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Model 512 Instruction Manual Page iii March 3, 2005 MODEL 512 INSTRUCTION MANUAL (Part Number 5900325) Cablescan A Eubanks Company 3022 Inland Empire Blvd. Ontario, California 91764 (909) 483-2436 Fax (909) 483-2463 www.cablescan.com...
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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.
Model 512 Instruction Manual Page v TABLE OF CONTENTS Specifications..................x System Overview................. 1 Major Features....................1 Front Panel Controls and Display ..............2 Front Panel Display ................3 Rear Panel Layout ..................3 Disk Drive ......................4 Printer ......................4 Keyboard/CRT Terminal................4 User Labels.....................4 PC Interface and Control................4...
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Model 512 Instruction Manual Page vi TABLE OF CONTENTS - Continued Sub-Menu Functions ..................25 Display Current Time .................25 Set Date....................25 Set Time ....................26 Clear Memory..................26 Default System Settings ..............26 Set Printer Baud Rate .................26 Set Terminal Baud Rate ..............26 Format Drive 0 ...................27 Format Drive 1 ...................27...
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Model 512 Instruction Manual Page vii TABLE OF CONTENTS - Continued Label Codes....................39 Label Definition ..................39 Conditional ..................39 Printer Commands................40 Label Examples ....................41 Printing Labels .....................42 Introduction to Wire List Programming........43 Discussion ....................43 Wire List .....................43 User Notation List ................43 Setup Options..................43...
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Terminal Cable ...................71 PC Interface....................72 PC Cable.....................72 Application Notes................73 Scanner Module Adapter Cables..............73 Interfacing with a PC..................73 Summary of Keyboard Commands ..........74 Care of the Model 512 ..............76 Maintenance ....................76 Repair ......................76 Memory Backup Battery ................76 Replacement Parts ..................77...
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LIST OF FIGURES Figure Description Page Front Panel Controls and Display ................2 Model 512 Rear Panel.................... 3 Simplified LEARN KNOWN GOOD Procedure..........7 Simplified TEST Procedure................... 8 Simplified ERROR LIST Procedure..............9 Simplified LOOP TEST Procedure ..............10 Simplified SAVE PROGRAM Procedure ............
Page 1 SYSTEM OVERVIEW The Cablescan Model 512 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 2 FRONT PANEL CONTROLS AND DISPLAY All modes and functions of the Model 512 are controlled by keys on the front panel. Five modes are selected by individual keys, and 19 menu modes and functions are selected through Up and Down keys and executed by the Menu Run Key.
Page 3 FRONT PANEL DISPLAY The Model 512 employs a 40-character alphanumeric vacuum fluorescent display. The display provides the user with test conditions, and error information. During Test the display provides data in four fields: CONDITION, FROM POINT, TO POINT, and CIRCUIT LABELS. All four fields use alphanumeric characters.
USER LABELS The Model 512 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). (User Labels are also referred to as cross references, user notation, and point ID.) Each user label used in the wire list must have a tester point number assigned.
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). Cablescan Model 512 Ready will display and a short tone will sound.
Model 512 Instruction Manual Page 6 PROGRAM STORAGE Refer to Save Program (menu-selected) in the Operating Instructions section for details. 1. Engage ENABLE plug. 2. Press RESET, and then arrow down through the menu until Save Program is displayed. The display will show: Drive 0: Program 1 3.
After becoming properly acquainted with the Model 512, the user can refer to the abbreviated procedures illustrated in Figures 3 through 11. Detailed procedures are provided in the Operating Instructions section.
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1. Load program (Figure 8). 2. Connect harness to be tested. 3. Press TEST, and the Model 512 will perform one test scan. 4. For a successful test, the display will show: PASSED If an error is found, test will halt and display will show OPEN or SHORT, with the From/To points.
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3. Connect printer per setup instructions in "Preparation" section. 4. Press ERROR LIST. 5. The Model 512 will perform a test of the harness; all errors will be printed, or "Passed" will be printed and displayed for a successful test.
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Model 512 Instruction Manual Page 10 INPUT RANGE 110/220 V~ 2A 50/60HZ 1.6 A/250V CAUTION! For continued protection against risk of fire, replace only with same type and rating of fuse. SPEAKER ENABLE FOOTSWITCH PROBE PRINTER TERMINAL 2, 6 MODEL 512...
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Model 512 Instruction Manual Page 11 INPUT RANGE 110/220 V~ 2A 50/60HZ 1.6 A/250V CAUTION! For continued protection against risk of fire, replace only with same type and rating of fuse. SPEAKER ENABLE FOOTSWITCH PROBE PRINTER TERMINAL MODEL 512 RANDOM...
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Model 512 Instruction Manual Page 12 INPUT RANGE 110/220 V~ 2A 50/60HZ 1.6 A/250V CAUTION! For continued protection against risk of fire, replace only with same type and rating of fuse. SPEAKER ENABLE FOOTSWITCH PROBE PRINTER TERMINAL MODEL 512 RANDOM...
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Model 512 Instruction Manual Page 13 INPUT RANGE 110/220 V~ 2A 50/60HZ 1.6 A/250V CAUTION! For continued protection against risk of fire, replace only with same type and rating of fuse. SPEAKER ENABLE FOOTSWITCH PROBE PRINTER TERMINAL MODEL 512 RANDOM...
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Model 512 Instruction Manual Page 14 INPUT RANGE 110/220 V~ 2A 50/60HZ 1.6 A/250V CAUTION! For continued protection against risk of fire, replace only with same type and rating of fuse. SPEAKER ENABLE FOOTSWITCH PROBE PRINTER TERMINAL 6, 7 4, 8...
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Model 512 Instruction Manual Page 15 INPUT RANGE 110/220 V~ 2A 50/60HZ 1.6 A/250V CAUTION! For continued protection against risk of fire, replace only with same type and rating of fuse. SPEAKER ENABLE FOOTSWITCH PROBE PRINTER TERMINAL MODEL 512 RANDOM...
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 512 will then test for the remaining stored sequence steps until the next open circuit in the sequence is found.
Model 512 Instruction Manual Page 17 9. When the last sequence step has been tested, the display will show "OK." A test of the assembly may now be performed to find any shorts or opens that may have developed during assembly.
3. Connect harness to be tested. 4. Press ERROR LIST. The Model 512 will perform a single test and will print a list of all errors, or it will print Passed if there are no errors. 5. When test and printouts are finished, disconnect harness.
7. When testing is finished, disconnect harness. 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 will read Cablescan Model 512 Ready.
Model 512 Instruction Manual Page 20 MENU - SELECTABLE FUNCTIONS MAIN MENU FUNCTIONS The Main Menu has 12 functions that are not represented by mode keys. These additional functions are used for test, printing, programming, and program storage/retrieval. Directory of Drive 0...
This function is used to display and load programs from the external disk drive connected to the rear panel on some Model 512 testers. The operation of this function is identical to the Directory of Drive 0. (The external disk drive connector was available on earlier systems; it is no longer available.)
Save Program to Drive 1 This function is used to save to an external disk drive if the Model 512 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 23 Search for Wire ID The Model 512 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. Once familiarized, the user may refer to Figure 12.
Model 512 Instruction Manual Page 24 Print Wire List This procedure requires hookup of the optional printer. A wire list printout provides a hardcopy of the test program. The wire list printout also includes the signature for the program for future reference.
Model 512 Instruction Manual Page 25 Setup Sub-Menu A Setup Sub-Menu provides a number of functions used for changing tester setup parameters. Since these functions are not frequently used, they are placed in the sub-menu. To select the Setup Sub-Menu, press the arrow keys until "Setup Sub-Menu" is displayed and press MENU RUN.
Model 512 Instruction Manual Page 26 Set Time The Set Time function does the same thing for the time in the internal clock as the Set Date function described above. It is used in exactly the same way. The current time is shown as:...
30 seconds to complete and "formatting...complete" is displayed. Format Drive 1 This function is used to format a diskette if the Model 512 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.
OPERATING INSTRUCTIONS - KEYBOARD INTRODUCTION Operating the Model 512 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 Cablescan PC DOS Terminal Emulation Program, TERM.
TEST COMMANDS The following commands are related to the testing of opens and shorts, and the self testing of the Model 512. These are two-letter commands, which are executed by pressing the two letter keys followed with an ENTER. Tester...
Page 30 BUILD COMMANDS The following commands relate to using the assembly features of the Model 512. These modes use Body Conductance to locate desired wires for assembly. At the system prompt, enter the two-letter command, followed by an ENTER.
Model 512 Instruction Manual Page 31 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.
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Model 512 Instruction Manual Page 32 Print Options List - PO Prints a list of the current user-settable options. Printer On/Off - P This command enables the printer to print whatever is typed and what is displayed on the keyboard/CRT Terminal. This command is primarily a diagnostic function, and in certain modes of operation it may print non-valid data.
Model 512 Instruction Manual Page 33 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.
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R PN943 Save - S[d] [filename] Saves (writes) a wire list program from Model 512 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 35 SETUP COMMANDS The test parameters of the Model 512 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.
This option allows the user to change the number of transmit points used during a scan. Normally the maximum transmit point is set to the number of points in the system (512). This option is useful when the system has more points installed than the assembly being tested.
Learn Known Good Clock Speed - SL # This command sets up the clock speed for a Learn Known Good. The Model 512 has a user- programmable Learn Known Good clock speed. In most cases, this function is not necessary. In...
A label definition file defining the print label format and date is created using a PC and a text editor. The file is then copied from the PC to the Model 512 3.5-inch floppy, which also contains the wire list programs. The label file thus is loaded automatically each time a wire list program is loaded into the tester.
The label definition file is created with a PC and text editor/word processor, and saved as a text (ASCII) file. The file is then copied from the PC to the Model 512 3.5-inch floppy and given the file name LABEL.DEF. The floppy can then be inserted into the Model 512 and loaded using the Load Printer Label function as described above.
Model 512 Instruction Manual Page 40 $STATUS - defines when a single label is used for printouts. Prints PASS if the test passed, or FAIL if the test failed. $PROGRAM - prints the name of the program used to run the test.
Model 512 Instruction Manual Page 41 $EJECT 20; $POS - specifies the column positions of each label when printing to a multi-column label form. The POS label code requires the printer to have reverse line feed capability as described above under the BACKLINE label code. The numbers that follow the POS label code specify column positions of the labels across the form.
When the EJECT label code is used, the printer must be set up with the correct number of line feeds. When the EJECT and BACKLINE label codes are used, the Model 512 reverse-line-feeds the label form into position, prints the label, and then advances the form by applying line feeds to the printer, thereby allowing the operator to remove the label.
Model 512 Instruction Manual Page 43 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.
Model 512 Instruction Manual Page 44 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;...
Model 512 Instruction Manual Page 45 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.
Model 512 Instruction Manual Page 46 Wire List with User Notation When the user notation list is programmed, the wire list can be entered and displayed using connector/pin references. Shown below is the same Wire List program providing harness connector user labels. The user notation list relates each tester point number to its corresponding harness connector and pin.
The system will respond by displaying the following table selection prompt. Edit Table (W,U)? The Wire List program in the Model 512 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.
Model 512 Instruction Manual Page 48 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.
Model 512 Instruction Manual Page 49 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.
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Deletes number of lines specified by # and moves all remaining lines up. This command starts deleting with the current line. If # is not specified, the command will delete one line. Maximum number of lines is 512. Find Sequence - FS # This command is used only in the Wire List Table.
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Model 512 Instruction Manual Page 51 Find Wire Number - FW XXX This command is used only in the Wire List Table to find a specific wire number (circuit label). This command locates a string of characters that have been assigned in the circuit label field. If the FW command is entered without a circuit label, the last circuit label entered with the FW command will be searched.
5. Enter a TO point (between 1 and 512). The display then shows: STOP FROM PT ? 6. Enter the last FROM point of the block (between 1 and 512). The display then shows: STOP TO PT ? 7. Enter the last TO point of the block (between 1 and 512). The display then shows: POINT # INC ? 8.
Model 512 Instruction Manual Page 53 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.
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 512. To avoid incorrect point detection and assignment, make sure that no assembly is connected to the fixture.
Model 512. Since the User Notation Table relates harness connector/pin labels to test points, the fixture wiring should be determined before programming begins.
Model 512 Instruction Manual Page 56 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.
Model 512 Instruction Manual Page 57 Interface Wiring There are many ways to interface the wire harness to the tester. A backwired harness board often is used to provide interfacing as well as to serve as a holding fixture for the harness during build and test.
First, a Wire List for the test fixture harness is generated - for use in programming the User 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 512 uses 64-pin connectors. Test points are consecutively numbered on the tester starting with J1 pin 1 through J1 pin 64.
A label assigned in the User Notation Table must match exactly with the corresponding label used in the Wire List. The Model 512 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.
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Model 512 Instruction Manual Page 60 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.
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Model 512 Instruction Manual Page 61 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.
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Model 512 Instruction Manual Page 62 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] START? P2-1 Type P2-1, [ENTER] STOP? P2-5 Type P2-5, [ENTER] USER INC? 1...
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Model 512 Instruction Manual Page 63 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.)
Model 512 Instruction Manual Page 64 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: >...
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Model 512 Instruction Manual Page 65 > > ED EDIT (W, U) EDIT Wire List 0001 Initialize? Y 0001 RW 0001 NOTE Two lines are displayed while in the Replace mode each time a new circuit or wire is entered. The first line, with only a W to the left, is the data already entered for that sequence (line).
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Model 512 Instruction Manual Page 66 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...
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Model 512 Instruction Manual Page 67 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.
1. Make sure that the power switch on the back panel is set to 0 (off), and then plug in the power cord. 2. Turn power switch to 1 (on), and observe that a message is displayed. The Model 512 is ready for use. (If nothing happens, check power source, power cord connections, and the fuse on the rear panel.)
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 512 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...
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3. Verify that the cable is wired with the pin assignments shown above. 4. Verify that interface cable is plugged into PRINTER connector and not the TERMINAL port on the Model 512. 5. Turn power off and then on after making switch changes on the printer. This causes the printer to read the new switch settings.
Data In on the terminal and Data In on the tester must be wired to Data Out on the terminal. Both the Model 512 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:...
Cablescan provides an optional MS DOS based software program (TERM), which can be used to control and transfer programs between the Model 512 and the PC. The software also can be used to transfer programs between the Model 512 and other Cablescan testers.
Page 73 APPLICATION NOTES SCANNER MODULE ADAPTER CABLES The Model 512 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.
Model 512 Instruction Manual Page 74 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...
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Model 512 Instruction Manual Page 75 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...
If the Model 512 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 512 is beyond the warranty period, and repair is necessary, it is advisable to return the unit to the factory for repair.
Model 512 Instruction Manual Page 77 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°...