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Cablescan 4000C Instruction Manual

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CONTINUITY TESTER
MODEL 4000C
Cablescan

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  • Page 1 CONTINUITY TESTER MODEL 4000C Cablescan...
  • Page 2 Model 4000C Instruction Manual Page iii July 7, 2014 MODEL 4000C INSTRUCTION MANUAL (Part Number 5900330) Cablescan A Eubanks Company 3022 Inland Empire Blvd. Ontario, California 91764 (909) 483-2436 Fax (909) 483-2463 www.cablescan.com...
  • Page 3 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 4: Table Of Contents

    Model 4000C Instruction Manual Page v TABLE OF CONTENTS SPECIFICATIONS ................x General Description ................1 Basic Configuration ..................1 Optional Components ..................1 Main Chassis ....................1 Control Head ....................1 Floppy Disk Drive ..................1 Scanner Boards ....................2 Expansion Chassis ..................2 Lamp Driver (optional) ..................2 Printer (optional) ....................2...
  • Page 5 Model 4000C Instruction Manual Page vi Lamp Driver ..................7 Disk Controller Board ................7 Single Disk Drive System ..............7 Dual Disk Drive System ................7 Printer ....................7 Controls and Indicators – Control Head .......... 8 Key-Selected Functions ..................8 Reset ......................8 Test ......................8 Error List ....................8...
  • Page 6 Model 4000C Instruction Manual Page vii Printer Cable ..................16 Printer Troubleshooting ..............17 Terminal Interface ..................17 Data Format ..................18 Terminal Cable ...................18 PC Interface ....................19 PC Cable .....................19 Changing Power Settings ..............20 Operation Instructions – Using the Control Head ......21 Introduction ....................21...
  • Page 7 Model 4000C Instruction Manual Page viii Introduction To Wire List Programming ........42 Discussion ....................42 Wire List .....................42 User Notation List ................42 Setup Options ..................42 Sample Wire Harness ...................43 Wire List without Cross References ............44 Wire List with User Notation ..............44 Program Editor .................
  • Page 8 Assembly Commands ...................68 Print Commands ...................68 Programming Commands ................68 System Setup Commands ................68 Serial Communication Commands ...............69 Disk Commands ...................69 Editor Commands ..................69 Care of the Model 4000C ..............70 Maintenance ....................70 Repair ......................70 Memory Backup Battery ................70 Replacement Parts ..................71...

  • Page 9: Specifications

    Model 4000C Instruction Manual Page x SPECIFICATIONS TEST POINT CAPACITY Main Chassis: 1 to 16 Scanner Boards, 128 points each (2048 points max.) Expansion Chassis: 1 to 16 Scanner Boards, 128 points each (2048 points max.) Lamp Driver: 128 drivers on one board; expandable to 254 drivers by adding a second board.
  • Page 10 Model 4000C Instruction Manual Page xi PROGRAM STORAGE Floppy Disk: Built-in 3.5-in. (optional) Personal Computer: RS-232C (COM port) POWER REQUIREMENTS 115 V~, 50/60 Hz (104 to 127 V~), 220 V~, 50/60 Hz (208 to 252 V~), 100 V~, 50/60 Hz (85 to 110 V~)

  • Page 11: General Description

    Page 1 GENERAL DESCRIPTION The Cablescan Model 4000C is a microprocessor-based continuity tester. It can be used as an assembly aid, an in-process continuity tester, and a final interconnect verification instrument for harnesses, backplanes, and cables. Besides being self-programming, the tester provides a variety of programming methods and floppy-disk storage of programs.

  • Page 12: Scanner Boards

    TERMINAL PORT The Terminal Port enables an optional PC running a terminal emulation program or Cablescan software to enable keyboard entry of wire list (in lieu of learning by scanning a known good) and...

  • Page 13: Functional Description

    Control Head, the test continues on past the error. ASSEMBLY FUNCTION When the Model 4000C is used as an assembly aid, the system employs the lamp driver to assist the operator in the location of specified points on the assembly fixture. In the assembly modes, body conductance is used in locating specified wires, or any random wire, and provides the operator with the destination point for wire termination.

  • Page 14: System Overview

    Model 4000C Instruction Manual Page 4 SYSTEM OVERVIEW MAIN CHASSIS The Main Chassis is a cabinet containing plug-in circuit boards, fixed interconnect boards, cabling, and a power supply. Three of the plug-in circuit boards provide Test control and operation functions. These boards are: ...

  • Page 15: Overview Of Operating Modes

    Sequential Build Sequential build is used when a specific assembly sequence must be followed. The Model 4000C will display the next FROM/TO points to be assembled. When the proper termination has been competed the display advances to the next programmed pair of...

  • Page 16: Search Mode

    The record and load from tape are modes retained from earlier systems and are maintained for compatibility purposes. This enables a Control Head from an EHT-4000B to be used on the Model 4000C to load tapes and then saved to floppy. Print Mode When the optional printer is added to the system, it may be used for printing wire lists and error lists from the Control Head.

  • Page 17: Optional Equipment

    Single Disk Drive System A single 5.25 inch floppy disk drive may be added to the Model 4000C. The 5.25 inch floppy enables moving of programs between a 5.25 inch based personal computer to the Model 4000C.

  • Page 18: Controls And Indicators - Control Head

    Model 4000C Instruction Manual Page 8 CONTROLS AND INDICATORS – CONTROL HEAD All basic functions are controlled by keys on the front panel of the Control Head (Figure 2). Nine of the main functions are selected by individual keys and the remaining functions are menu-selected through Up and Down Keys, and executed by Menu Run key.
  • Page 19 Model 4000C Instruction Manual Page 9 MODEL 4000C ENABLE RANDOM SEQ. SEARCH ERROR TEST RESET BUILD BUILD LIST VOLUME PROBE MENU KNOWN FROM REMOTE GOOD TAPE CONTINUITY TESTER EARPHONE RANDOM - Initiates circuit assembly in random by displaying circuit information BUILD (termination) as each wire is touched while the wrist strap is attached.

  • Page 20: Seq. Build

    Control Head; the operation selected will be executed. From Tape This mode is for EHT-4000B user and is not a Model 4000C mode. This enables a Control Head from an EHT-4000B to be used on the Model 4000C to load tapes and then save to floppy.

  • Page 21: Miscellaneous Controls

    Model 4000C Instruction Manual Page 11 MISCELLANEOUS CONTROLS ENABLE Keyswitch Before Learn Known Good, Save to Disk, and Format Disk can be performed, the ENABLE keyswitch must be enabled (vertical position). This keyswitch prevents an existing program, on floppy disk, from being accidentally overwritten. The keyswitch also prevents unauthorized users to learn an assembly that may have errors.

  • Page 22: Alphanumeric Display

    Model 4000C Instruction Manual Page 12 Alphanumeric Display During the test cycle, the 32-character, single line alphanumeric display will provide data in four segments: CONDITION, FROM POINT, TO POINT, and CIRCUIT LABELS. All four segments use upper case alphanumeric characters. Within the CONDITION segment, any of the...

  • Page 23: Rear Panel Connections

    A built-in Disk Drive enables the storing of several test programs on a 3.5-inch diskette. The Model 4000C uses a proprietary disk format. Use double density (2DD) diskettes only. The Disk Drive port allows for the connection of an external 5.25-inch floppy disk drive system.

  • Page 24: Terminal

    User Labels The Model 4000C has the capability of assigning labels to the tester test points. These user labels relate tester point numbers to their corresponding harness connector/pin numbers (in the wire list).

  • Page 25: Preparation

    If such is found, notify Cablescan and the carrier at once. Save the shipping carton and packing materials for later use. INITIAL HOOKUP When shipped from the factory, the Model 4000C is set for operating from one of the following power sources: 115 V~, 50/60 Hz (104 to 127 V~),...

  • Page 26: Printer Setup

    Model 4000C from sending more data; the printer sets pin 11 low to re-enable printing. Printer Cable The printer connector on the Model 4000C 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 27: Printer Troubleshooting

    Model 4000C. 3. Turn the terminal power switch ON. 4. Set the Model 4000C power switch to ON. 5. Refer to Set Terminal Baud Rate in the Sub-Menu Functions section of this manual and set the baud rate to 9600.

  • Page 28: Data Format

    Data In on the terminal and Data In on the tester must be wired to Data Out on the terminal. Both the Model 4000C and the Terminal have 25-pin D-type female connectors; therefore, the interface cable has male connectors on both ends. The cable is wired as follows:...

  • Page 29: Pc Interface

    Cablescan provides an optional MS DOS based software program (TERM) or a Windows program (TestRite), which can be used to control and transfer programs between the Model 4000C and the PC. The software also can be used to transfer programs between the Model 4000C and other Cablescan testers.

  • Page 30: Changing Power Settings

    4. Hold the circuit board so that the desired voltage setting (120, 240, or 100 VAC) is facing up and rotated in proper reading directions. 5. Re-insert the circuit board back into the Power Line Module. 6. Connect power cord and the Model 4000C is now set with a new voltage setting.

  • Page 31: Operation Instructions - Using The Control Head

    2. Connect known-good harness through adapter interface to test connectors on rear panel. 3. Press KNOWN GOOD to initiate Learn Known Good. The Model 4000C will scan the connected circuit and store its configuration (wire List) in memory. After a few seconds the Control Head display will show OK, accompanied by a momentary tone.

  • Page 32: Testing (Single Test)

    3. Connect printer, turn on power, and verify that the SELECT light is lit on the printer. 4. Press ERROR LIST. The Model 4000C will perform a single test and will print a list of all errors, or it will print Passed if there are no errors.

  • Page 33: Random Build

    Model 4000C Instruction Manual Page 23 11-26-96 Error List USER PROGRAMMABLE CUSTOM HEADER From Pt. To Pt. Circuit ID Without User Labels OPEN OPEN OPEN SHORT SHORT Failed 0000/0001 11-26-96 Error List USER PROGRAMMABLE CUSTOM HEADER From Pt. To Pt.

  • Page 34: Sequential Build (Seq Build)

    TO point is touched, and an intermittent tone will sound. The tone and the "F" or "T" will be present only while the points are touched. 7. The Model 4000C will then test for the remaining stored sequence steps until the next open circuit in the sequence is found.

  • Page 35: Search For Wire Id

    Page 25 Search for Wire ID The Model 4000C may be used as an assembly or troubleshooting aid, using the SEARCH mode and the wrist strap or probe. A complete procedure is provided below. 1. Insert wrist strap or probe lead into PROBE receptacle on rear panel.

  • Page 36: Main Menu Functions

    Model 4000C Instruction Manual Page 26 MAIN MENU FUNCTIONS MAIN MENU FUNCTIONS The Main Menu has 8 functions that are not represented by mode keys. These additional functions are used for test, printing, programming, and program storage/retrieval.  Directory 0 ...

  • Page 37: Directory Of Drive 0

    Directory of Drive 1 This function is used to display and load programs from the external disk drive connected to the rear panel on some Model 4000C testers. The operation of this function is identical to the Directory 0. Print Wire List This function prints the program currently in memory.

  • Page 38: Loop Test

    Model 4000C Instruction Manual Page 28 11-26-96 Wire List USER PROGRAMMABLE CUSTOM HEADER Sequence From Pt. To Pt. Circuit ID J1-5 P1-4 With J1-4 P1-5 User Labels J1-3 P1-3 J1-2 P1-2 J1-1 P1-1 J1-9 J1-8 End of List Figure 5. Sample Wire List Printouts Loop Test Executing LOOP TEST will initiate continuous scanning through the connected assembly.

  • Page 39: Sub-Menu

    RESET. Self Test This mode is used to test the Model 4000C. Basically it checks for opens and shorts on the scanner transmit and receive lines (Scanner Modules). If any opens or shorts are found, an error message is displayed. No test harness or fixture should be connected to the unit during Self Test;...

  • Page 40: Sub-Menu Functions

    Save to Drive 1 This function is used to save to an external disk drive if the Model 4000C has an external disk drive connector and an external disk drive is connected. The operation of this function is identical to the Save Program to Drive 0.

  • Page 41: Format Drive 0

    After formatting, COMPLETE – READY will displayed. Format Drive 1 This function is used to format a diskette if the Model 4000C has an external disk drive connector and an external disk drive is connected,. The operation of this function is identical to the Format Drive 0 described above.

  • Page 42: Operating Instructions - Keyboard

    Page 32 OPERATING INSTRUCTIONS – KEYBOARD Operating the Model 4000C from a keyboard instead of the front panel allows the operator greater versatility and control over the tester. Keyboard control can be added by interfacing to an optional CRT/Terminal or a Personal Computer (PC) that is running a Terminal Emulation Program like Cablescan TERM program.
  • Page 43 Model 4000C Instruction Manual Page 33 Test Scan Continuities Test Opens Scan Opens Test Shorts Scan Shorts Loop Test Continuous Test Self Test Test Tester Scan Test - SC Same as TEST button on Front Panel. A scan is executed on the assembly under test, and each error (open or short) is displayed.

  • Page 44: Build Commands

    Page 34 Build Commands The following commands relate to using the assembly features of the Model 4000C. These modes use Body Conductance to locate desired wires for assembly. At the system prompt, enter the two-letter command, followed by an ENTER.

  • Page 45: Print-Related Commands

    Model 4000C Instruction Manual Page 35 Print-Related Commands The following list contains all print-related commands. The printout also will appear on the monitor during printing, or the monitor only if no printer is connected. Verify the Printer power switch is on and the Printer Select light is on. At the system prompt, enter the two- letter command, followed by an ENTER.
  • Page 46 Model 4000C Instruction Manual Page 36 This command causes the printer to advance to the top of the form. Refer to printer owner's manual for setting the Top of Form. Set Heading - SH This command allows a custom heading to be printed at the top of a printout when a print command is performed.

  • Page 47: Disk Commands

    Model 4000C Instruction Manual Page 37 Disk Commands The following commands provide control over the disk drive in loading and saving programs, deleting and replacing programs, and initializing (formatting) new diskettes. New diskettes must first be initialized before programs can be stored on them. Disk commands are single-letter entries followed with a disk drive number (0 or 1) and a file name if required.
  • Page 48 R PN943 Save - S[d] [filename] Saves (writes) a wire list program from Model 4000C memory to the disk drive specified by [d] with the name specified by [filename]. The file name must not already exist on the disk. (Use the Replace command to save to an existing filename.) To save the program in memory and...

  • Page 49: Setup Commands

    Page 39 Setup Commands The test parameters of the Model 4000C are originally set up to test most harnesses without any problems. Therefore, although some of the following functions may never be needed, they are made accessible to the user to permit the greatest versatility in specialized applications. Setup commands are two-letter entries followed with a space and a number.
  • Page 50 Default = 800 milliseconds Test Clock Speed - SE # This command sets up the clock speed for Test. The Model 4000C has a user-programmable test clock speed. In most cases, this function is not necessary. In special cases, however, where a long cable or a cable with higher than normal capacitance is being tested, the user may need to set the test clock to a slower speed to obtain consistent results.

  • Page 51: Chaining Programs

    Model 4000C Instruction Manual Page 41 This command sets up the clock speed for a Learn Known Good. The Model 4000C has a user- programmable Learn Known Good clock speed. In most cases, this function is not necessary. In special cases, however, where a long cable or a cable with higher than normal capacitance is being tested, the user may need to set the scan clock to a slower speed to obtain consistent results.

  • Page 52: Introduction To Wire List Programming

    Model 4000C Instruction Manual Page 42 INTRODUCTION TO WIRE LIST PROGRAMMING DISCUSSION Before a test can be performed on an assembly, a Wire List program must be created. The Program Editor can be used to create the entire Wire List program or parts of the Wire List.

  • Page 53: Sample Wire Harness

    Model 4000C Instruction Manual Page 43 SAMPLE WIRE HARNESS Provided below is a simple wire harness with five wires and three connectors. This application consists of the wiring harness under test and its connectors; a harness board with harness mating connectors and harness board connector;...

  • Page 54: Wire List Without Cross References

    Model 4000C Instruction Manual Page 44 The following table represents how the mating connectors and the harness board connector are backwired. Both the harness board connector and the tester corresponding connector are 64-pin connectors and are wired with a one-to-one relationship. Therefore, the harness board connector pin number and the tester test point number are the same.
  • Page 55 Model 4000C Instruction Manual Page 45 connector user labels. The user notation list relates each tester point number to its corresponding harness connector and pin. WIRE LIST USER LABELS From Point # Label PA1-1 PB1-A PA1-1 PA1-2 PB1-B PA1-2 PA1-3...

  • Page 56: Program Editor

    The system will respond by displaying the following table selection prompt. Edit Table (W,U)? The Wire List program in the Model 4000C consists of two separate lists. One is known as the Wire List Table, and the other the User Notation Table. The Wire List table contains the From/To tester point pairs for all continuities.

  • Page 57: User Notation Table - U

    Model 4000C Instruction Manual Page 47 EXAMPLE: Wire List Table Display 0001 100 RED_WIRE Denotes Wire List Table, 0001 Sequence number one, The FROM point, The TO point. RED_WIRE Circuit Label If no FROM or TO point has been assigned to the sequence number, the FROM and TO display areas will be blank.

  • Page 58: Edit Commands

    Model 4000C Instruction Manual Page 48 EDIT COMMANDS The following commands are entered after a table has been selected (Wire List or User Notation). There are three modes of operation where the Editor can process data. These are: Display, Replace, and Add. When the Editor is first entered, you are in the Display mode. This mode allows you to scroll through the table and to position the cursor to a location to edit.

  • Page 59: Replace - R

    Model 4000C Instruction Manual Page 49 Initialize command is entered, a question will appear asking you "ARE YOU SURE?". Typing Y carries out the command; typing N cancels the command. Replace - R Replaces displayed information, at the cursor, with information typed after the Replace command.

  • Page 60: Find - F (Point Number)

    Model 4000C Instruction Manual Page 50 Find - F (point number) Finds a specified point number, or user notation, denoted by (point number). Use a numeric number to locate the tester point number. Use an alphanumeric number to locate the user label.

  • Page 61: Block Programming Commands

    Model 4000C Instruction Manual Page 51 BLOCK PROGRAMMING COMMANDS INTRODUCTION Block programming allows the user to specify a sequential block of data to be entered automatically into a table instead of keying in each entry of the block. Block programming does not 'insert' data into the table, but instead writes over any data in the block of sequences in the same manner as the Replace mode.

  • Page 62: User Notation Table

    Model 4000C Instruction Manual Page 52 All numbers entered for the Start and Stop points must be arranged to indicate a logical arithmetic sequence. USER NOTATION TABLE In general, the capability to block assign cross references is the most useful. However, it requires the interface fixturing to be wired so that the mating connector pins are backwired in numeric order to a block of consecutive tester point numbers.

  • Page 63: Interactive User Notation Programming

    User Notation Table. This mode normally is used when assigning the user notation while probing the test fixture. 1. Connect the test fixture to the Model 4000C. To avoid incorrect point detection and assignment, make sure that no assembly is connected to the fixture.

  • Page 64: Programming Example

    Model 4000C. Since the User Notation Table relates harness connector/pin labels to test points, the fixture wiring should be determined before programming begins.

  • Page 65: Harness Wire List

    Model 4000C Instruction Manual Page 55 HARNESS WIRE LIST A Harness Wire List typically is a part of wire harness documentation. One form of a Harness Wire List is shown below. This list is used when entering the From/To points into the Wire List Edit.

  • Page 66: Interface Wiring

    Model 4000C Instruction Manual Page 56 INTERFACE WIRING There are many ways to interface the wire harness to the tester. A back-wired harness board often is used to provide interfacing as well as to serve as a holding fixture for the harness during build and test.

  • Page 67: Interface Wire List

    Notation Table and also for fabricating the interface harness. For this example, all 22 pins can be interfaced to a single tester connector since the Model 4000C uses 64-pin connectors. Test points are consecutively numbered on the tester starting with J1 pin 1 through J1 pin 64.

  • Page 68: Wire List Programming

    A label assigned in the User Notation Table must match exactly with the corresponding label used in the Wire List. The Model 4000C will display "not found" if a label is entered as the From or To point in the wire list and is not assigned to a point number in the User Notation Table.
  • Page 69 Model 4000C Instruction Manual Page 59 2. The User Notation Table may contain previous data (as represented by JA-32 in the previous display). To initialize the list type I, and press ENTER. Type Y to the prompt "Initialize ?" 3. User Notations should be entered while in the Replace mode. To select the Replace mode, type R and press ENTER.
  • Page 70 Model 4000C Instruction Manual Page 60 BLOCK ASSIGN Since the connectors in the interface harness are wired to consecutive test points, user notations can be assigned using block edit commands. For a description of block commands, refer to the Block Assign Mode in the Advanced Programming Features section.
  • Page 71 Model 4000C Instruction Manual Page 61 17. Type E2 to assign it to point 22, and press ENTER. RU 0008 P1-J RU 0009 P1-K RU 0010 P1-L RU 0011 Press ESC Type B, [ENTER] POINT #INC? 1 Type 1, [ENTER]...
  • Page 72 Model 4000C Instruction Manual Page 62 CORRECTING A USER NOTATION ERROR To correct an error, follow the procedure below: 1. If the Replace mode is selected with an RU in the left column, press ESC once to select the Cursor Positioning mode. (Pressing ESC again, from the Cursor Positioning mode, exits the editor.)

  • Page 73: Wire List Table

    Model 4000C Instruction Manual Page 63 Wire List Table 1. Exit the User Notation Table by pressing ESC twice. The system prompt will appear. 2. Type ED, and press ENTER. The last three lines should be as shown below: ...
  • Page 74 Model 4000C Instruction Manual Page 64 5. Wire continuities are typically entered while in the Replace mode. (The Add mode is used only to insert wire continuities between lines.) To select the Replace mode, type R and press ENTER. While in the Replace mode, the screen should display RW to the left of each new line as it is displayed, as shown below: ...
  • Page 75 Model 4000C Instruction Manual Page 65 12. Type each of the remaining eight circuits from the wire list document. After all circuits have been entered, the screen should display the following: 0001 0001 P3-4 P1-A WS01 RW 0001 P3-2 P1-B...
  • Page 76 Model 4000C Instruction Manual Page 66 MOVING THE CURSOR IN THE WIRE LIST Before the cursor can be moved, the editor must be in the Cursor Positioning mode denoted only by W displayed in the left column. The cursor can be moved using the arrow keys, or the Find commands.

  • Page 77: Application Notes

    Page 67 APPLICATION NOTES SCANNER MODULE ADAPTER CABLES The Model 4000C should be connected to the test fixture with cables having 64-pin flat cable socket connectors on one end and an appropriate means for interconnection to the assembly at the other.

  • Page 78: Summary Of Keyboard Commands

    Model 4000C Instruction Manual Page 68 SUMMARY OF KEYBOARD COMMANDS TEST COMMANDS Scan for Opens And Shorts Scan for Opens Only Scan for Shorts Only Continuous Test (Loop Test) Self Test ASSEMBLY COMMANDS Sequential Build Random Build Search with Body Conductance...

  • Page 79: Serial Communication Commands

    Model 4000C Instruction Manual Page 69 SERIAL COMMUNICATION COMMANDS Enable Interactive Assembly Mode Disable Interactive Assembly Mode Receive Serial Data Transmit Serial Data DISK COMMANDS Catalog Listing Initialize Diskette D# (filename) Delete File L# (filename) Load File R# (filename) Replace File...

  • Page 80: Care Of The Model 4000C

    All "wetted" areas must be thoroughly dried after cleaning. REPAIR If the Model 4000C requires repair due to any defect of manufacture, and it is within the warranty period, contact Cablescan, Inc., for instructions on returning it to the factory. Even if the Model 4000C is beyond the warranty period, and repair is necessary, it is advisable to return the unit to the factory for repair.

  • Page 81: Replacement Parts

    Model 4000C Instruction Manual Page 71 REPLACEMENT PARTS The following part numbers are provided for use in ordering replacements from Cablescan: Enable Plug ..................5210915 Foot Switch (5-pin connector) ............2100016 Foot Switch (Phone Jack) ..............2100086 Program Cartridge (16 programs) ............5210943 Wrist Strap Kit ...................5210061 Scanner Board connector (64-pin 90...
  • Page 82 NOTES...
  • Page 83 Cablescan 5900330 Rev C...

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