CONTINUITY TESTER AND FIXTURE MODEL 128/PC

Transcription

1 i CONTINUITY TESTER AND FIXTURE MODEL 128/PC

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3 Model 128/PC Instruction Manual Page iii February 25, 2005 MODEL 128/PC INSTRUCTION MANUAL (Part Number ) Cablescan A Eubanks Company 3022 Inland Empire Blvd. Ontario, California (909) Fax (909)

4 Page iv Model 128/PC Instruction Manual COPYRIGHT NOTICE This manual is proprietary, copyrighted material. No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose other than the purchaser's personal use, without written permission of Cablescan Inc. Copyright Cablescan Inc. All rights reserved. THIS IS A LIMITED WARRANTY CABLESCAN (hereinafter CABLESCAN ) products are warranted to the original owner for a period of twelve (12) months from the date of shipment from CABLESCAN s factory, or in the first 2,080 hours of operation by the customer (whichever comes first), to be free from defects in material and workmanship for the use for which they are intended by CABLESCAN, under normal operating conditions and maintenance. CABLESCAN s obligation under this Warranty is limited, upon prompt notification, to the repair or exchange at the CABLECAN factory of any CABLESCAN product or part which proves to be defective. If a product under warranty is returned to the CABLESCAN factory for repair or replacement, freight charges will be borne by the customer in accordance with CABLECAN s policy of selling F.O.B. the CABLESCAN factory. If repairs are made at the customer s factory, the customer will bear the cost of the service person s travel and living expenses. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED. THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. THIS WARRANTY STATES CABLESCAN S ENTIRE AND EXCLUSIVE LIABILITY WHETHER IN TORT OR IN CONTRACT AND BUYER S EXCLUSIVE REMEDY FOR ANY CLAIM FOR DAMAGES IN CONNECTION WITH THE SALE OR USE OF CABLESCAN S PRODUCTS, THEIR DESIGN, SUITABILITY FOR USE, INSTALLATION OR OPERATION, OR FOR ANY CLAIMED DEFECTS THEREIN. UNDER NO CIRCUMSTANCES WILL CABLESCAN BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, ECONOMIC, DIRECT, INDIRECT, GENERAL, OR SPECIAL DAMAGES. NO ACTION UNDER THIS WARRANTY MAY BE BROUGHT BY BUYER MORE THAN ONE YEAR AFTER THE CAUSE OF ACTION HAS OCCURRED. This warranty does not apply to equipment or replacement parts that have not been given proper care and maintenance and does not cover any defect, failure, deficiency, or error that is: a) Not reported to Cablescan within the applicable warranty period; b) Due to accident, misapplication, negligence, modification, alteration, disassembly, abuse, misuse, abnormal conditions of temperature, dirt, or corrosive matter; or c) Due to operation, either intentional or otherwise, above rated capacities, or in an otherwise improper manner. If it is determined that the equipment defect is not the result of original manufacture but is related to customer negligence or operational error, the customer will pay all incurred charges including, but not limited to, parts and labor.

5 Model 128/PC Instruction Manual Page v TABLE OF CONTENTS Specifications... viii System Overview...1 The Model 128/PC...1 Major Features...1 Front Panel Controls and Display...2 Display Format...3 Rear Panel Layout...3 Interface Fixture...4 Signature Codes...4 Program Storage...5 User Labels...6 Quick Start...7 Tester Setup...7 Adapter Card Installation...7 Learn Cable Assembly...7 Test Cable Assembly...7 Program Storage...8 Simplified Instructions...9 Operating Instructions...14 Front Panel Modes...14 Learn...14 Search...15 Error List...16 Test...17 Reset...18 Menu-selected Modes and Functions...19 Save Program...19 Load Program...20 Delete Program...21 Clear Memory...22 Set Baud Rate...22 Print Wire List...23 Print User List...24 Loop Test...25 Self Test...26

6 Page vi Model 128/PC Instruction Manual TABLE OF CONTENTS- CONTINUED PC Keyboard Operating Instructions...27 Introduction...27 Entering Commands...27 Test Commands...27 Print Commands...28 Program Commands...28 System Setup...30 Unpacking...30 Initial Setup...30 Power Turn-On and Self Test...30 Return of Faulty Unit...31 Printer Setup...31 PC Interface...33 Changing Power Setting...34 Remote Output Signals...36 Adapter Cards...37 Selection...37 Installation...37 Custom Adapter Cards...37 Setting Adapter Codes...39 Adapter Card List...40 Care of the Model 128/PC...43 Maintenance...43 Repair...43 Memory Backup Battery...43 Replacement Parts...43

7 Model 128/PC Instruction Manual Page vii LIST OF FIGURES Figure Description Page 1 Front Panel Controls and Display Rear Panel Layout Interface Fixture Program Storage - Accommodations and Use Simplified Self-programming (LEARN) Procedure Simplified Test Procedure Simplified Wire Identification (SEARCH) Procedure Simplified Save Program Procedure Simplified Load Program Procedure Sample Error List Printouts Sample Wire List Printouts Sample User List Printout Power Switch and Jumper Locations Schematic - Model 128 CPU/Scanner Board...44

8 Page viii Model 128/PC Instruction Manual SPECIFICATIONS TEST POINT CAPACITY 128 points, 64 points per connector OPERATING SPEED Test: < 0.5 sec.; Self Test: < 2 sec.; Learn: < 0.5 sec. TEST PARAMETERS Short Threshold: < 100 Ohms Open Threshold: > 1000 Ohms Continuity Threshold: < 100 Ohms Test Current: < 3 milliamps Body Current: < 5 microamps TEST VOLTAGE 10 VDC, max. INTERWIRE CAPACITANCE.01 microfarad, max. DISPLAY 16-character Alphanumeric LCD PROGRAM STORAGE Battery-backed CMOS RAM containing a test program area and 112 stored program locations without User Labels, or 28 program locations with User Labels. BATTERY LIFE 5 years POWER REQUIREMENTS (INTERNALLY SELECTABLE) 104 to 126 VRMS, 50/60 Hz or 208 to 252 VRMS, 50/60 Hz TEMPERATURE Operating: 32 to 105 F (0 to 40 C) Storage: -40 to 165 F (-40 to 74 C) DIMENSIONS x x 3.5 in. (34.4 x 28.6 x 8.9 cm) WEIGHT 7.0 lbs. (3.2 kg)

9 Model 128/PC Instruction Manual Page 1 THE MODEL 128/PC SYSTEM OVERVIEW The Cablescan Model 128/PC is a microprocessor-based continuity tester with a built-in interface fixture. It tests for both opens and shorts from one point to all other points in cables and harnesses of up to 128 connections. Testing is programmed by the Learn method or by programs downloaded from a PC. Up to 112 programs may be stored in memory for future use. The built-in interface fixture enables testing of a wide variety of connector types and sizes, using Cablescan's library of test adapter cards. Circuit types that can be tested include flat ribbon cables, discrete wiring harnesses, and those having jumpers, daisy chains, open contacts, and other interconnect devices. An RS-232C interface accommodates either an optional printer, or a personal computer (PC). MAJOR FEATURES Major features and functions of the Model 128/PC are as follows: Self programming by "learning" a "known good" or sample harness from a batch. Programming by downloading from a PC. Automatic test of each cable or harness to be tested, and display of error locations. Built-in interface fixture for quick and inexpensive connection of test cable. Program save and load. Identification or location of wires through touch, using wrist strap or probe. Self test of the Model 128/PC. Alphanumeric test point labels (user labels). Memory for 112 wire list programs (without user labels) or 28 programs (with user labels). Optional features are: Printout of wire list learned during self programming. Printout of errors encountered during test. Control by PC with Cablescan TERM software.

10 Page 2 Model 128/PC Instruction Manual FRONT PANEL CONTROLS AND DISPLAY The Model 128/PC employs a 16-digit alphanumeric backlighted LCD (Liquid Crystal Display). The display provides the user with test conditions, signature codes, adapter codes, and error information. All modes and functions of the Model 128/PC are controlled by keys on the front panel. Six modes are selected by individual keys, and nine menu modes and functions are selected through Up and Down keys and executed by the Menu Run key. See Figure 1, below. LCD Display Front Panel Mode Keys MODEL 128 LEARN SEARCH ERROR LIST TEST RESET MENU RUN Menu-select Keys LEARN SEARCH ERROR LIST TEST RESET MENU RUN UP/DOWN ARROWS - Initiates a scan on a known-good cable (harness assembly, ribbon cable, etc.), and stores the resultant wire list data in the Test Memory. A 4-digit signature code is calculated based on the wire list stored in memory and the adapters cards installed, and it is displayed for program identification. - Initiates a continuous scan of the adapter card connectors and displays each point that is touched with the wrist strap or probe. (See Figure 2 for location of the probe input.) - Initiates a test on a connected cable assembly and produces a printout of errors, or prints "Passed" if no errors. - Initiates a continuous test of the connected cable and displays errors, or displays "Passed" if no errors. - Terminates current mode and places Model 128/PC in "wait" state until next mode selection is made. - Initiates the menu mode selected and currently displayed. Also used to advance a menu mode and to respond yes to a menu prompt. - Used for stepping up and down through menu to select one of nine available functions or modes. (Refer to Menu-selected Modes and Functions in the Operating Instructions section.). - Also steps through Program Memory to select wire list to load Figure 1. Front Panel Controls and Display

11 FUSE Model 128/PC Instruction Manual Page 3 DISPLAY FORMAT The Model 128/PC has 128 test points, which are divided between two adapter card locations; side A and side B, with 64 test points on each side. When displaying from/to information during test, an A or a B prefix is attached to the pin number to identify the connector. Therefore, an open between pin 5 on A side and pin 10 on B side is displayed as: O A-05 B-10. The relationship between test point and adapter card connector/pin numbers is provided in the table below: Description Left Side Right Side Adapter Connector Side A Side B Adapter Pin # 1 to 64 1 to 64 Test Point # to 128 Displayed Connector/Pin # A-01 to A-64 B-01 to B-64 NOTE User labels (Test point labels) can be programmed to replace the displays A-01 through B-64. This requires a PC for programming the labels in a text editor and then downloading the labels to the tester using an optional software program. REAR PANEL LAYOUT The rear panel contains a power switch; an AC receptacle for line power connection; a power fuse; Probe connector for either a probe or wrist strap, an Enable receptacle; a serial port connector for a printer or personal computer (PC). A wrist-strap kit provides the capability to locate wires during troubleshooting through body conductance, using either a probe provided in the kit, or touch by fingers. An optional 80-column serial printer provides hard copies of error lists, wire lists, and user label lists. Refer to Printer Setup instructions in the System Setup section. Probe/Wrist Strap Learn/Save Enable PROBE ENABLE 250mA/250V FUSE FUSE CAUTION! For continued protection against risk of fire, replace only with same type and rating of fuse. Power Switch AC Receptacle Power Fuse PC/Printer Interface Figure 2. Rear Panel Layout

12 1 Page 4 Model 128/PC Instruction Manual INTERFACE FIXTURE The interface fixture (Figure 3) has cam-operated ZIF connectors for easy exchange of adapter cards, and rapid connection and disconnection of cable assemblies being tested. Information on Cablescan adapter cards and configurations is provided in the Adapter Cards section. Cards are replaced by simply lifting the ZIF levers and sliding the cards up A SIDE B SIDE Adjustable Adapters Adjustable Hold-down Bar Cards Hold-down Bar A-01/Pin #1 (Top) ZIF Levers B-01/Pin #65 (Top SIGNATURE CODES Figure 3. Interface Fixture The Model 128/PC is designed for the use of signature codes in achieving harness identification, tracebility, and configuration control, as follows: When the first harness (usually a "known good") of a specific part number is run through the Learn mode, the Model 128/PC calculates and displays a four-digit signature code unique to the cable wiring configuration and the adapters used. If a printer is connected, that signature code are included on the wire list printout. Whether in hard copy (printout) form, or recorded manually, the signature code is paired up with the part number for that harness, and kept on file for identification of future batches. Every time a batch of the same part number is to be tested, a random sample of that batch is run through Learn for self programming, and the displayed signature code must match the signature code on file. Since the Model 128/PC can also store multiple wire list programs in memory, the signature is used in identifying the wire list program when loading from memory. Signature codes eliminate the need to assign names to wire lists for identification.

13 Model 128/PC Instruction Manual Page 5 PROGRAM STORAGE The Model 128/PC has memory accommodations either for 112 wire list programs without user labels or for 28 programs with User Labels, as well as a Test Memory location for the wire list currently in use (see Figure 4). A program may be loaded into the Test Memory from any one of the 112/28 Program Memory locations, and the program in the Test Memory may be moved to a Program Memory location. These modes and functions are accomplished through four of the Menu-selected modes. (Refer to Menu-selected Modes and Functions.) Signature codes are used to identify wire lists in Program Memory for loading and for identifying the wire list currently in Test Memory. TEST MEMORY LOCATION PROGRAM #1 PROGRAM #2 PROGRAM #112 Create test program in Test Memory during Learn procedure. (Program may also be downloaded through the RS-232C Printer/Serial port into Test Memory.) To store a newly created program for future use, copy it to Program Memory using the Save Program function (Menu-selected). All tests are run from Test Memory. To use a program that is stored in Program Memory, copy it into the Test Memory using the Load Program function (Menu-selected). All programs remain in Program Memory. Save Program and Load Program functions only copy them to and from Test Memory. Programs are eliminated only by using the Delete Program function (Menu-selected). The Clear Memory mode (Menu-selected) is used to erase wire lists from the Test Memory only. NOTE Each program with a user label occupies 4 Program Memory locations. Figure 4. Program Storage - Accommodations and Use

14 Page 6 Model 128/PC Instruction Manual USER LABELS The Model 128/PC does not have a built-in user label or wire list editor. Programming of user labels, as well as programming wire lists without learning a wire list, is performed with a PC and Cablescan s optional MS DOS-based software program, TERM. TERM provides keyboard control over the Model 128/PC through the printer/serial port. The TERM program is basically a terminal emulation program that allows keyboard entry and control over the tester. The program also has features to allow wire lists and user labels to be transferred to and from the Model 128/PC. Six-character user labels can be assigned to test points for each wire list program stored in the Model 128/PC. Since testing on the Model 128/PC using adapter cards is typically limited to two-ended cables, user labels are not generally necessary. User labels are more useful when the Model 128/PC is interfaced to a harness board or external fixture. These applications usually have more than two connectors and, therefore, locating specific connector/pin locations using the standard display of the Model 128/PC is more difficult since the display refers to side A and side B connectors. When user labels are assigned to test points, all displays and printouts will show user labels in lieu of the A and B connector identification on the interface fixture. Once user labels are assigned, connector/pin locations are displayed between the actual connector and pin numbers on the wire harness. This eliminates the need to have a separate translation chart cross referencing the test points to the actual harness connector/pin numbers.

15 Model 128/PC Instruction Manual Page 7 QUICK START Ordinarily, the setup and operation of the Model 128/PC requires a thorough understanding of this manual. This section, however, is provided for situations where immediate use is required. When using this procedure, refer to the sections indicated within the procedure when more detail is required for specific steps. TESTER SETUP Refer to the System Setup section for details. 1. Remove Model 128/PC from shipping container and set on suitable work station. 2. Connect line cord between rear panel and a properly grounded outlet. (See Figure 2.) 3. Turn power on by moving switch on rear panel to 1 (on). A Ready message will display and a short tone will sound. 4. Press Down arrow to step through menu modes until Self Test is displayed. 5. Press MENU RUN to initiate Self Test. Passed Self Test will display. ADAPTER CARD INSTALLATION Refer to the Adapter Cards section for details. 1. Select cable assembly to be tested and match an adapter card to each end of the cable. 2. Open ZIF connector levers, slide adapter cards in from the top and all the way laterally into their respective connectors. Each adapter card is designed to fit only the right or left side. 3. Close ZIF connectors and install the cable to be tested between A and B adapter cards. LEARN CABLE ASSEMBLY Refer to Learn mode in the Operating Instructions section for details. 1. Press RESET, and then press LEARN. 2. A 4-digit signature will display after learn is complete. (See Signature Codes in System Overview.) TEST CABLE ASSEMBLY 1. Press RESET, and then TEST. The cable is good when Passed is displayed. Tests are continuously run until the cable is removed. 2. Remove the cable from the adapter cards. (As soon as the cable is removed, an open circuit will display.) 3. Test the remaining cables.

16 Page 8 Model 128/PC Instruction Manual PROGRAM STORAGE Refer to Save Program (menu-selected) in the Operating Instructions section for details. 1. The 4-digit signature code is used to identify wire list programs in memory. Record the signature code for the cable assembly. (Refer to Signature Codes in System Overview section.) 2. Insert the supplied microphone plug into Enable jack on rear panel. 3. Press RESET, and then arrow down to step through the menu until Save Program is displayed. 4. Press MENU RUN to initiate Save Program. (Refer to Save Program in Operating Instructions section.) After the program is saved, the display will show "Saved XXXXXX," where XXXXXX is the signature code of the program.

17 1 Model 128/PC Instruction Manual Page 9 SIMPLIFIED INSTRUCTIONS The Cablescan Model 128/PC Continuity Tester is simple and easy to use. As with any microprocessor-based device, however, the user first should become familiar with its features and functions, how to operate it, and how to care for it. After becoming properly acquainted with the Model 128/PC, the user can refer to the abbreviated procedures illustrated in Figures 5 through 9. Detailed procedures are provided in the Operating Instructions section. 2 3, MODEL 128 LEARN SEARCH ERROR LIST TEST RESET MENU RUN Press RESET. 2. Install appropriate adapter cards for the cable to be tested. 3. Install sample, or known-good cable or harness assembly. 4. Press LEARN. Signature code will display after Learn is complete. 5. Select and Print Wire List from the menu, or record signature code manually. 6. Remove sample, or known-good cable or harness assembly. Figure 5. Simplified Self-programming (LEARN) Procedure

18 1 Page 10 Model 128/PC Instruction Manual 2 3, MODEL 128 LEARN SEARCH ERROR LIST TEST RESET MENU RUN 4 5b 4, 5a 1 1. Press RESET. 2. Install appropriate adapter cards for the cable to be tested. 3. Install cable or harness to be tested. 4. Press TEST; observe Passed on Display. 5. Remove tested cable or harness, and install the next cable to be tested. If Failure Encountered (Open or Short): 5a) Repair fault, or press TEST again to view additional errors. 5b) To get a hardcopy of the errors, press RESET, and then ERROR LIST. Figure 6. Simplified Test Procedure

19 1 Model 128/PC Instruction Manual Page 11 3 PROBE ENABLE 250mA/250V FUSE FUSE FUSE CAUTION! For continued protection against risk of fire, replace only with same type and rating of fuse MODEL 128 LEARN SEARCH ERROR LIST TEST RESET MENU RUN 1. Press RESET Install appropriate adapter cards for the cable to be tested 3. Connect wrist strap or probe to Probe receptacle. 4. Press SEARCH. 5. Touch wire end with fingers or probe. Pin numbers will be displayed. Repeat for each wire or circuit point to be identified. Figure 7. Simplified Wire Identification (SEARCH) Procedure

20 1 Page 12 Model 128/PC Instruction Manual 2 PROBE ENABLE 250mA/250V FUSE FUSE FUSE CAUTION! For continued protection against risk of fire, replace only with same type and rating of fuse MODEL 128 LEARN SEARCH ERROR LIST TEST RESET MENU RUN 4, 7 3, 6 1, 5 1. Press RESET. 2. Engage Enable plug on rear panel. 3. Select and initiate Save Program. 4. The display will read Are You Sure? 5. If it is decided not to save the program, press RESET. 6. To save the program, press MENU RUN. The program will be copied from the Test Memory into a Program Memory location. 7. After the program is saved, the display will show SAVED XXXXXX, where XXXXXX is the signature code of the program. Figure 8. Simplified Save Program Procedure

21 1 Model 128/PC Instruction Manual Page MODEL 128 LEARN SEARCH ERROR LIST TEST RESET MENU RUN 3, 4, 7 2, 4, 6 1, 5 1. Press RESET. 2. Select and initiate Load Program. 3. The display will show a signature code of a program stored in Program Memory. 4. Use Up/Down arrows to step to the signature code for the desired program, as shown in the display. 5. If it is decided not to load the program, press RESET. 6. Press MENU RUN to load the program into the Test Memory. 7. Verify signature code on display against the code recorded for the cable assembly to be tested. Figure 9. Simplified Load Program Procedure

22 Page 14 Model 128/PC Instruction Manual FRONT PANEL MODES OPERATING INSTRUCTIONS The following detailed procedures are provided for acquainting the new user with the front panel modes and functions of the Model 128/PC. All modes and functions are selected and controlled by keys on the front panel. Five modes are controlled by individual keys across the top of the panel. Three keys across the bottom are provided to control nine modes and functions from a menu. MODEL 128 LEARN SEARCH ERROR LIST TEST RESET MENU RUN Learn Before testing, it is necessary to prepare a program for the harness to be tested, unless a program already exists. This is done through the Learn mode. A complete programming procedure, using a known-good harness, is provided below. Once familiarized, however, the user may need only refer to Figure Select and install a pair of adapter cards (Adapter Cards section) for the cable assembly to be tested. 2. Mate each connector on the cable assembly to the appropriate adapter card. 3. Press LEARN. The Model 128/PC instantly scans the cable assembly, stores its configuration (wire list) in Test Memory, and calculates a signature code for that configuration. The display will show: Learned (Signature code #) 4. If printer is connected, select and initiate Print Wire List from the menu. Notice that the printout also will contain the signature code shown on the display. Refer to the Print Wire List procedure later in this section. 5. Retain the wire list for future use in identifying the program just created. If no printout is made, record the displayed signature code for future use. 6. Follow Save Program function to save wire list program in Program Memory. 7. Disconnect learned harness from Model 128/PC.

23 Model 128/PC Instruction Manual Page 15 NOTE The Learn mode and the signature code can be used in lieu of saving the program in Program Memory. Learning a cable assembly each time from a batch, and comparing the signature code with the recorded one eliminates the need to save the program and then load it from memory each time a batch of cables requires testing. However, if the preferred procedure is to save the program and load it for testing a new batch, refer to the Save Program and Load Program procedures later in this section. Search Search mode enables use of a wrist strap or probe as an aid in identifying wires or circuit points. Each point contacted will be displayed in succession. To select and use the SEARCH mode, proceed as follows: 1. Press RESET. 2. Select and install a pair of adapter cards for the cable assembly to be probed. 3. Mate each connector on the cable assembly to the appropriate adapter card. 4. Insert wrist strap or probe lead into Probe jack on rear panel (see Figure 2). 5. Fasten strap around one wrist, or grasp probe. 6. Press SEARCH. 7. Touch wire end with hand or probe, and the display will show the pin number(s) of that wire. 8. Touch another wire, and its corresponding pin number(s) will be displayed. NOTE If more than one wire is touched at a time, or if the wire touched is connected to others, the display will scroll through the numbers in succession.

24 Page 16 Model 128/PC Instruction Manual Error List This mode requires hookup of the optional printer. When ERROR LIST is selected, it performs a single test and prints a list of errors encountered, or it prints Passed when there are no errors. Sample error lists using adapter connector numbers and user labels are shown in Figure 10. To select and use ERROR LIST, proceed as follows: 1. Press RESET. 2. Select and install a pair of adapter cards for the cable assembly to be tested. 3. Mate each connector on the cable assembly to the appropriate adapter card. 4. Verify printer is connected. (Refer to Printer Setup in System Setup section.) 5. Load program to be used. (Refer to "Load Program" later in this section). 6. Press ERROR LIST. The Model 128/PC performs a single test and prints a list of all errors, or prints Passed if there are no errors. 7. When test and printout are finished, disconnect harness. Adapters A: 05 B: 06 Signature: Error List Condition From Point To Point OPEN A 3 B 12 SHORT A 3 B 10 OPEN A 1 B 10 SHORT A 8 B 12 OPEN A 8 B 16 Failed (Error list without user labels) Adapters A: 05 B: 06 Signature: Error List Condition From Point To Point OPEN J1-3 P1-3 SHORT J1-3 P1-1 OPEN J1-1 P1-1 SHORT J1-8 P1-3 OPEN J1-8 E2 Failed (Error list with user labels) Figure 10. Sample Error List Printouts

25 Model 128/PC Instruction Manual Page 17 Test When TEST mode is selected, the Model 128/PC continuously scans all points of the cable assembly, using the wire list program in Test Memory as a comparison. The wire list program can be created using the Learn mode, or it can be loaded from Program Memory if previously learned and saved. Refer to the Learn mode or the Load Program function in this section. A complete Test procedure is provided below. Once familiarized, however, the user may refer to Figure 6. To select and use TEST, proceed as follows: 1. Press RESET. 2. Select and install a pair of adapter cards for the cable assembly to be tested. 3. Mate each connector on the cable assembly to the appropriate adapter card. 4. Press TEST. If the harness passes the test, "Passed" will display, and a tone will sound. 5. Remove the passed cable, and connect next cable to be tested. Test will automatically resume. NOTE For subsequent harnesses of the same configuration, it is not necessary to press TEST for each harness. Upon insertion of each new harness, TEST automatically continues. FAULTY CABLE ASSEMBLY If an open, short, or miswire has been detected, an O (for Open) or an S (for Short or Miswire) will display at the far left of the display, and the two point numbers (From and To points) will display to the right of the error type as follows. O A-03 B-03 If a failure is between points on the same side of the adapter card, the display will show: S A-04 A To continue the test, either correct the error, or press TEST. If an error was corrected, and no other errors are detected, a Passed will display after all circuits have been retested. If the error was not corrected, and TEST was pressed to resume testing, the test scan will cycle through and back to the original error, unless another error is detected, in which case that error will be displayed. 5. If the printer is connected, press ERROR LIST to obtain a printout of failures. A sample Error List Printout is shown in Figure Remove harness and connect the next cable assembly to be tested.

26 Page 18 Model 128/PC Instruction Manual Reset The RESET mode is available for terminating any mode currently in operation. Pressing RESET is required with some modes that display an end message upon completion. When RESET is pressed, the display alternates between displaying the signature code of the wire list in Test Memory and one of the menu modes.

27 Model 128/PC Instruction Manual Page 19 MENU-SELECTED MODES AND FUNCTIONS The nine menu-selected modes and functions are as follows: Save Program * Self Test Load Program Loop Test Delete Program * Set Baud Rate * Clear Memory * Print Wire List Print User List * Requires the Enable jack to operate. These menu-selectable modes and functions are accessed through the MENU RUN key and the Up and Down arrow keys. To select one of the menu modes or functions, use the following standard procedure: 1. Press Up or Down arrow to step through the menu until the desired function or mode is displayed. 2. Insert the Enable plug if the mode, in the above list, ends with an asterisk (*). 3. Press MENU RUN to initiate the function or mode. MODEL 128 LEARN SEARCH ERROR LIST TEST RESET MENU RUN Menu-select Keys (3) Save Program The Save Program function is used to copy the program from the Test Memory to the Program Memory. A complete Save Program procedure is provided below. Once familiarized, however, the user may refer to Figure 8. To select and use the Save Program function, proceed as follows: 1. Insert Enable jack in the rear panel. (See Figure 2.) 2. Press the Up or Down arrow to step through the menu to display Save Program. 3. Press MENU RUN to initiate the save function. If there is sufficient Program Memory for the program, the display will query: Are You Sure?

28 Page 20 Model 128/PC Instruction Manual 4. Press MENU RUN again to save the program. After the program has been saved, the display will show: Saved (signature #) 5. If you decide not to save the program, press RESET instead of MENU RUN. 6. If there is insufficient Program Memory to save the program, the display will show: MEMORY FULL 7. Evaluate the programs currently saved to determine if any are no longer needed. Refer to the Delete Program procedure to make room in memory for new programs. (Remember, a wire list with user labels occupies 4 memory locations.) 8. Rerun the above Save Program procedure after programs have been deleted. Load Program The Load Program function is used to copy one of the stored programs (in Program Memory) to the Test Memory. The program in Test Memory will be over-written by the program being loaded. If the program in Test Memory is to be retained for future use, first save it by means of the Save Program function before performing this procedure. A complete Load Program procedure is provided below. Once familiarized, however, the user may refer to Figure 9. To select and use the Load Program function, proceed as follows: 1. Press Up or Down arrow to step through the menu to display Load Program. (Enable jack not required for loading programs.) 2. Press MENU RUN to initiate Load Program, and the display will show the signature for the last program that was selected with the Load or Delete function: Load Program (signature #) 3. Press Up or Down arrow until the display shows the signature for the program to be loaded into Test Memory. (Each time the arrow is pressed, the next program signature will display.) A Bottom of List message will appear after all programs have been displayed using the Down arrow. A Top of List message will appear after all programs have been displayed using the Up arrow. 4. If it is decided not to load the program, press RESET. 5. When the desired program signature is reached, press MENU RUN and the program will be copied into the Test Memory.

29 Model 128/PC Instruction Manual Page 21 Delete Program The Delete Program function is used to erase a program from Program Memory. (It does not affect the program currently in Test Memory.) A complete Delete Program procedure is provided below. To select and use the Delete Program function, proceed as follows: 1. Insert Enable jack in the rear panel. (See Figure 2.) 2. Press Up or Down arrow to step through the menu to display Delete Program. 3. Press MENU RUN to initiate the mode, and the display will show the signature for the last program that was selected with the load or delete function: Delete Program (signature #) 4. Press Up or Down arrow until the display shows the signature for the program to be deleted. (Each time the arrow is pressed, the next program signature will display.) A Bottom of List message will appear after all programs have been displayed using the Down arrow. A Top of List message will appear after all programs have been displayed using the Up arrow. 5. If you decide not to delete a program, press RESET. 6. Press MENU RUN to delete the program for the displayed signature, the display will query: Are You Sure? 7. Press MENU RUN a second time to delete the program. After the program has been deleted, the display will show: Deleted (signature #)

30 Page 22 Model 128/PC Instruction Manual Clear Memory This mode is required for clearing the Test Memory of the wire list and user labels before running the Learn mode. (The wire list in test memory is automatically deleted when Learn is initiated.) If user labels are in the Test Memory along with the Test program, the labels will be attached to the test points for the new program generated with the Learn mode. Clearing memory before Learn will prevent labels from being attached to the new program. Clear Memory must first be enabled by the Enable jack on the rear panel. To initiate and use Clear Memory, proceed as follows: 1. Engage Enable jack on the rear panel. (See Figure 2.) 2. Press Up or Down arrow to step through the menu until Clear Memory is displayed. 3. Press MENU RUN key to initiate Clear Memory. The display will show: CLEAR MEMORY? 4. If you selected Clear Memory in error, or otherwise have decided not to use it, press RESET to exit the mode. If you do wish to clear the Test Memory, press MENU RUN key a second time, and the memory will be cleared. The display will now show: Memory Cleared A cleared test memory will display a signature code of Set Baud Rate The Model 128/PC has two baud rate settings: 1200 and The 1200 baud rate is used for printing. The 9600 baud rate is used when interfacing the serial port to a PC. The Set Baud Rate function must first be enabled by the Enable jack on the rear panel. To initiate and use Set Baud Rate, proceed as follows: 1. Engage Enable jack on the rear panel. (See Figure 2.) 2. Press Up or Down arrow to step through the menu until Set Baud Rate is displayed. 3. Press MENU RUN key to initiate the mode. The display will show one of the following as the current setting: Baud Rate 1200 or Baud Rate To change the baud rate, press the Up or Down arrow. The baud rate will change between 1200 and Press MENU RUN or RESET when the desired baud rate is displayed. The display will show: Completed

31 Model 128/PC Instruction Manual Page 23 Print Wire List This mode requires hookup of the optional printer. A wire list printout provides a hardcopy of the test program in Test Memory. The wire list printout also includes the program signature for future reference. To select and run Print Wire List, proceed as follows: 1. Verify that a serial printer is connected and is on line. Refer to Printer Setup in the System Setup section. 2. Press Up or Down arrow to step through the menu to display Print Wire List. 3. Press MENU RUN to initiate printing. The printout will show the test program in Test Memory. Sample wire lists are shown below. Adapters A: 05 B: 06 Signature: Wire List Sequence From Point To Point A-05 B A-04 B A-03 B A-02 B A-01 B A-09 B A-08 B-16 End of List (Wire list with user labels) Adapters A: 05 B: 06 Signature: Wire List Sequence From Point To Point J1-5 P J1-4 P J1-3 P J1-2 P J1-1 P J1-9 E1 007 J1-8 E2 End of List (Wire list with user labels) Figure 11. Sample Wire List Printouts

32 Page 24 Model 128/PC Instruction Manual Print User List This mode requires hookup of the optional printer. A user list printout provides a hardcopy of the user labels and wire list signature currently loaded in Test Memory. To select and run Print User List, proceed as follows: 1. Verify that a serial printer has been connected, according to the Printer Setup procedure in the System Setup section. 2. Press Up or Down arrow to step through the menu to display Print User List. 3. Press MENU RUN to initiate printing. A sample user list is shown below. Adapters A: 05 B: 06 Signature: User List 001 J J J J J J J J J P P P P P E1 016 E2 End of List Figure 12. Sample User List Printout

33 Model 128/PC Instruction Manual Page 25 Loop Test Executing the Loop Test mode will initiate continuous scanning of the cable assembly, useful for locating intermittent connections. When an error is encountered, the test is halted and the error is displayed. The error will remain on display until MENU RUN is pressed to continue. This mode differs from the Test mode. The Test mode automatically continues the test when the error is removed, whereas, the Loop Test remains halted, displaying the error, even if the error is no longer present. A complete Loop Test procedure is provided below. To select and use Loop Test, proceed as follows: 1. Press RESET. 2. Select and install a pair of adapter cards for the cable assembly to be tested. 3. Mate connectors on the cable assembly to the appropriate adapter cards. 4. Load wire list to be used in this test (refer to Load Program), or learn the wire list using the Learn procedure. 5. Press Up or Down arrow to step through the menu until Loop Test is displayed. 6. Press MENU RUN to initiate the Loop Test mode. Each time a successful scan is completed, a loop count on the display is incremented by one as shown below: Loop # An O for open or S for short, with the From/To points, will be displayed when an error is encountered. A short between test point 63 on adapter card A (A-63), and 32 on adapter card B (B-32), will be displayed as follows: S A-63 B To restart the test, press MENU RUN, and the loop counter will reset to zero; or to continue through the current cycle to locate additional errors, press TEST. 9. Press RESET when testing is complete.

34 Page 26 Model 128/PC Instruction Manual Self Test This mode is used to verify the test points within the Model 128/PC. Basically it checks for opens and shorts on the scanner transmit and receive lines. When an error is located, the error type (Open or Short) and the faulty points are displayed. No test harness may be connected to the unit during Self Test; connections between test points caused by the cable assembly will result in failing Self Test. Performing a Self Test while the adapter cards are connected will result in the cards also being tested for shorts. If shorts are displayed, however, remove the cards and rerun the Self Test to isolate the problem to either the cards, or the tester. A complete Self Test procedure is provided below. To select and use Self Test, proceed as follows: 1. Press RESET and remove the cable assembly, if connected. 2. Press Up or Down arrow to step through the menu until Self Test is displayed. 3. Press MENU RUN to initiate Self Test. During the start of Self Test the display will show the part number of the PROM (software) of the Model 128/PC as follows: PROM #340XXXX Where 340XXXX is the current version of software in the Model 128/PC. 4. After the test is complete, with no errors displayed, Passed Self Test will display. 5. If an error is located, testing stops and the error is displayed. To continue past the error, press MENU RUN again. 6. If the adapter cards are installed and the Self Test failed, remove the adapter cards and rerun Self Test. 7. If the tester fails without the adapter cards installed, verify that the ZIF connectors are free of debris. 8. Clean the ZIF connectors with isopropyl alcohol and a brush 9. After cleaning, rerun Self Test. 10. If the Model 128/PC fails Self Test with no adapter cards, and the ZIF connectors have been cleaned, contact Cablescan for repair.

35 Model 128/PC Instruction Manual Page 27 INTRODUCTION PC KEYBOARD OPERATING INSTRUCTIONS The Model 128/PC can be controlled from a PC keyboard instead of the front panel controls. Keyboard control can be added by interfacing to a personal computer (PC) that is running Cablescan s Terminal Emulation Software, TERM. Refer to the System Setup section for setting up a PC. Using the PC keyboard, the operator can execute most functions available through the front panel mode keys and Menu selections. The PC also allows the operator to view 24 lines of information on the monitor instead of just the single line on the front panel display. ENTERING COMMANDS Commands are entered at the system prompt. To get the prompt, press the ESC key on the keyboard. All commands are two letters that are executed by pressing their two keys, followed by an ENTER. There are three categories of commands, as shown below: Test - test-related commands that allow a single or continuous test to be run, self test of the tester, and pin number identification. Print - used to obtain a hardcopy of test programs and test results. Program - used to load, save, and maintain programs in memory. TEST COMMANDS The following commands are used in the testing for opens and shorts, self testing of the Model 128/PC, and identifying test points. These are two-letter commands, which are executed by pressing the two letter keys, followed with an ENTER. Scan Test - SC Same as TEST button on Front Panel. A continuous test is executed on the cable assembly under test, and each error (open or short) is displayed. After each error is displayed, testing may be continued by pressing ENTER. Passed is displayed on the monitor after each successful test. Loop Test - CT Same as Loop Test selected from the Menu. A loop count of the number of passed tests is displayed on the monitor. Self Test - TT Same as Self Test selected from the Menu. Displays software version of Model 128/PC, and displays test results on the monitor.

36 Page 28 Model 128/PC Instruction Manual Search - SB Same as SEARCH key on the front panel. Displays the test points or user label assignments on the monitor as points are probed. PRINT COMMANDS The following list contains all print-related commands. The printout will appear on the monitor during printing since the PC uses the same port as the printer. Output will pause after displaying 20 lines. If there are additional lines, MORE will display at the end of each full screen. Pressing ENTER will continue the output. At the system prompt, enter the two-letter command, followed by an ENTER. Print Wire List - PW Same as Print Wire List selected from the front panel Menu. Print Error List - PE Same as ERROR LIST key on the front panel. Print User Labels List - PU Same as Print User List selected from Menu. PROGRAM COMMANDS The following list contains commands related to loading, saving, and deleting wire list programs. These are two-letter commands, which are executed by pressing the two letter keys followed with an ENTER. Clear Memory - CM This command is the same as Clear Memory selected from the Menu. When the prompt Are you sure? is displayed, pressing the letter Y will erase the program and User Labels in Test Memory. If you decide not to clear memory, press the letter N. Delete Program - DI This command is the same as Delete Program selected from the Menu. Delete Program is used to erase a wire list program in the Program Memory. When the DI command is typed, followed by an ENTER, the signature of one of the programs in memory is displayed. Pressing the letter D advances down through the list displaying the next program signature. Pressing the letter U displays the signature in the reverse order. When the signature of the program to be deletes is displayed, press ENTER. The prompt prompt Are you sure? is then displayed. Pressing the letter Y will erase the program. If you decide not to erase the program, press the letter N.

37 Model 128/PC Instruction Manual Page 29 Learn - LG This command is the same as the LEARN key on the front panel. It is used to create a wire list program automatically by scanning a connected harness assembly and storing the continuities in the Test Memory. The learned program overwrites the program that is in the Test Memory. If the program in the Test Memory has not been saved and is to be used later, use the Save Program command before running Learn. Load Program - LI This command is the same as Load Program selected from the Menu. Use the Load Program command to load a stored program from the Program Memory into the Test Memory. When the LI command is typed followed by an ENTER, the signature of one of the programs in memory is displayed. Press the letter D to advance down the list of programs, or press the letter U to advance up the list. The next program signature will display each time the letter is pressed. To load the program corresponding to the displayed signature, press ENTER. Save Program - SI This command is the same as Save Program selected from the Menu. The Save Program command is used to copy the program currently in the Test Memory into the Program Memory. If there is insufficient Program Memory to store the wire list, Memory Full is displayed. If there is sufficient Program Memory, prompt Are you sure? is displayed. To save the program, press the letter Y.

38 Page 30 Model 128/PC Instruction Manual SYSTEM SETUP UNPACKING Upon unpacking the Model 128/PC from its shipping carton, inspect it for evidence of abuse during shipment. If such is found, notify Cablescan and the carrier at once. Save the shipping carton and packing materials for later use. INITIAL SETUP When shipped from the factory, the Model 128/PC is set for operating from one of the following power sources: 104 to 126 VRMS at 50/60 HZ. 208 to 252 VRMS at 50/60 HZ. The line power cord receptacle on the rear panel (Figure 2) is labeled for one of the above voltage settings. 1. Be sure that the source voltage and Model 128/PC are of the same rating before connecting the power cord. If they are not, refer to "Changing Power Settings." 2. Make sure that the power switch on the back panel is set to 0 (off), and then plug in the power cord. 3. Turn power switch to 1 (on), and observe that a message is displayed. The Model 128/PC is ready for use. (If nothing happens, check power source, power cord connections, and the fuse on the rear panel.) POWER TURN-ON AND SELF TEST Verify that the power cord is connected to the proper power source, as described under the initial hookup, then proceed as follows: 1. Turn power on at the unit by moving the power switch on the rear panel to 1 (ON); the display will light up with a message and the tone will sound. 2. For self test of the basic Model 128/PC, verify that no cable assembly is connected and adapter cards are not installed. 3. Press the Up or Down arrow to step through the menu to reach Self Test. 4. Press MENU RUN to initiate Self Test. If the unit passes its self test, the display will show Self Test Passed, and a tone will sound; if it fails, the display will show one of the following: O for open, plus the internal connector pin number. S for short, plus the internal connector pin numbers. 5. The self test will stop if an error is encountered. To resume the test, press MENU RUN again.

39 Model 128/PC Instruction Manual Page 31 RETURN OF FAULTY UNIT If a unit should fail self test upon delivery, notify Cablescan immediately. PRINTER SETUP An RS-232C PRINTER/SERIAL port is provided on the rear panel (Figure 2) to accommodate an 80-column serial printer. 1. Prepare printer for use and connect it to its proper power source, in accordance with the instruction manual supplied with the printer. 2. Connect printer interface cable to the PRINTER/SERIAL connector on the rear panel of Model 128/PC. 3. On the printer, turn printer switch ON, and verify that the printer SELECT light is on. 4. Set Model 128/PC power switch to 1 (on). 5. Press the Up or Down arrow to step through the menu to reach Set Baud Rate. 6. Press MENU RUN to initiate setting the baud rate. 7. If the display reads "Baud Rate 1200," press RESET to continue. 8. If the display shows: "Baud Rate 9600," press the Down arrow to change to 1200 and then press MENU RUN. Data Format If the printer was not provided by Cablescan, the following setup data are required: Transmission to the printer is at 1200 Baud, with 8 data bits, 1 stop bit, and no parity. Printer Cable The printer connector on the Model 128/PC is also used for external control signals that are not printer related. Therefore, a fully loaded 25-pin printer cable should not be used. The pin assignments for the printer are as follows: Description Symbol Tester 25-Pin D Printer 25-Pin D Receive Data RD 3 3 Signal Ground SG 7 7 Supervisory Send Data SSG (Printer Cable P/N )