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Table of Contents
Related Manuals for Cablescan 90 Series
Summary of Contents for Cablescan 90 Series
- Page 1 Cablescan Series 90 SETUP MANUAL...
- Page 3 May 4, 2015 Series 90 SETUP MANUAL (Part Number 5900407-00) 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.
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Page 5: Table Of Contents
Series 90 Setup Manual Page v TABLE OF CONTENTS Series 90 Family of Test Systems ............1 Series 90/Series 90HV ..................1 Series 90L4/Series 90L8/Series 90H8............1 System Components ................4 Series 90 ......................4 Series 90HV ....................4 ... - Page 6 Page vi Series 90 Setup Manual TABLE OF CONTENTS - Continued 5210982 Cable Assembly ..............19 High-voltage Interface Cables and connectors ........21 5211036 Connector Kit...............21 5211037 Cable Assembly ..............21 5211038 Cable Assembly ..............22 5211088 Connector Kit...............22 ...
- Page 7 Series 90 Setup Manual Page vii TABLE OF CONTENTS - Continued Range Group ................36 Tester Group ................36 Calibration Group ..............37 Test Selections Group ...............37 Advanced Tab ..................38 Output Group ................38 Factory Testing .................38 Style Menu ..................38 ...
- Page 8 Page viii Series 90 Setup Manual TABLE OF CONTENTS - Continued Series 90S9 and Series 90S32 Fuse Replacement ........48 Series 90L4/H8 Fuse Replacement ............49 Care of Series 90 ................50 Maintenance ....................50 Repair ......................50 Handling Circuit Boards ................50 ...
- Page 9 Page The Series 90 Test Systems .................2 The Series 90HV Test System ..............3 The Series 90 Series 90L4 and 90Series Series 90H8 Test Systems ...3 Series 90/90HV Simplified Diagram ............4 Series 90L4/L8/H8 Simplified Diagram ............5 ...
- Page 10 Page x Series 90 Setup Manual ABOUT THIS MANUAL This manual provides setup and installation information on all Cablescan Series 90 Test Systems: Low Voltage Models High Voltage Models Series 90 Series 90HV Series 90L4 Series 90H8 Series 90L8 Information that is not identified by model number(s) pertains to all models. Where information is identified by certain models, read the portions pertaining to your model.
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Page 11: Series 90 Family Of Test Systems
SERIES 90 FAMILY OF TEST SYSTEMS SERIES 90/SERIES 90HV The Cablescan Series 90 (Figure 1) is a high-speed continuity tester that you also can use as an assembly aid and a final interconnect verifier. The Series 90HV (Figure 2) is a high-voltage model that typically is used for testing quality of insulation and quality of harness connections. - Page 12 Page 2 Series 90 Setup Manual SERIES 90-S9 (Nine-board Expansion Cabinet) SERIES 90-S32 (Thirty-two-board Expansion Cabinet) Figure 1. The Series 90 Test Systems...
- Page 13 Series 90 Setup Manual Page 3 SERIES 90HV-S23 (Twenty-three-board Expansion Cabinet) Figure 2. The Series 90HV Test System (Controlled by your PC) (Controlled by your PC) Series 90L4 (Four-board Cabinet) Series 90H8 (Eight-board Cabinet) Figure 3. The Series 90 L4 and Series 90H8 Test Systems...
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Page 14: System Components
Page 4 Series 90 Setup Manual SYSTEM COMPONENTS SERIES 90 The Series 90 consists of a system control and one to thirty-two expansion cabinets to accommodate scanner boards. See Figure 4. There are two models: the Series 90-S9, with a nine-board Expansion Cabinet (which may be ordered with 1 to 9 boards);... -
Page 15: Expansion Cabinets
SERIES 90L4/L8/H8 The Series 90L4/L8/H8 has no system controller; you control it through your own PC using Cablescan-supplied software. See Figure 5. There are no provisions for additional expansion cabinets. Series 90L4: Four scanner boards with 128 test points each, yielding 512 maximum possible test points. -
Page 16: Series 90 System Setup
Carefully unpack the components, and set the containers aside for future use. Visually inspect each component for damage or deficiency. Record any damage or deficiency and report it to Cablescan. In the event the equipment has been damaged because of shipping, notify both the carrier and Cablescan immediately. -
Page 17: Series 90/Series 90Hv System Controller Interfacing
Figure 6. System Controller Rear Panel I/O Board The Cablescan I/O Board is a high-speed communication board used in sending and receiving test information to the Scanner Control Boards located in Series 90 expansion cabinets. (The Scanner Control Board controls the Scanner Boards, which contain the test points in its cabinet.) One of the main purposes of the Scanner Control Board is to allow up to 32 cabinets to be daisy chained together as one system. -
Page 18: Series 90/90Hv Connection Procedure
Page 8 Series 90 Setup Manual SERIES 90/90HV CONNECTION PROCEDURE Basic System Hookup Arrange the Series 90/90HV with the system controller alongside the expansion cabinet. Connect the system as shown in Figure 7, and as described below: 1. Connect power cord (part number 9200016) from INPUT power connector (male) on rear panel of expansion cabinet to AC receptacle. -
Page 19: Adding Expansion Cabinets
Series 90 Setup Manual Page 9 7. Connect female end of the short (1 foot) 9-conductor cable (part number 9100086) to bottom connector of Expansion Input/Output Board (COM IN); connect male end to serial communication port (COM1). 8. Connect female end of 9-conductor cable (part number 9100069) to top connector of Expansion Input/Output Board (EXPANSION);... -
Page 20: Series 90L4/Series 90L8/Series 90H8 Scanner Control
The Scanner Control Boards in the Series 90L4, Series 90L8 and Series 90H8 are designed to communicate through a serial port (COM) instead of a Cablescan I/O board. Since a PC serial port cannot be daisy chained, the Series 90L4, Series 90L8 and Series 90H8 are limited to one cabinet (512 test points or 1024 test points for the Series 90L8). -
Page 21: Connecting To Usb Port On Pc
Series 90 Setup Manual Page 11 Connecting to USB Port on PC Arrange the Series 90L4/90L8/90H8 alongside your PC. Connect the power cords as shown in Figure 10, and as described below: 1. Verify power switch on rear panel is in OFF position. 2. -
Page 22: Adding Scanner Boards
Page 12 Series 90 Setup Manual ADDING SCANNER BOARDS Scanner boards are added to the expansion cabinet to increase test point capacity. To add a scanner board to an expansion cabinet, turn off power and disconnect the power cord. (Power must be shut off on the entire system.) Series 90E9/Series 90E32 Cabinets On the 9-card Series 90E9 cabinet, remove the rear panel. -
Page 23: Series 90Hv23 Cabinet
Series 90 Setup Manual Page 13 Series 90HV23 Cabinet Starting at the left, remove blank panel for each high-voltage scanner board to be added. All scanner boards must be installed consecutively in the card cage without skipping one. As shown in Figure 12, scanner boards are installed from the left. -
Page 24: Series 90L4/L8/H8 Cabinet
Page 14 Series 90 Setup Manual Series 90L4/L8/H8 Cabinet Remove front panel from tester. Starting at the left side, install scanner boards consecutively in the card cage without skipping a slot, as shown in Figure 13. High-voltage scanner boards cannot be installed in a Series 90L4 or Series 90L8 and low-voltage scanner boards cannot be installed in a Series 90H8. -
Page 25: Low-Voltage Scanner Board Jumpers
Series 90 Setup Manual Page 15 Low-voltage Scanner Board Jumpers Each low-voltage scanner board 520944-00 and 520944-01 must have a jumper installed for configuration. (The 5210944-02 low voltage scanner boards and the high-voltage scanner boards do not have jumpers.) As illustrated, the jumper is installed across two pins of a three-pin connector located on the component side, opposite the test point connectors. -
Page 26: Scanner Board Pins And Test Point Assignments
Page 16 Series 90 Setup Manual SCANNER BOARD PINS AND TEST POINT ASSIGNMENTS Scanner Board #1 Scanner Board #2 SERIES 90 LOW-VOLTAGE SYSTEMS Pin 1 Pin 2 Pin 1 Pin 2 The Series 90 low voltage test systems use scanner boards Point 1 Point 2 Point 129... -
Page 27: Series 90 High Voltage Systems
Series 90 Setup Manual Page 17 SERIES 90 HIGH VOLTAGE SYSTEMS The Series 90 high voltage test systems use scanner boards that have 64 test points each. These scanner boards use selectively loaded 96-pin DIN connectors. The connectors are loaded with pins in the even-numbered outer two rows, A and C. -
Page 28: Interface Cable Assemblies And Connectors
.570 inches to allow a strain relief socket connector (7200481) to be used. The latch will not work with a substitute socket connector of a different height. Cablescan provides the following three 8-foot interface cable assemblies for interfacing the tester to the assembly under... -
Page 29: 5210917-03 Cable Assembly
Series 90 Setup Manual Page 19 5210917-03 Cable Assembly The 5210917-03 cable assembly has a 64-pin socket connector (7200481) on one end and an AMP Champ flat cable connector (5210446) on the second end. This cable can be used to interface to a panel mountable discrete-wired type AMP Champ connector. - Page 30 5210917-3 64-conductor flat cable 7200481 7200446 5210982 64-conductor Harness Board 7200449 (no connector) (discrete) Cablescan to AMP Conversion Table Cablescan Description Part No. Part No. 7200426 64-pin latch and eject header, PCB connector 1-499141-2 7200446 64-pin male AMP Champ flat cable connector...
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Page 31: High-Voltage Interface Cables And Connectors
Series 90 Setup Manual Page 21 HIGH-VOLTAGE INTERFACE CABLES AND CONNECTORS The Series 90 high-voltage test systems use selectively loaded 96-pin DIN connectors to interface between the test points on the scanner boards and the assembly under test. For isolation purposes, the scanner board connectors have pins in only every-other position of the outer two rows. -
Page 32: 5211038 Cable Assembly
Page 22 Series 90 Setup Manual 5211038 Cable Assembly The 5211038 is a 96-conductor, eight-foot, discrete-wired, high-voltage cable assembly. It uses three, 32-conductor cable assemblies; 5211037 on one end and a 96-pin ZIF connector (plug) on the second end. The 96-pin ZIF plug is an ITT-600 series connector. This cable is used to interface to a test fixture. - Page 33 Description Part No. Part No. 5211036 32-pin DIN male connector 100-932-124 Strain Relief 100-000-071 Housing 100-000-064 Cablescan-to-ITT Cannon Part Number Conversion Cablescan ITT Cannon Description Part No. Part No. Cable End Connector Components 5211061 96-pin ZIF connector, plug DL2-96P 96-pin ZIF connector shell kit...
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Page 34: Remote Signals
Page 24 Series 90 Setup Manual REMOTE SIGNALS OUTPUT SIGNAL TIMING The Series 90 provides external signals for use in controlling external devices and equipment. Refer to the following pages for locations of the signals. These signals are active during Test mode: ... -
Page 35: Input/Output Connectors
EXECUTE TEST PASS/FAIL END-OF-TEST A footswitch connection is provided on the I/O board for systems using a Cablescan System Controller. This connection becomes active when device selected for the Primary I/O Port is the same as the Communication Port. All input signals are triggered when going from a positive to a negative state. For example, an... -
Page 36: 25 Pin D Connector Parallel Port
Page 26 Series 90 Setup Manual positive state to the negative state. Pull up resistors (10kΩ) are required on all input signals after the remote signals are enabled. . 25 Pin D Connector Parallel Port TestRite can utilize a parallel port for I/O signals. Use of parallel port for I/O signals is not supported under Windows 7 and later versions of Windows. -
Page 37: 15 Pin D Connector I/O Port
Series 90 Setup Manual Page 27 15 Pin D Connector I/O Port Older Series 90 system, using the ISA version of the I/O Board, has a 15 pin D connector that provides the I/O signals. Primary I/O Port Pin Number Function Direction EXECUTE TEST... -
Page 38: Testdiag
TESTDIAG THE TESTDIAG PROGRAM TestDiag is one of three programs provided in Cablescan's TestRite software. It is primarily a test and diagnostic software for Series 90 and Series 90HV test systems. However, it can also run the built-in self-test of the standalone testers including TestMate, Model 64, Model 64x2, Model 256/PC, and Model 512. -
Page 39: Testdiag Opening Screen
Series 90 Setup Manual Page 29 TESTDIAG OPENING SCREEN TestDiag is fast and easy to learn, and has an intuitive design: title bar, menus, message and dialog boxes, and comparable commands. TestDiag uses similar keyboard and mouse operations as most Windows applications to select objects and choose commands. Shown below is the TestDiag screen. -
Page 40: Title Bar
Page 30 Series 90 Setup Manual In addition to these items the window contains menu access for Style, About, and Application Menus by clicking a appropriate button. Clicking the Application Menu opens the menu as shown below. Style Menu About Menu Application Menu Title Bar... -
Page 41: Status Banner
Series 90 Setup Manual Page 31 the top of the ribbon or use the keyboard shortcut Control+F1. Once the ribbon has been minimized, it can be restored by clicking the same icon or using the same keyboard shortcut. Status Banner The Status Banner on the TestDiag screen displays the operating status of the tester and the status of the test. -
Page 42: Application Menu
Page 32 Series 90 Setup Manual Application Menu The Application Menu is the first tab in the ribbon. Clicking the Application Menu opens a drop down menu for selecting commands for tester settings and printing. These commands include Print, Print Preview, Print Setup, Print to File, and Tester Settings. Style Menu The Style Menu provides settings for customizing the look of the ribbon menu. -
Page 43: Application Menu
Series 90 Setup Manual Page 33 APPLICATION MENU The Application Menu is opened by clicking the tester icon on the left of the ribbon menu. The Application Menu provides buttons for printing test results, printing to text files, previewing before printing, and printer setup. The Application Menu also provides a button for accessing Tester Settings which are described below. -
Page 44: Communication Port
Page 34 Series 90 Setup Manual Communication Port Specifies PC port connected to the tester. The Communication port is selected by clicking the drop-down list. The Status bar will display the port specified and will display “On-line” if PC and tester are communicating. High Precision Cap. -
Page 45: Ribbon Menu
Series 90 Setup Manual Page 35 RIBBON MENU The TestRite ribbon menu contains two tabs for setting up how the test is run, what tests to run, and running the test. As in other Windows applications, controls for commands that do not apply to the situation or to the type of tester at the time are grayed out and cannot be selected. -
Page 46: Range Group
Page 36 Series 90 Setup Manual Range Group Range group contains options for specifying the range of test points the self-diagnostic tests will be performed on. Full Range The Full Range check box is selected when all test points in the tester are to be tested. For special test setup situations, the range can be limited by unchecking the Full Range box and entering the Start, beginning test point, and the Stop, ending test point, of the range to be tested. -
Page 47: Calibration Group
Series 90 Setup Manual Page 37 Calibration Group Calibration group is used during the calibration of the tester. Capacitance Offset (1) Capacitance Offset Function measures the amount of capacitance in the system. This value is used as an offset to the measurements made during test to improve capacitance measurement accuracies. -
Page 48: Advanced Tab
Page 38 Series 90 Setup Manual Advanced Tab Advanced Tab is the second ribbon menu tab and contains controls for displaying measurements and special factory settings. Output Group Output group contains a control for displaying all measurements performed by the self- diagnostic tests. -
Page 49: About Menu
Series 90 Setup Manual Page 39 About Menu Clicking the About Menu opens a dialog box with information about the registered user and supported tester types. Register Clicking the Register button opens a dialog box for changing the registered user name, the company name, and the serial number. -
Page 50: Diagnostic Tests
Series 90 Setup Manual DIAGNOSTIC TESTS Diagnostic tests can be performed on all Cablescan testers that are capable of interfacing to TestRite software. TestDiag automatically configures the Test Selection Window for, and provides tests based on, the type of tester selected from the Tester/Settings window. Functions that do not apply to the situation or tester type at the time are grayed out and cannot be selected. -
Page 51: Low-Voltage Tests
Series 90 Setup Manual Page 41 LOW-VOLTAGE TESTS Application Low Voltage Tests are basic Series 90 test functions and are run on both low voltage and high voltage Series 90 systems. Low-voltage Tests are available when the tester type is set to Series 90 or Series 90HV. -
Page 52: High-Voltage Tests
Page 42 Series 90 Setup Manual HIGH-VOLTAGE TESTS Application High-voltage tests are available when the tester type is set to Series 90HV. The high-voltage tests are performed on the high-voltage circuits after the low voltage tests are run. Some of the high voltage tests require a shorting bar to be installed and other tests require a resistor bank to be installed. -
Page 53: Isolation Amplifier
Series 90 Setup Manual Page 43 Isolation Amplifier Isolation Amplifier tests the performance of the isolation amplifier and the high-voltage- generator when loaded. This test uses a 100Mohm load resistor between test point 1 and test point 57. Controller Leakage Controller Leakage tests for high-voltage leakages on the scanner control board. -
Page 54: Series 90 Calibration
This test verifies that an open or short displayed during regular operation is not caused by a faulty test point. The Series 90 must be returned to Cablescan for repair if the tester fails to pass diagnostics. -
Page 55: Low-Voltage Test Procedure
Series 90 Setup Manual Page 45 Low-voltage Test Procedure The following steps are performed while running the diagnostic tests. The check box for each of the low-voltage tests below is assumed checked. 1. Remove all interface cables from scanner board connectors. 2. -
Page 56: High-Voltage Test Procedure
Page 46 Series 90 Setup Manual High-voltage Test Procedure The following steps are performed while running the diagnostic tests. The check box for each of the high-voltage tests below is assumed checked. High Voltage Warning Caution must be taken when performing diagnostic tests on high-voltage systems. The Series 90 high-voltage system generates up to 1500 vdc, and during testing applies 1500 vdc to the scanner board connectors. - Page 57 Series 90 Setup Manual Page 47 12. TestDiag pauses and displays a message box prompting to install resistor bank on first scanner board connector (J1). Install Calibration board using connectors opposite of side marked "Shorting Bar." 13. Click OK, and verify Resistor Bank test passes. 14.
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Page 58: Fuse Replacement
Page 48 Series 90 Setup Manual FUSE REPLACEMENT SERIES 90S9 AND SERIES 90S32 FUSE REPLACEMENT There are two 0.5-amp fuses in the Series 90, both in the expansion cabinet. One fuse is internal and is mounted on the power supply board. On early low-voltage Series 90 systems, the second fuse is an in-line fuse located between the lamp power connector on the rear panel and the power supply. -
Page 59: Series 90L4/H8 Fuse Replacement
Series 90 Setup Manual Page 49 SERIES 90L4/H8 FUSE REPLACEMENT There are two fuses in the Series 90L4/90H8. One fuse is internal and is mounted on the power supply board. The second fuse is on the rear panel and is marked Lamp Fuse. 1. -
Page 60: Care Of Series 90
If it is necessary for the user to replace parts, the replacement parts must be Cablescan, Inc., parts, or parts of equivalent rating and quality. -
Page 61: Replacement Parts
Series 90 Setup Manual Page 51 REPLACEMENT PARTS The following part numbers are provided for use in ordering replacements from Cablescan: Cable Assembly – Expansion cabinet interface ..........9100069 Connector – High-voltage scanner board (32 pins) ........7200557 Connector – Low-voltage scanner board (64 pins) ........7200426 Power Supply –... -
Page 62: Specifications
Page 52 Series 90 Setup Manual SPECIFICATIONS PARAMETER LOW-VOLTAGE HIGH VOLTAGE SERIES 90 SERIES 90HV Series 90 S9 Series 90HV S23 MODELS Series 90 S32 Series 90 H8 Series 90 L4 Series 90 L8 Up to 131,072 test points (in Up to 47,104 test points TEST POINT increments of 128) - Page 63 Series 90 Setup Manual Page 53 SPECIFICATIONS – CONTINUED PARAMETER LOW-VOLTAGE HIGH VOLTAGE SERIES 90 SERIES 90HV Continuity: 500 points/sec TEST SPEED Component: 50 points/sec High Current: 20 points/sec Isolation: 20 points/second* (* plus dwell & ramp-up time) Less than 10 µA BODY CONDUCTANCE Scanner boards can be assigned to drive lamps and relays.
- Page 64 12.75 x 9.75 x 12.25 inches (32.4 x 24.8 x 31.1 cm) 18 lbs. (8.2 kg) plus 1 lb. (0.5kg) per 128 points Cablescan makes product improvements as required and therefore all specifications and system configurations are subject to change without notice.
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Page 65: Appendix A - Scanner Resistor Bank
Series 90 Setup Manual Page 55 APPENDIX A - SCANNER RESISTOR BANK A bank of resistors is used to test the scanner board and scanner control board. The resistors can be soldered directly to a mating connector, or optional calibration boards may be used. The low- voltage testers use thirteen resistors and the high-voltage testers use fourteen. -
Page 66: Appendix B - Calibration Boards
The low-voltage and high-voltage resistor banks, shown in Appendix A, are available from Cablescan. The boards are constructed with two sets of connectors, one set on each side of the board. The resistor bank is connected to one set, while the second set of connectors is used as a shorting bar. - Page 67 Series 90 Setup Manual Page 57 NOTES...
- Page 68 Cablescan A EUBANKS COMPANY 5900407 Rev E...