Reactos Debug Cable

 

There are a number of ways to make a Null Modem Cable, so you can't just pick one up from the store - I tried - it won't be wired right and it won't work with ReactOS. We are going for the least expensive routes. In any case the part of the trouble here is getting the wire in a smaller size than 100' which in most cases is very expensive($77) - but I have a $5 workaround. Wiring: see reactos debugging wiki.

Caution: Note that you need to wash your hands after a soldering session if you are using leaded solder, and the burning rosin fumes/smoke may make you sick if you spend a long time in the room with a lot of soldering (with rosin core solder), so make sure you have adequate ventilation (read: fan & window or a fume extractor). If you have a problem with that, I suggest Organic-core solder (it is 7x more expensive to buy). In general, you shouldn't have a problem with a project this size. Also, you will probably get some callouses/burns from soldering - I've been sizzled quite a number of times (I don't have a 3rd hand tool handy). Parts do get hot. Comes with the territory.

You should make sure that you use just enough solder to wet the connection well, but don't get solder blobs. You will need the desoldering tool for that. soldering is a balancing act unless you have a good 3rd hand handy (some electronics shops sell those, but I don't think Radio shack sells those anymore). remember, water in the sponge gets old, so squeeze it out after you are done.

Note: OK Industries' parent company is Jonard Industries Corp.

I recommend buying, gathering:

  • a $5 25' cat5/cat5e/cat6 (could be cat3 I think) straight-thru pre-fab ethernet cable w RJ45 ends (unshielded is fine) - don't cut off the ends - leave the cable the way it is.
  • (4) RJ45F-DB9F kits (2 extra in case of mistakes, saves on $10 shipping costs, and they are cheap)
  • a pair of fine point pliers. $19
  • a $9 15-40Wsoldering iron (for electronics - not a soldering gun or a coldheat!) - you can get one from Radio Shack
  • $8 soldering iron holder. preferably one that has a place for a sponge or comes with a sponge. get a sponge and dip it in water.
  • $4 solder. Some tin/lead or silver or lead-free, organic or rosin core - again, you can get some from radio shack or from your local electronics shop.
  • $24 desoldering tool (solder sucker) - I like the high-powered ones best.
  • $4 heat shrink tubing
  • *maybe* spend the money on some pin extraction tools. $12-$148

Total cost: $72-$84+$30shipping. If you already have the tools and solder, it will only cost about $8.30+$10shipping.

Methods

solder cup DB9F+hood method

got a soldering iron ? you might singe your fingers, but we've all got callouses... a vulcanized rubber mat or silicone mat handles the hot solder droplets and makes a nice mat to handle the heat of the part. you may need to buy an extra connector in case you cause meltdown on the first one.

You want to take advantage of the twisted pair nature of the cable that you buy - it reduces unwanted crosstalk between the wires. in your case, you would want 9&5, 2&3, 7&8, 4&6-1 using 5 with the shield. You want 4-pair twisted pair stranded copper cable or a 3-pair shielded twisted pair cable.

I am assuming here for these 2 tables that brown is twisted with red, orange is twisted with yellow, green is twisted with blue, violet is twisted with grey.

You can avoid using heat shrink tubing if you can fit both wires into pin 6.

1st connector (straight thru)
db9 pin cable color
2 (1) brown
3 (2) red
4 (3) orange
6 (4) yellow. if 3-pair cable, this is the shield wire.
7 (5) green
8 (6) blue
1 (7) violet (cut violet wire short at cable end and splice into pin 6 (4) yellow, solder 7 violet into db9 pin 1). use heat shrink tubing if you can to protect the connection from shorting against the connector pins and the shell.
5 (8) grey. gnd. If 3-pair cable, this is the shield wire. use a piece of cable wire to connect the shield wire.

2nd connector (twisted pair)
db9 pin cable color
3 (1) brown
2 (2) red
6 (3) orange
4 (4) yellow.
8 (5) green
7 (6) blue
1 (7) violet (cut violet wire short at cable end and splice into pin 6 (3) orange, solder 7 violet into db9 pin 1). use heat shrink tubing if you can to protect the connection from shorting against the connector pins and the shell.
5 (8) grey. gnd. If 3-pair cable, this is the shield wire. use a piece of cable wire to connect the shield wire.

RJ45F-DB9F kit method

you will need an RJ45 crimper/stripper to do this job, and some crimp-on RJ45 connectors. you will also need to do some soldering and probably some crimping (hope you have one of those - $50 for each crimper, but you can get by using a pair of pliers instead of the db9 pin crimper). You might also want to solder the connection too to make sure the connection is good, but don't get solder outside the pin or you might have a hard time inserting the pin.

You want to take advantage of the twisted pair nature of the cable that you buy - it reduces unwanted crosstalk between the wires. in your case, you would want 9&5, 2&3, 7&8, 4&6-1 using 5 with the shield. You want either a 4-pair twisted pair solid copper cable, the kind used with the RJ45 ethernet cables - plenum is kind of expensive, but if you really need to be running the cable through heating ducts, then it's required. you can find plenum at newark.com, mouser.com, or digikey.com or at cyberguys.com.

You want solid cable instead of stranded because you will be feeding the wire into the rj45 connector's wire slots. You do not have to strip the wire first. You only have to strip the outer 2nd jacket off of the cable using the built-in cable stripper.

Make sure you crimp the RJ45 connector real good [if you have to crimp one]. The more expensive ratcheting crimpers from Paladin (1300 and 8000 series) take care of this for you without the extra effort.

1st connector (straight thru)
db9 pin RJ45 enet cable color rj45-db9f color
2 W-G (TX+) 1 brown
3 G (TX-) 2 red
4 W-O (RX+) 3 orange
5 BL 4 yellow
1 W-BL 5 green (cut green wire short at rj45 end and splice into 6 blue, plug 5 green into db9 pin 1)
6 O (RX-) 6 blue
7 W-BR 7 violet
8 BR 8 grey

2nd connector (twisted pair)
db9 pin RJ45 enet cable color rj45-db9f color
3 W-G or W-O 1 brown
2 G or O 2 red
6 W-O or W-G 3 orange
5 BL 4 yellow
1 W-BL 5 green (cut green wire short at rj45 end and splice into 6 blue, plug 5 green into db9 pin 1)
4 O or G 6 blue
8 W-BR 7 violet
7 BR 8 grey

Supplies

DB9F solder cup
small connector, 9 pins, for serial ports (on a PC (which is a DTE) they are mail (pins). So you need a female connector (DB9F) to connect to a PC as a DCE.
D-SUB SOLDER CUP DB9F, available from computercasesandcables.com $1.08
this is it.
db9 hood
this is the shell that encases the connector - the part that you are supposed to hold on to when you plug the cable in. the plastic ones at least come with a screw (not a thumbscrew, that's something entirely different) to secure the cable in place so it doesn't come out. usually, you have to screw them in all the way...
DB9 DIECAST METAL HOOD 161-2180, available from computercasesandcables $3.77
DB9 METALIZED HOOD W/THUMBSCREW 161-2165, available from computercasesandcables $2.34
DB9 METALIZED HOOD 161-2153, available from computercasesandcables $2.05
DB9 PLASTIC HOOD GRAY 161-2140, available from computercasesandcables $1.08
RJ45F-DB9F kit
the cat5 cable you need to use with this is NOT flat. it is round.
DB9F/RJ45F 8WIRE UNASSEM DB9F/RJ45F 8WIRE UNASSEM GC-01602, available from computercasesandcables $0.79
3-pair shielded multiconductor data cable
use this with the DB9F solder cup connector.
87K7396 BELDEN 9873 060100 Shielded Paired Cable, No. of Pairs:3; Conductor Size AWG:24; Jacket Color:Chrome; Jacket Material:Polyvinylchloride (PVC); No. Strands x Strand Size:7 x 32; , available from newark $136.36
4-pair multiconductor data cable
you can look on newark for the following: Cable, Wire & Accessories|Cable, Multipaired. Criteria: No of pairs=4, Conductor Material=Copper. You can also choose Cat5, Cat3, Cat5e, Cat6. You can get cable for very cheap in bulk for a 1000' spool if you want to go that far. The solid (incl. cat5e) wire is used for the RJ45F-DB9F kit. You don't want to use solid wire unless you can avoid it. You don't have a choice with the RJ45. You do with the solder-cup.
Assembled Cat 5e 25 foot Cable (you choose color), available from computercasesandcables.com $5.90
use this with the rj45 kit. just cut the ends off. you can't find any cheaper bulk cable than this.
cat5e 250ft solid cable bulk, available from cyberguys.com $37.95
use this with the rj45 kit
Ziotek 1000ft. CAT5e Plenum Solid Bulk Cable Grey, available from cyberguys.com $229
use this with the rj45 kit. use this kind of cable for going through heating ducts and air conditioning [HVAC] (the plenum spaces of buildings).
87K7358 BELDEN 9504 060100 Shielded Paired Cable No. of Pairs:4; Conductor Size AWG:24; Jacket Color:Chrome; Jacket Material:Polyvinylchloride (PVC); No. Strands x Strand Size:7 x 32; , available from newark $69.12
use this with the solder cup connectors. shielded twisted pair is the best kind of cable you can get. it prevents noise from getting into the signal (if you ground the shell or the outer metal part of the connector).
Multiconductor Communication & Control Cable Conductor Size AWG:22; No. of Conductors:8; Jacket Color:Gray; Jacket Material:Polyvinylchloride (PVC); No. Strands x Strand Size:7 x 30; , available from newark $76.31
use this with the solder cup connectors. This is not the preferable cable because it is not twisted-pair (I do not know entirely how much crosstalk happens at 115kbps?). it is less expensive bulk than the other.
Multiconductor Paired Communication & Control Cable No. of Pairs:4; Conductor Size AWG:18; Jacket Color:Gray; Jacket Material:Polyvinylchloride (PVC); No. Strands x Strand Size:16 x 30; 03F6257 ALPHA WIRE 2244C SL005 , available from newark $274.03
use this with the solder cup connectors.
RJ45 crimp tools
Paladin 1541 Ecomonomy CRIMPER TELEPHONE PLUG RJ11/RJ45 PAL1545.1-ND, available from digikey $38.69
Ratcheted, Embedded cable cutter and stripper, Strips BOTH flat satin phone AND round data cables including Cat5, Cat5e, & Cat6
Paladin Tools 1374 TOOL CRIMP MOLEX/AMP STP RJ45 1374-ND, available from digikey $58.99
Fully-ratcheting cycle with built-in safety release, Interchangeable die sets made from heat treated steel for longer use, Easy to use and maintain, Available as complete tool with die inserted or separate tool frame and individual die sets, Foam-lined case or soft zipper case available to hold tool and assorted dies together, EZI-Change™ die screws make changing dies quick & easy, Most precise and tightest tolerances on die sets in the industry, 6 ratchet gear settings for optimum crimp performance
fine-point pliers
for all I know youi may be able to get these at sears, but I suspect you will be going to the local electronics shop.
[Newark 96F8887] COOPER TOOLS / XCELITE - L4 - TOOLS,PLIERS,WIRE TWISTING/SEALING , available from newark $18.74
fine point spring-loaded short-nose pliers (Tip Dimensions 3/64"x1/32"), so I think it will fit in the socket of the db9.
[Newark 18M9952] COOPER TOOLS / WELLER 2443P, available from newark $64.85
very fine point pliers, I think for use on watches, so it's sure to fit in the socket of the db9!
ToolsGS HTX-450S Xuron Serrated Tweezernose™ Pliers, available from toolsgs $16.75
The HTX-450S is the ultimate in serrated needlenose pliers, precise enough to handle the most delicate parts while strong enough to form and bend wire. Multiple milling operations on each plier's nose ensure the blades match in size, shape and alignment. Cushioned grips enhance control and increase comfort. Serrated tip improves grip. ships in roughly 3 to 5 days
RJ45 modular unshielded crimp-on connectors
380-1008-ND 943-SP-370808M2-A264 CONN 8-8 MOD PLUG CAT5 37 Stewart Connector Systems, Inc Round Cable, Solid or Stranded Wires 8p8c (RJ45, Ethernet) Category 5e Unshielded Crimp Translucent - Clear 0.845"(21.46mm) Plug, available from digikey $0.48
380-1098-ND SS-37000-002 CONN MOD PLUG 8-8 CAT5E 37 Stewart Connector Systems, Inc Round Cable, Solid or Stranded Wires 8p8c (RJ45, Ethernet) Category 5e Unshielded Crimp Translucent - Clear 0.845"(21.46mm) Plug, available from digikey $0.42
Soldering Iron
Weller PRO SOLDERING IRON DIRECT PLUG 25W, available from digikey $37.07
weller makes some good low-end irons (when you aren't looking for a reflow station). Eventually necessary is the retaining nut possibly $3
Radio Shack 25-Watt Pencil, available from radioshack.com $8.79
radio shack special - careful it has a wide tip and the $3 tip 64-2073 eats away somewhat fast.
Radio Shack Soldering Work Station with Dual-Powered Iron 64-2184, available from radioshack $22.99
this has a holder and sponge. this one should be a little more ideal for the inexpensive. radio shack special - careful it has a wide tip and the $3 tip 64-2065 eats away somewhat fast.
Soldering Iron Holder
radio shack Soldering Iron Holder and Cleaner (sponge) 64-2078, available from radioshack $7.99
Solder
I can't remember whether silver solder had a lower melting point than tin-lead or not. The lead-free solder usually has more tin.
Radio Shack Lead-Free Solder (0.5 Oz.) 64-026, available from radioshack $9.89
Great for repairing joints on printed circuit boards in computers, TVs and more.
Radio Shack Rosin Core Solder (8.0 oz.) 64-009, available from radioshack $9.89
Standard 60/40 formula for electronics work. 0.032 diameter. 8.0 oz. spool.
Radio Shack Rosin Core Solder (1 Lb.) 64-008, available from radioshack $12.99
Standard 60/40 formula for electronics work. 0.062 diameter. 1 lb. spool.
Kester 331 Organic Water Soluble Lead-Free Solder 18 Guage, 3.3% Flux, .050 (1.27mm) dia, 1lb. KE1129-ND, available from digikey $52.40
Kester 331 Organic Flux is a water soluble formula for use in flux-cored solder wire. The flux is more heat stable than most organic fluxes, resulting in minimal smoke and odor. The residue can be completely removed with a simple water rinse. Kester 331 is classified as ORH1 per J-STD-004.
Kester 331 Organic Water Soluble Lead-Free Solder 25 Guage, 3.3% Flux, .020 (0.51mm) dia, 1lb. KE1126-ND, available from digikey $67.28
Kester 331 Organic Flux is a water soluble formula for use in flux-cored solder wire. The flux is more heat stable than most organic fluxes, resulting in minimal smoke and odor. The residue can be completely removed with a simple water rinse. Kester 331 is classified as ORH1 per J-STD-004.
Desoldering pump
useful for taking the excess solder out from between stuff, etc. you should have one.
OK Industries High-Vac Desoldering Pump with Tip, Blue K412-ND, available from digikey $18.75
K413-ND extra tip $3. This looks like the famous old Soldapullt. It twists open and unlocks so you can remove any solder off of the innards (I haven't had any trouble). Usually I am picking stuff out of the tip if it isn't already ejected out. The tip has a long wear.
OK Industries ESD Safe Desoldering Pump with Tip, Black K414-ND, available from digikey $23.75
K415-ND extra tip $5. This looks like the famous old Soldapullt. not necessary to have the esd-safe unless you are doing IC's (chips) and transistors too. It twists open and unlocks so you can remove any solder off of the innards (I haven't had any trouble). Usually I am picking stuff out of the tip if it isn't already ejected out. The tip has a long wear. You don't have to worry about the plastic being overly conductive. It must be somewhat conductive, or something - it makes my DMM spaz out in the megohms range (RF signal?). It is possible that it is made of plastic that does not generate static, rather than being conductive. I don't know. I prefer the ESD safe version, because I do more than just soldering wires.
pin extractor
I have found no easy way of extracting a pin without bending something I shouldn't or having one of these tools.
Jonard Industries R-5926 TOOL PIN EXTRACTOR SIZE 16-20, available from digikey $11.95
there are no docs, so I don't know if this is the one or not.
Jonard Industries KR-260 TOOL KIT EXTRACTION SIZE12,16,20 K540-ND, available from digikey $148.60
handles just about every connector out there except F I guess and there's another tool out there for that.
pin inserter
you can probably do the same thing with a very small pair of pliers to push the pins in.
Jonard Industries KA-260 TOOL KIT INSERTION SIZE 12,16,20 K539-ND, available from digikey $135.40
handles just about every connector out there except F I guess and there's another tool out there for that.
3rd hand
this is optional - I can't find mine, so I juggle things with my fingers. In using a 3rd hand, you must make sure that if you are clamping a wire, that the wire is not heated, which will cause the gator clip to bite into the insulation at 800°.
3rd hand with 2 adjustable arms and 2 alligator clips, available from digikey $12.95
twin grip [same thing], available from toolsgs $18.95
sponges
this is for cleaning your soldering iron. the solder on the tip turns into burned up slag. so it's a good idea to clean the tip when you see it needs it. If you don't have a sponge, I guess you can shake the iron sharply and throw the excess solder off, but this doesn't really do the job well. the slag seems to ruin the tip (or something does I don't know what). It's a sponge for a reason. I learned you are supposed to use them with water. Otherwise, the 800° simply burns them and they become useless. Don't put too much water on it.
Weller sponge with slits K416-ND, available from digikey $1.24
Heat Shrink Tubing
this protects your spliced connections from shorting against other wires & pins. Of course, there is always scotch tape if you don't want to make the expense (though it could slip).
QKY018C-ND Qualtek Q-150K-1/8-02-QB48IN-25 HEATSHRINK KYNAR 1/8" X 4' CLEAR Q-150K Clear Flame Retardant 0.062" (1.6mm) 0.125" (3.2mm) 4.0' (1.22m) Polyvinylidene Fluoride, available from digikey $3.57
QKY316C-ND Qualtek Q-150K-3/16-02-QB48IN-25 HEATSHRINK KYNAR 3/16" X 4' CLR Q-150K Clear Flame Retardant 0.093" (2.36mm) 0.187" (4.8mm) 4.0' (1.22m) Polyvinylidene Fluoride, available from digikey $2.52
Benchtop Fume Absorber
this is entirely optional these jobs don't usually warrant this much equipment, especially if you use the organic Kester solder.
Benchtop Fume Absorber, 115V with 3 Filters K416-ND, available from digikey $101.20

Comments? email Jim