Futura Apsol PHTM320 User Manual

Cable harness tester

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USER'S MANUAL(ver4.4)

CABLE HARNESS TESTER

MODEL PHTM320 / PHTM640 / PHTM960

FUTURA APSOL PVT. LTD.

1212/B/2, Apte Road,

Shivajinagar,

PUNE 411 004.

TELE- FAX: 020- 2553 1832

E-MAIL: info@futuras.com.

www.futuras.com

Software Version: PHTM_GEN_5.5 and PHTM_320_4k_2.5 (19/12/2012)

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Page 1 USER’S MANUAL(ver4.4) CABLE HARNESS TESTER MODEL PHTM320 / PHTM640 / PHTM960 FUTURA APSOL PVT. LTD. 1212/B/2, Apte Road, Shivajinagar, PUNE 411 004. TELE- FAX: 020- 2553 1832 E-MAIL: info@futuras.com. www.futuras.com Software Version: PHTM_GEN_5.5 and PHTM_320_4k_2.5 (19/12/2012)
Page 2: Important Notes
Cable Harness Tester Models PHTM320 / PHTM640 / PHTM960 Packing List Cable Harness Tester 1 no. This User’s Manual 1 no. Mains cord 1 no. similar to PC mains cord. A pair of multimeter test probes for board check and continuity check.
Page 3: Table Of Contents
INDEX 1. IMPORTANT NOTES 1.1. Safety notes. 1.2. Changes in Various versions. 2. INTRODUCTION. 2.1. Description of the system. 2.2. Specifications 2.3. Tester. 2.3.1 Testing Features. 2.3.2 General Features. 2.3.3 Harness Data (Circuit Data). 2.3.4 Input / Output cards (I/O cards). 2.3.5 Keyboard.
Page 4 4.4.2 Error types and reporting. 4.5. Interfacing Printer. 4.6. Interfacing Relay output. 4.7. Buzzer. 4.8. Interfacing barcode scanner / reader. 4.9. Analysis. 5. Discription of menus and user general instructions: 5.1 Power on learn menus: 5.2 Normal LRN menu: 5.3 Analyse Menu: 6.
Page 5: Operation
9. RIG (BOARD) WIRING FOR FUTURA’S CABLE HARNESS TESTER MODEL. 10. CALIBRATION OF FUTURA’S CABLE HARNESS TESTER MODEL PHTM320. 11. OTHER CABLE HARNESS RELATED PRODUCTS 10.1 Harness Assembly Aid / Tester (HAA64). 10.2 One To One Continuity Tester with Parts Counter (CT121).
Page 6: Safety Notes
1: IMPORTANT NOTES: 1.1: afety notes: Safety Notes! Please read before putting the system into operation! This system has been checked for safe and correct functioning before being shipped. In order to keep this safety, the user has to pay attention to the corresponding notes and advice of the operating manual.
Page 7 1.1 : Changes in this versions: PHTM_GEN_3.0 1) Label data size has been increased to 4k (4096 bytes). 2) Facility to scan two operator codes. 3) On label operator codes can be printed by variables @B & @C. PHTM_GEN_4.4 1) Provision for second relay is made in software. 2) If Hardware for second relay is present in the tester then second relay can be used.
Page 8 PHTM_GEN_5.5 or PHTM_320_4K_2_5 1 ) @W is added in label printing variable. User details with maximum 16 bytes can be added through serial port and will be printed via @W. On every power on if valid user details are present then displayed on LCD.
Page 9 Installation of PHTM960. 1. PHTM960 is similar to PHTM640 except Maximum number of I/O cards can be 15 i.e. 960 points. Keyboard, Learn lock key, Display, Buzzer, continuity and board check terminals are separated in a hand-held enclosure called MMI (Man-machine Interface) unit.
Page 10 • When operator code is to be changed, ‘A’ key is pressed. Display is ‘Check Continuity’. • Down Arrow key displays ‘Operator codes?’ • ‘Enter’ accepts command and display is ‘Receiving code 1’. • First operator’s code is to be scanned by barcode scanner. •...
Page 11 : INTRODUCTION : 2.1: Description of the system: Futura’s Cable Harness Tester (CHT), is designed to test Cable Harnesses, Cable Looms, Cable Forms. CHT locates interchanged connections, shorted connections, open connection and extra points. CHT facilitates two stage testing of harnesses.
Page 12 A: Analyse: continuity, board check, and display count, change cable number, display harness data. ∧ : Next command / number. ∨ : Previous command / number. Cable Harness Tester PHTM320 Front Panel Futura Apsol Pvt. Ltd., Pune 411 004, India. Cable Harness Tester HTM320 front panel DOC. NAME DOC. NO.
Page 13 25 pin D type M. Points 40-64 speaker Tone To Printer Cable Harness Tester PHTM320/640 Back Panel Futura Apsol Pvt. Ltd., Pune 411 004, India. Cable Harness Tester HTM320 / 640 back panel DOC. NAME DOC. NO. HTM320BP DRN BY...
Page 14 * Buzzer, audio output on pass, with tone and volume control. * Potential free Relay output up to 230V AC, 5A load. * Piezo Buzzer, for continuity. • Interfaces: (PHTM320/PHTM640/PHTM960) * Printer: Centronics parallel port for printers. Can print learnt data and label on Pass.
Page 15 5 / 10 cards. The tester stores the data into memory and compares it with the tested data. If any error is found it reports through the 16 character LCD display. It also recognizes the key pressed and functions accordingly. PHTM320 PHTM640 PHTM960 Maximum number of points.
Page 16 • Facilitates two stage testing. For example for fuse box. First stage complete harness and second stage only fuses. Does not test for extra points in second stage. • Switches a relay contact of 230 V AC, 5A capacity on for settable time (1 to 10 seconds) on for any application as stamp printing etc.
Page 17 • Check rig / board, as a part of periodic performance check. • Download harness data, label data, harness name, barcode etc. from a PC Using DOS as well as windows based software. • Relay on time is settable through software. (1 to 10 sec). 2.3.3: Harness Data (Circuit Data): Tester stores harness data in its memory which is retained even on power off.
Page 18 2.3.6: Rig: As the testing time reduces to one to five seconds; the harness mounting time on the rig becomes very significant. All the harness points are to be mounted on the rig. If connectors are used in a harness then time taken is very less. We have developed some parts which take less efforts and time mount them on rig.
Page 19: Unpacking The Equipment
“Learn” lock key for learning a harness. o Cable from tester to board / rig as per number of points or connectors. o Serial Cable with models PHTM320 PLUS and PHTM640. o A CD containing DOS as well as windows based PC software for serial communication with tester and other details.
Page 20 4: OPERATION 4.1: Operating Instructions: Key Definitions: Key operations are as follows. For any wrong key pressed; message “CHEK KEY” will be displayed. Key “LRN” : Learn from mounted harness. Key “TEST” : Test mounted harness and show results. Key “A” : Analyse;...
Page 21 Keys, Menus and submenus Setup mode LRN pressed during power on. auto manual Mode Enter MANUAL TESTING? Enter AUTO TESTING? SET MANL TESTING SET AUTO TESTING Skip Extra point testing CHECK EXTRA PNT? SKIP EXTRA PNT? Enter Enter SET CHECK EXTRA SET SKIP EXTRA...
Page 22 LRN pressed during power on. Relay on fail Relay on pass mode RELAY ON FAIL? RELAY ON PASS? Enter Enter SET RELAY ON FAIL SET REALY ON PASS Printer Ready CHK PRN READY? SKIP PRN READY? Enter Enter No key Enter Set relay on time?
Page 23 Analyse key pressed during power on without harness on the rig / board. mounted Self Test mode: Tests for any shorted points on the board. Shorted points found No shorted points Displays pass, relay and buzzer on. Displays error and shorted points. Operation Halted.
Page 24 Power on Page 1 Keys, Menus and submenus Power On FUTURA VER XX Cards xx All Circuits? Set All Circuits. Enter Cable No. 00 Cable Number increments / decrements upto maximum / minimum. If Harness Name is stored, displays name instead of Cable No. Enter No point , if empty memory.
Page 25 Power on Page 2 No of stages x No key Enter Change no of stages? No of stages x Up /Down Enter Clear Count @5 Seconds Enter Count Cleared...
Page 26 Label printing off Label Printing on Print Label? @5 Seconds Off Print Label? @5 Seconds Enter Enter Print Label on Print Label off Clear serial no? Enter Cleared...
Page 27 Power on Page 3 Barcode Matching on Barcode matching off Match Barcode? @5 Seconds Bar Reader on Enter Bar Reader on Command? All required settings are over and ready to accept command like test or learn or analyse.
Page 28 Test Data? Enter Board to Data? Enter Learn? Enter Learning. 2 Bar on 2 Bar PC To Hrn Data Enter Receiving. Set 2 Bar On? Reset 2 Bar On? Enter Enter Hrn Data To Printer Enter Sending 2 Bar on 2 Bar off Hrn Data To PC Enter...
Page 29 2 Bar off 2 Bar on Enter Receiving Bar 1 Receiving. Receiving Bar 2 Bar Reader Off. Disable Barcode Enter Receiving. Enter Harness Name Test starts testing selected harness.
Page 30 Keys, Menus and submenus TEST (Starts testing selected harness, stops at first fault, displays faults, Buzzer, relay on pass.) A I.e. ANALYSE Check Continuity? Enter Continuity. Display Data? Board 0000. (Display Harness Data) Enter Count NNN. (Pass Counter). Change Cable number? Enter Cable No.
Page 31: Setting Tester To Test: Key Lrn
4.2: Setting tester to test: Key LRN: Learn Lock key position: For ‘LRN’ key operation, tester checks for key switch on ‘Learn’ position. For any other key operation, tester checks for key switch not on ‘Learn’ position. If it is, then displays “Key lock on learn”...
Page 32: Interfacing With Pc
the data, tester will be ready to accept any command. Data can be verified by using display data mode. Windows based programme also can be used. If two stage data is transmitted from PC to tester, 2 stage testing is automatically set and need not be set through keyboard.
Page 33 To load from PC to tester, a file has to be created. For harness data filename extension required is .hrn, and for others extension required is .lbl. This can be generated by using any text editor. EDD.EXE is one editor in the CD. Others like edit, notepad can be used with care that file should be non document pure test file and it should have proper extension.
Page 34 Details of TCHT screen and sample files are as follows. Select Task here Sample files Harness Data: FILE EXTENSION SHOULD BE .HRN THIS IS DUMMY DATA FOR A HARNESS. NOTE: HASH CHARACTER AT THE START AND END. FIRST LINE IS NUMBER OF POINTS. EACH POINT IS SEPARATED BY A SPACE.
Page 35 1 2 6 50 77 90 Date Time: FILE EXTENSION SHOULD BE .LBL dd = date in 2 digits mm = month in 2 digits yy = year in 2 digits = time hours in 24 hours format in 2 digits mn = minutes in 2 digits = seconds in 2 digits HASH CHARACTER AT THE START AND END.
Page 36 Barcode: EXAMPLE OF BAR CODE. THIS WILL BE COMPARED WITH SCANNED LABEL NOTE EXTENSION OF FILE SHOULD BE .LBL START AND END WITH # NAME CAN BE OF MAXIMUM 32 CHARACTERS SAMPLE BAR LABEL Harness Name: EXAMPLE OF HARNESS NAME. NOTE EXTENSION OF FILE SHOULD BE .LBL START AND END WITH #...
Page 37: Testing And Test Results
• First number should be number of points in the following harness data. If this number and actual number of points do not match then tester gives error. • Data is to be entered net by net, each net separated by a carriage return and line feed i.e.
Page 38 Two stage testing: While testing, selected cable number program, is taken as stage 1 and next cable number is taken as stage number 2. Tester checks for complete correctness of harness in stage 1 if correct gives a small beep along with display “PASS 1” meaning stage 1 passed.
Page 39 Interchange: “LOCN xxx1 yyy1”, “OR”, “LOCN xxx2 yyy2”: If interchange has occurred between two nets of two points each, tester cannot locate exact interchanged point. It displays both possible interchanges. Open group: “OPEN xxxx yyyy”. In case of two point net from ‘xxxx’ to ‘yyyy’ or if some wires with point ‘yyyy’ from a circuit starting with point ‘xxxx’...
Page 40 • In Printing of labels, Following are special characters to be used. @1: Date, Complete date in dd/mm/yy format @2: Time (hr: mm:ss) @3: Week @4: Month @5 : Year @6---@6: Serial number, numbers between @6--@6 indicate serial no size. Maximum serial no size allowed is 9.
Page 41 4.7: Buzzer: On passing a harness a ringing buzzer sounds for @ 3 seconds. Buzzer’s tone and volume can be controlled from presets at the back side. Different tones can differentiate passed harnesses and to avoid confusion. 4.8: Interfacing barcode scanner / reader. Function: To read bar code on each harness before testing;...
Page 42 To manually check continuity in a harness, use this mode. In continuity checking mode, display is “CONTINUITY”, the red and black terminals on the front panel are to be used as two probe points. Please refer the attached front panel diagram. A pair of probes is also provided.
Page 43 5: Description of menus and user general instructions. 5.1 Power on learn menus (After pressing LRN key on power on and key position on LRN) Auto testing: Testing will be done in auto mode. Manual testing: Testing will be done in manual mode. Skip Extra pnt: Disable extra point testing at harness testing.
Page 44 • Change cable number: Navigates through cable number 1-25, and selects • Pass count: Displays Pass count. • Board check: Checks board at every point. • Operator codes : Facility to scan two operator codes.
Page 45 6: TROUBLESHOOTING: Futura Apsol Pvt. Ltd. is not responsible for any modifications done in tester circuit without consultation with Futura or by an unauthorized person. General: CHT tester is thoroughly tested before leaving the factory. It is recommended that in case CHT fails, the user should follow the troubleshooting guide before contacting FUTURA.
Page 46 6.4: How to increase number of points i.e. capacity of tester? • Capacity of PHTM320 is maximum 320 points and PHTM640 is maximum640 points. • If tester has less number of I/O cards than its maximum capacity, it can be increased by adding an I/O card in the next available slot.
Page 47 7: HOW TO … 7.1: How to replace I/O card. Switch off tester. Remove mains cord. Remove these 2 screws near edge. Back view of tester I/O card If it cannot be removed then Remove this plate with I/O PCB remove this second plate first by Plate Remove PCB from...
Page 48 7.2: How to add I/O card. Switch off tester. Remove mains cord. Remove these 2 screws near edge. Back view of tester Previous I/O card Remove this plate with I/O PCB. Remove these screws and remove covering plate. Keep holding painted blocks from inside. Assemble new I/O card using blocks and screws provided.
Page 49 7.3: Connections Of new CPU Following photos indicate internal view of PHTM CPU and all its connections. Front view of tester. Here CPU PCB is located. 10 pin Connector from IO cards FRC connector for Display FRC connector from motherboard Program Module of CPU CPU overview...
Page 50 8: BASICS OF TROUBLE FREE OPERATION: (PROPER USE OF TESTER) The following basic procedures are essential for safe and trouble free operation of the system. • Installation and operation of the tester or system according to the directions in the manual. •...
Page 51 5. In Future’s PHTM320; each and every point acts as “from” or “to”. Hence to wire the rig circuit of harness is not taken into consideration and any point can be connected anywhere.
Page 52 Another advantage of PHTM320 is that since it does not have “from and to” concept; one rig can be designed to mount different types of harnesses. For this purpose; all the required harnesses are to be collected and a board is designed to have all the end points of the harnesses.
Page 53 Connection details for I/O card to 36 pin centronics connector i.e cable wiring details from tester to board. I/O Number I/O card 36 Centronics Connector connected as displayed to cable (M), on board / Rig (F) on tester. (use brd chk) Connector no.
Page 54 I/O Number I/O card 36 Centronics Connector connected to as displayed cable (M), on board / Rig (F) on tester. (use brd chk) Connector no. Pin no. Printed Connector Pin No. Printed on on connector connector Above details can be used to repair, correct or to make a new cable from tester to board / rig.
Page 55 1: As the tester compares data or connections of a standard harness with the connections of Harness under Test; calibration is not required. 2: PHTM320 does not measure any absolute quantity hence calibration is not required. 3: To confirm functionality of the test system i.e. test equipment along with test rig, following procedure can be repeated after fixed period say 3 months or 6 months.
Page 56 11: OTHER CABLE HARNESS RELATED PRODUCTS: 11.1: Harness Assembly Aid / Tester (HAA64): Function: Harness Assembly aid is a tool useful for harness assembly / sub assembly. Basis of HAA64 is that harness assembly is done in steps. Each step involves picking up a part either a crimped cable / cable assembly or a grommet etc.
Page 57 Each step is programmable for tray and points of choice. Complete system consists of HAA64, a set of trays with LED at each tray along with numbers, a fixture with LED at each point along with numbers. Technical Specifications: Power Supply: 230V ac +/- 10% AND or OR 12 V DC, 800 mA. Number of programmable steps 99, with 48 number of trays and 64 number of points, programmable by user, by ‘Learning’.
Page 58 Now first available point LED will be on. Selected point will be end A or starting point of circuit. It can be selected by using ‘up’ and ‘down’ Once finalized, remaining terminals are to be inserted at respective locations. As soon as terminals are inserted, corresponding LEDs will be on.
Page 59 11.2: One To One Continuity Tester with Parts Counter (CT121): Function: One to One continuity tester is to test point to point continuity of a circuit. Application can be a fixture with limit switches, a connector or a coupler with open ends. It does not check midjoints.
Page 60 12 : FUTURA’S PROFILE : Futura Apsol Pvt. Ltd. Visit www.futuras.com for details. Sr. No. Futura's Products 1 Testers for cable / wiring harness 1.1 Cable Harness Tester, 320 points, with serial, parallel. 1.2 Cable Harness Tester, 640 points, with serial, parallel.
Page 61 6 Switch Testing 6.1 Switch Harness tester (without load) 6.2 Combiswitch tester (switch test with load) 6.3 Switch test endurance 6.3.1 Programmable load / power supply. 6.3.2 Waveform Capture. 7 Computer Peripheral: 7.1 Printer sharer Auto 4*1 7.2 Printer sharer Auto 2*1 7.3 Printer data switch, manual 1*2 7.4 Printer data switch, manual 2*2 7.5 Printer data switch, manual 4*1...

This manual is also suitable for:

Phtm960 Phtm640