Step 1: Background
I am an industrial automation engineer and I am currently working on a large electrical system where we are providing the network, plc automation and scada system for a large number of low and medium voltage breakers.
we selected profinet as our communication standard due to its massive speed relative to other industrial communication protocols and the easy transfer for data to and from breakers with the assistance of gxml files
learn more about profinet here: http://us.profinet.com/technology/profinet/
and gxml here: https://wiki.gnome.org/GXml)
I hope this will be useful to some and interesting to others to see a communication method many don't even know exists.
Step 2: Stripping
Profinet cable is always green and only has 4 cores, compare this to cat 5 for example that has 8. The cores are also much heavier than cat 5. Profinet cable is also shielded with a metal braid, this is important for the reduction of interference in your automated system. Cat 5 will work but your installation will not be as reliable.
The cable should cut square to ensure all cores are of equal length.
Using a profinet cable stripper (this one is from Siemens) insert the cable with about 1 cm excess, the pictogram indicates which side the tool strips from.
The tool uses a cam to push on the back of 2 blades, one strips the outer insulation, the other cuts through the shielding. The tool needs a couple of rotations and then a pull to remove the waste. The resultant cut can be seen in the last image.
Step 3: The Connector
The ultimate termination is an RJ45 but the connector is designed to accommodate the larger cores and to ground put the shielding at both ends of the cable.
the connectors I am using here are from phoenix contact, the project uses straight and 90degree connectors.
These aluminium connectors are also self crimping so there are small blades that pierce the outer insulation of the cores.
There is a small sticker inside the connecter to tell you the colour order: blue, white, orange, yellow.
This is a big step where people go wrong, they lay the wires across the top of the channels, however, there are small holes to pass the cores through to enter the channels.
Step 4: Correct Insertion of Cables
No core should pass the end of the green section of the connector, but all cores must reach the widened area in their respective channel to ensure they are crimped.
Step 5: Crimping
You must ensure that the connection is completely closed (no graps along the connectors to effect data flow)
Once you are happy with the cable.
Step 6: Insert and Test
Pig it in the test it. If the orange light on the device stays on the you have device to device comms.
You can ping test across profinet but in my experience cat 5 micro mappers do not work as the cables are such a heavy gauge they soak up the small test current over a very short distance.