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Cablescan 128/PC Instruction Manual

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CONTINUITY TESTER
AND FIXTURE
MODEL 128/PC

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  • Page 1 CONTINUITY TESTER AND FIXTURE MODEL 128/PC...
  • Page 3 Model 128/PC Instruction Manual Page iii February 25, 2005 MODEL 128/PC INSTRUCTION MANUAL (Part Number 5900389) Cablescan A Eubanks Company 3022 Inland Empire Blvd. Ontario, California 91764 (909) 483-2436 Fax (909) 483-2463 www.cablescan.com...
  • Page 4 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.

  • Page 5: Table Of Contents

    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...
  • Page 6 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...
  • Page 7 Model 128/PC Instruction Manual Page vii LIST OF FIGURES Figure Description Page Front Panel Controls and Display................2 Rear Panel Layout....................3 Interface Fixture.......................4 Program Storage - Accommodations and Use ............5 Simplified Self-programming (LEARN) Procedure..........9 Simplified Test Procedure ..................10 Simplified Wire Identification (SEARCH) Procedure ..........11 Simplified Save Program Procedure..............12...

  • Page 8: Specifications

    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: >...

  • Page 9: System Overview

    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.

  • Page 10: Front Panel Controls And 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.

  • Page 11: Display Format

    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.

  • Page 12: Interface Fixture

    Figure 3. Interface Fixture SIGNATURE CODES 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.

  • Page 13: Program Storage

    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).

  • Page 14: User Labels

    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.

  • Page 15: Quick Start

    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.

  • Page 16: Program Storage

    Page 8 Model 128/PC Instruction Manual PROGRAM STORAGE Refer to Save Program (menu-selected) in the Operating Instructions section for details. 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.)

  • Page 17: Simplified Instructions

    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.

  • Page 18: Simplified Test Procedure

    Page 10 Model 128/PC Instruction Manual 3, 5 MODEL 128 ERROR LEARN SEARCH TEST RESET LIST MENU 4, 5a 1. Press RESET. Install appropriate adapter cards for the cable to be tested. Install cable or harness to be tested. Press TEST; observe Passed on Display.

  • Page 19: Simplified Wire Identification (Search) Procedure

    Model 128/PC Instruction Manual Page 11 PROBE ENABLE 250mA/250V CAUTION! For continued protection against risk of fire, replace only with same type and rating of fuse. MODEL 128 ERROR LEARN SEARCH TEST RESET LIST MENU 1. Press RESET. Install appropriate adapter cards for the cable to be tested Connect wrist strap or probe to Probe receptacle.

  • Page 20: Simplified Save Program Procedure

    Page 12 Model 128/PC Instruction Manual PROBE ENABLE 250mA/250V CAUTION! For continued protection against risk of fire, replace only with same type and rating of fuse. MODEL 128 ERROR LEARN SEARCH TEST RESET LIST MENU 4, 7 3, 6 1, 5 1.

  • Page 21: Simplified Load Program Procedure

    Model 128/PC Instruction Manual Page 13 MODEL 128 ERROR LEARN SEARCH TEST RESET LIST MENU 3, 4, 7 2, 4, 6 1, 5 1. Press RESET. Select and initiate Load Program. The display will show a signature code of a program stored in Program Memory.

  • Page 22: 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.

  • Page 23: Search

    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.

  • Page 24: Error List

    Verify printer is connected. (Refer to Printer Setup in System Setup section.) Load program to be used. (Refer to "Load Program" later in this section). 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.

  • Page 25: Test

    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.

  • Page 26: Reset

    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...

  • Page 27: Menu-Selected Modes And Functions

    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.

  • Page 28: Load Program

    Page 20 Model 128/PC Instruction Manual Press MENU RUN again to save the program. After the program has been saved, the display will show: Saved (signature #) If you decide not to save the program, press RESET instead of MENU RUN.

  • Page 29: Delete Program

    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: Insert Enable jack in the rear panel.

  • Page 30: Clear Memory

    Set Baud Rate The Model 128/PC has two baud rate settings: 1200 and 9600. 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.

  • Page 31: Print Wire List

    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.

  • Page 32: Print User List

    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...

  • Page 33: Loop Test

    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.

  • Page 34: Self Test

    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.

  • Page 35: Pc Keyboard Operating Instructions

    PC KEYBOARD OPERATING INSTRUCTIONS INTRODUCTION 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.

  • Page 36: Print Commands

    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.
  • Page 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.

  • Page 38: System Setup

    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.

  • Page 39: Return Of Faulty Unit

    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...
  • Page 40 Page 32 Model 128/PC Instruction Manual NOTE Pin #11 is used to indicate when the printer is ready to receive data. In Okidata printers, the signal name is "Supervisory Send Data"; it may also be referred to as "Printer Busy." The printer sets this signal HIGH to indicate the print buffer is full and to stop sending data.

  • Page 41: Pc Interface

    Computer (PC) when a printer is not connected. Cablescan provides an optional MS DOS based software program (TERM), which can be used to control and transfer programs between the Model 128/PC and the PC. The software also can be used to transfer programs between the Model 128/PC and other Cablescan testers.

  • Page 42: Changing Power Setting

    Model 128/PC Instruction Manual CHANGING POWER SETTING The Model 128/PC can be set to the other alternate power by opening the unit and changing an internal Voltage Select switch (SW1) on the CPU Circuit Board (Figure 13) as follows: Disconnect power cord from unit.

  • Page 43: Power Switch And Jumper Locations

    Model 128/PC Instruction Manual Page 35 CPU CIRCUIT BOARD Printer/Serial Enable Probe Voltage Select Switch Connector Connector Connector (115 or 220) 115V REMOTE OUTPUT JUMPERS BUZZER LITHIUM BATTERY 3vdc Model 128/PC Ready ASSY NO. 5211057 REV __ MADE IN USA...

  • Page 44: Remote Output Signals

    Page 36 Model 128/PC Instruction Manual REMOTE OUTPUT SIGNALS Two output signals are provided for controlling external devices through unused pins on the printer/serial connector. The pins are connected to the CPU board where jumpers may be installed to activate the signals. Refer to Figure 13 for jumper locations. The output signals are: Pass/Fail and End of Test, and are brought out on pins 24 and 25, respectively.

  • Page 45: Adapter Cards

    Cable adapters normally are employed in pairs, one for the left side of the interface fixture, and one for the right side. Select each adapter to match its respective end of the cable being tested. Cablescan adapters are described at the end of this manual. A list of adapter cards is provided later in the section.
  • Page 46 Page 38 Model 128/PC Instruction Manual A Universal Adapter Card is available for mounting connectors that do not have a standard adapter card available. The Universal Adapter Card is basically an extra wide circuit board with plated-through holes connecting to the edge-card contacts. Unlike the standard adapter cards which can be installed on either the left side or the right side of the fixture, the universal card is wired to operate on one side or the other.

  • Page 47: Setting Adapter Codes

    At the top of each adapter card is a set of jumper locations. Jumpers on the adapter cards supplied by Cablescan are preset. The code for each adapter is provided in the Adapter Card List at the end of this section. The jumpers are not set when bare boards only (no connector installed) are purchased from Cablescan.

  • Page 48: Adapter Card List

    Page 40 Model 128/PC Instruction Manual ADAPTER CARD LIST Cablescan stocks a wide range of adapters for use with the Model 128. Adapters currently available are listed below. Information on additional configurations may be obtained from Cablescan. PART TYPE PC BOARD...
  • Page 49 Model 128/PC Instruction Manual Page 41 ADAPTER CARD LIST (CONTINUED) PART TYPE PC BOARD ADAPTER NUMBER TESTED DESCRIPTION NUMBER CODE RIBBON CONNECTORS 5210901-50 Female 14-pin Champ 5004554 5210901-51 Male 14-pin Champ 5004555 5210901-52 Female 24-pin Champ 5004556 5210901-53 Male 24-pin Champ...
  • Page 50 Page 42 Model 128/PC Instruction Manual ADAPTER CARD LIST (CONTINUED) PART TYPE PC BOARD ADAPTER NUMBER TESTED DESCRIPTION NUMBER CODE .050" DUAL ROW PIN HEADER 5210998-50 Female 10-pin Header 5004575 5210998-51 Female 20-pin Header 5004575 5210998-52 Female 30-pin Header 5004575...

  • Page 51: Care Of The Model 128/Pc

    REPAIR If the Model 128/PC requires repair due to any defect of manufacture, and it is within the warranty period, contact Cablescan, for instructions on returning it to the factory. Even if the Model 128/PC is beyond the warranty period, and repair is necessary, it is advisable to return the unit to the factory for repair.

  • Page 52: Schematic - Model 128 Cpu/Scanner Board

    Model 128/PC Instruction Manual Page 44 Figure 14. Schematic - Model 128 CPU/Scanner Board (1 of 5)
  • Page 53 Figure 14. Schematic - Model 128 CPU/Scanner Board (2 of 5) Model 128/PC Instruction Manual Page 45...
  • Page 54 Model 128/PC Instruction Manual Page 46 Figure 14. Schematic - Model 128 CPU/Scanner Board (3 of 5)
  • Page 55 Figure 14. Schematic - Model 128 CPU/Scanner Board (4 of 5) Model 128/PC Instruction Manual Page 47...
  • Page 56 Model 128/PC Instruction Manual Page 48 Figure 14. Schematic - Model 128 CPU/Scanner Board (5 of 5)
  • Page 57 NOTES...
  • Page 58 NOTES...
  • Page 59 Cablescan 5900389 Rev D...

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