channel includes patch cords
Channel has a plug on each end
Channel testing is recommended
Channel is what the devices actually see
Link has a jack on each end (90 meters max)
Link is not what the devices will see, only part of the communication path!

18. Testing & Certification
Testing Two Pair Systems
Requires user configured set-up
Only two pair M12 approved
Use M12 to RJ-45 adaptor patch cord
Single end grounding of the shield and wire mapping
Use unshielded cable setting

19. Testing & Certification
Test Documentation
Proves everything was OK when you left!
Final Check Out
Connectors fully engaged to switch or device
Unused connectors capped

20. Troubleshooting Wiring Errors Wire map checks wiring pin out
Reversed pair
Split pair
Transposed Pairs

21. Correct Wire Map 1 2 6 3 5 4 7 8
Correct pairing

22. Incorrect Wire Maps 1 2 6 3 5 4 7 8 Transposed pairs Split pairs
Reversed pair

23. Troubleshooting Length and VP VP is Velocity of Propagation
IF VP is set high, measured length will be too long
Testers have default VP, may not be correct
Consult the cable manufacturer’s data sheet

24. Troubleshooting Failures in Testing Check setting (link vs.channel)
Check limits (Cat 5e vs. Cat 6)
*Pass or *Fail
Too close to call within the accuracy of the tester

25. Troubleshooting Temperature and Attenuation
Tester measures absolute attenuation
Temperature correction not included
Good idea to test at operating temperature
An hour or more may be needed to allow cabling to reach the ambient temperature

26. Troubleshooting Time Domain Reflectometry Pulse is sent down the pair
Reflections are correlated to length
Shows impedance/RL discontinuities
Lists value as a percent of the total power reflected
Typically termination issues

27. Troubleshooting Time Domain NEXT Pulse is sent down the transmit pair
Reflections are correlated to length on receive pair
Shows NEXT source(s)
Lists value as a percent of the total power reflected
Typically termination issues

28. Troubleshooting Noise measurements
Handheld testers give ambient noise warning
May show a crosstalk failure
Spectrum analyzer would be needed to determine noise source and magnitude
Most noise sources are intermittent. Must catch the offender “in the act”

29. Standards Update Specification available
Planning and Installation Manual available
Both are continually being reviewed and updated

30. Standards Update (cont)
TR-42.9
Currently on Draft 2
M.I.C.E. Table
Mechanical
Shock, vibration, etc.
Ingress (sealing)
Climatic
UV radiation, temperature, etc.
Environmental (EMC)

31. Standards Update (cont)
M.I.C.E. 1 is commercial off the shelf (COTS)
M.I.C.E. 2 will be “light industrial”
M.I.C.E. 3 will be “heavy industrial”
Defining these will happen next week
Standard is scheduled for end of 2004 release
Balloting process has yet to begin

32. Standards Update (cont)
Working group progressing toward a standard
Originated M.I.C.E. concept
Standard by the end of 2004?
Technical advisory group (TAG) from US working closely with ISO/IEC

33. Standards Update (cont)
Group is working to insure interoperability and harmonization among the different standards groups
Installation guide available

35. Summary Copper cable installation guide Troubleshooting
Be gentle!
Troubleshooting
Use the right tools!
Standards Update
Stay tuned!

36. Questions?