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Cablescan 90 Series Setup Manual

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Series 90
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90
SETUP MANUAL

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  • Page 1 Cablescan Series 90 SETUP MANUAL...
  • Page 3 May 25, 2006 Series 90 SETUP MANUAL (Part Number 5900407) 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

    Series 90 Setup Manual Page v TABLE OF CONTENTS Series 90 Family of Test Systems............1 Series 90/Series 90HV ..................1 Series 90L4/Series 90H8................1 System Components ................4 Series 90......................4 Series 90HV....................4 Series 90 System Controller ................4 Expansion Cabinets..................5 Series 90....................5 Series 90HV ..................5 Series 90L4/H8....................5 Series 90 System Setup ...............
  • Page 6 Page vi Series 90 Setup Manual TABLE OF CONTENTS - Continued Interface Cable Assemblies and connectors........17 Low-voltage Interface Cables..............17 5210914-03 Cable Assembly ..............17 5210917-03 Cable Assembly ..............17 5210982 Cable Assembly..............18 High-voltage Interface Cables and connectors........19 5211036 Connector Kit...............19 5211037 Cable Assembly..............19 5211038 Cable Assembly..............19 5211088 Connector Kit...............19 Remote Signals ..................
  • Page 7 Series 90 Setup Manual Page vii TABLE OF CONTENTS - Continued Diagnostic Tests ................29 Test Range....................29 Test Level..................29 Point Count ................29 Loop Self Test ................29 Command Buttons..................30 Diag ....................30 Adv ......................30 Download Firmware..............30 Capacitance Offset Function.............30 Set Voltage Type...............30 Reset....................30 Low-Voltage Tests ..................31 Application..................31...
  • Page 8 Page viii Series 90 Setup Manual TABLE OF CONTENTS - Continued Series 90 Calibration ................ 34 Purpose ......................34 Low-voltage Test Procedure...............35 High-voltage Test Procedure..............36 Fuse Replacement ................38 Series 90S9 and Series 90S32 Fuse Replacement ........38 Series 90L4/H8 Fuse Replacement............39 Care of Series 90 ................
  • Page 9 Description 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/H8 Simplified Diagram ............5 System Controller Board Locations.............7 Series 90/90HV Cable Connections ............8 Multiple Expansion Cabinet Hookup ............9...
  • 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 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.

  • 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...

  • Page 14: System Components

    Page 4 Series 90 Setup Manual SYSTEM COMPONENTS SERIES 90 The Series 90 consists of system control components 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/H8 The Series 90L4/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 Rear Panel

    COM1 port, as shown above. 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 6. Connect VGA monitor to High-density 15-pin D connector (Monitor) on System Controller. 7. Connect speakerphone jack to Line Out receptacle on System Controller. The Line Out (Speaker output) phone receptacle is typically green. 8.

  • Page 20: Series 90L4/Series 90H8 Scanner Control

    The Scanner Control Boards in the Series 90L4 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 and Series 90H8 are limited to one cabinet (512 test points). For Series 90L4 and Series 90H8, the other external signals, which include the footswitch and wrist strap connections, and the remote signals, are available on one of the PC’s parallel (LPT) ports,...

  • Page 21: Adding Scanner Boards

    Series 90 Setup Manual Page 11 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 22: Series 90Hv23 Cabinet

    Page 12 Series 90 Setup Manual 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 11, scanner boards are installed from the left.

  • Page 23: Series 90L4/H8 Cabinet

    Series 90 Setup Manual Page 13 Series 90L4/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 12. High-voltage scanner boards cannot be installed in a Series 90L4 and low-voltage scanner boards cannot be installed in a Series 90H8.

  • Page 24: Low-Voltage Scanner Board Jumpers

    Page 14 Series 90 Setup Manual Low-voltage Scanner Board Jumpers Each low-voltage scanner board must have a jumper installed for configuration. See Figure 13. (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 25: Scanner Board Pins And Test Point Assignments

    Series 90 Setup Manual Page 15 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 Point 1 Point 2 Point 129 Point 130 The Series 90 low voltage test systems use scanner boards that have 128 test points each.

  • Page 26: Series 90 High Voltage Systems

    Page 16 Series 90 Setup Manual 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 odd-numbered outer two rows, A and C.

  • Page 27: 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 28: 5210982 Cable Assembly

    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...

  • Page 29: High-Voltage Interface Cables And Connectors

    Series 90 Setup Manual Page 19 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 30 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...

  • Page 31: Remote Signals

    Series 90 Setup Manual Page 21 REMOTE SIGNALS 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 32: Output Connectors

    Series 90 Setup Manual OUTPUT CONNECTORS On systems with the Cablescan System Controller, signals listed on the left-hand table below are provided on the 15-pin D-type connector on the I/O board, usually located on slot One of the System Controller. For Series 90 L4/H8, which connects to your PC, the signals in the right- hand table are provided on the parallel port connector on the PC.

  • Page 33: 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 34: Testdiag Opening Screen

    Page 24 Series 90 Setup Manual TESTDIAG OPENING SCREEN Being a Windows 95/98/NT application, TestDiag is fast and easy to learn, and has a familiar look: title bar, menus, message and dialog boxes, and comparable commands. TestDiag uses similar keyboard and mouse operations as most Windows 95/98/NT applications to select objects and choose commands.

  • Page 35: Menu Bar

    Series 90 Setup Manual Page 25 Menu Bar The Menu Bar provides four menu categories: File, Tester, View, and Help. Choosing a menu name displays a drop-down list of commands. Most commands in the File and Help menus are Windows commands. TestDiag-specific commands are located in the Tester menu. Status Banner The Status Banner on the TestDiag screen displays the operating status of the tester and the status of the test.

  • Page 36: Testdiag Menus

    TestDiag program. Tester Menu The Tester Menu has operating commands relating to the selecting and testing of a Cablescan continuity tester. For the standalone testers such as the Model 64 through TestMate, TestDiag commands the testers to run their built-in self test function ( the same test that is run when selected from tester front panel controls).
  • Page 37 Series 90 Setup Manual Page 27 Setting Communication Port Specifies which port is connected to the tester. The Communication port is selected from the drop-down list. The Series 90L4 and Series 90H8 operate from a serial port on your PC. Select the COM port connected to the tester.

  • Page 38: Reset

    TestDiag; however, the current version of TestDiag can be viewed by selecting the About TestDiag command. A Register button, on the About window, opens a Register dialog box for viewing and entering the company and user name and a serial number. The Cablescan phone number and address also are provided in this window.
  • Page 39 Page 29 DIAGNOSTIC TESTS Diagnostic tests can be performed on all Cablescan testers that are capable of interfacing to TestRite software. TestDiag automatically configures the main screen for, and provides tests based on, the type of tester selected from the Tester/Settings window. As in other Windows applications, functions that do not apply to the situation or tester type at the time are grayed out and cannot be selected.
  • Page 40 Page 30 Series 90 Setup Manual COMMAND BUTTONS TestDiag has three command buttons: Diag, Adv, and Reset. A command can also be selected by pressing the letter key that is underlined in the button. Diag The Diag button is used to begin a diagnostic test. If a high-voltage tester is connected, make sure all hands are clear of tester before clicking Diag button.
  • Page 41 Series 90 Setup Manual Page 31 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 42 Page 32 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 43 Series 90 Setup Manual Page 33 Scanner Relay Res Scanner Relay Resistance test measures the on resistance using a high-current and a low- current source. This test requires a shorting bar to be installed. Isolation Amplifier Isolation Amplifier tests the performance of the isolation amplifier and the high-voltage- generator when loaded.

  • Page 44: 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 45: Low-Voltage Test Procedure

    Series 90 Setup Manual Page 35 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.

  • Page 46: High-Voltage Test Procedure

    Page 36 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 47 Series 90 Setup Manual Page 37 13. Verify High Voltage Generator test passes 14. Verify High Voltage Discharge test passes. 15. TestDiag pauses and displays a message box prompting to install a shorting bar (connector) on the first scanner board connector (J1). Install Calibration board using connectors marked "Shorting Bar."...

  • Page 48: Fuse Replacement

    Page 38 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 49: Series 90L4/H8 Fuse Replacement

    Series 90 Setup Manual Page 39 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 50: 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 51: Replacement Parts

    Series 90 Setup Manual Page 41 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 52: Specifications

    Page 42 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 Up to 131,072 test points (in Up to 47,104 test points TEST POINT increments of 128) (in increments of 64)
  • Page 53 101-key AT-style keyboard 100 to 252 V~, 1 amp, 50/60 Hz.* User Labels: 16-character * Automatically adjusts to input voltage Circuit Labels: 32-character Cablescan makes product improvements as required and therefore all specifications and system configurations are subject to change without notice.

  • Page 54: Appendix A - Scanner Resistor Bank

    Page 44 Series 90 Setup Manual 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 55: 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 57 Cablescan 5900407 Rev D...

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