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MODEL 256/PC

CONTINUITY TESTER

Summary of Contents for 256/PC

Page 1: ...MODEL 256 PC CONTINUITY TESTER ...

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Page 3: ...truction Manual Page iii February 25 2005 MODEL 256 PC INSTRUCTION MANUAL Part Number 5900379 Cablescan A Eubanks Company 3022 Inland Empire Blvd Ontario California 91764 909 483 2436 Fax 909 483 2463 www cablescan com ...

Page 4: ...f the service person s travel and living expenses THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THIS WARRANTY STATES CABLESCAN S ENTIRE AND EXCLUSIVE LIABILITY WHETHER IN TORT OR IN CONTRACT AND BUYER S EXCLUSIVE REMEDY FOR ANY CLAIM FOR DAMAGES IN CONNECTION WITH THE SALE OR US...

Page 5: ...es 2 Signature Codes 2 User Labels 2 PC Interface and Control 3 Program Storage 3 USING THE MODEL 256 PC 6 PREPARATION 15 Unpacking 15 Initial Hookup 15 Program Cartridge Installation 15 Power Turn on and Self Test 16 Printer Hookup 17 PC Interface 19 Changing Power Setting 20 CONTROLS AND DISPLAY 21 Controls 21 Key selected Functions 21 Menu selected Functions 24 Display 26 OPERATING INSTRUCTIONS...

Page 6: ... Setting Baud Rate 38 Print User List 39 OPERATING INSTRUCTIONS KEYBOARD 40 Introduction 40 Entering Commands 40 Test Commands 41 Build Commands 42 Print Commands 43 Program Commands 44 MODEL 256 PC VERSUS MODEL 256 46 MODEL 256 PC HARDWARE CHANGES 48 Remote Output Signals 48 Scanner Board Jumpers 49 CARE OF THE MODEL 256 PC 50 Cleaning 50 Repair 50 Memory Backup Battery 50 Replacement Parts 50 PA...

Page 7: ...PROGRAM Procedure 9 8 Simplified LOAD PROGRAM Procedure 10 9 Simplified DELETE PROGRAM Procedure 11 10 Simplified ERROR LIST Procedure 12 11 Simplified SEQUENTIAL BUILD Procedure 13 12 Simplified RANDOM BUILD Procedure 14 13 Program Cartridge Label Format 16 14 CPU Board Voltage Select Switch and Jumper Locations 20 15 Front Panel Keyboard and Display 22 16 Sample Wire List Printouts 28 17 Sample ...

Page 8: ...er Alphanumeric LCD PROGRAM STORAGE Internal Memory Battery backed CMOS RAM containing working memory area and 8 program locations without User Labels or 2 program locations with User Labels Removable Memory EEPROM cartridge containing 16 program locations without User Labels or 4 program locations with User Labels BATTERY LIFE 5 years POWER REQUIREMENTS 104 to 126 VRMS 50 60 Hz or 208 to 252 VRMS...

Page 9: ...having jumpers daisy chains and other interconnect devices MAJOR FUNCTIONS Major functions of the Model 256 PC are as follows Self Programming for circuit testing by learning a known good circuit Programming by downloading from a PC Automatic Test of each circuit cable harness etc to be tested Printout of Error List Printout of Wire List Assembly assistance by displaying build information Program ...

Page 10: ...r is run through the LEARN KNOWN GOOD mode on the Model 256 PC which calculates and then displays a six digit signature code unique to that wiring configuration The signature is then used in identifying the wire list program when selecting it for loading from memory The signature code eliminates the requirement of assigning program names to programs for identification If a printer is connected the...

Page 11: ... see Figure 3 The internal memory is a RAM random access memory which holds eight programs or two with user labels and also provides the working memory An EEPROM electrically erasable programmable read only memory Program Cartridge holds sixteen programs or four with user labels The Program Cartridge receptacle is located either on the rear panel or the right side of the tester A program may be lo...

Page 12: ...e replace only with same type and rating of fuse FOOTSW ITCH P R O B E E N A B LE P R IN T E R S E R IA L J2 J4 127 128 255 256 65 66 64 63 193 194 191 192 1 2 129 130 J1 J3 Rear Panel Layout SEQ BUILD RANDOM BUILD ERROR LIST TEST RESET MENU RUN MODEL 256 Front Panel Layout Figure 2 Model 256 PC Layout ...

Page 13: ...ram locations using either SAVE INTERNAL or SAVE CARTRIDGE mode All test and assembly procedures are conducted from the Working Memory To use a program that is stored in one of the twenty four program locations copy it into the Working Memory using either LOAD INTERNAL or LOAD CARTRIDGE mode All programs remain where recorded SAVE and LOAD functions only copy them They are eliminated only by using...

Page 14: ...ed in the Operations section 250mA 250V CAUTION For continued protection against risk of fire replace only with same type and rating of fuse FOOTSWITCH P R O B E E N A B LE P R IN T E R S E R IA L J 2 J4 127 128 255 256 65 66 64 63 193 194 191 192 1 2 129 130 J1 J3 1 2 6 SEQ BUILD RANDOM BUILD ERROR LIST TEST RESET MENU RUN MODEL 256 3 4 5 1 Engage ENABLE plug 2 Connect known good harness to conne...

Page 15: ...s to be tested 3 Press TEST and the Model 256 PC will perform one test scan 4 For a successful test the display will show Passed XXXX YYYY Where XXXX is the number of tests that have passed and YYYY is the number of tests that have been run Loading the program sets these numbers to zero If an error is found display will show O for open or S for short with From To points 5 To continue test beyond f...

Page 16: ...N MODEL 256 1 3 5 1 Load program Figure 8 2 Connect harness to be tested 3 Select and initiate LOOP TEST 4 For each successful test a loop count on the display will increment by one If an error is found testing will stop and the display will show O for open or S for short with the From To points 5 To continue through the current test and display additional errors press MENU RUN 6 To restart the Lo...

Page 17: ...D ERROR LIST TEST RESET MENU RUN MODEL 256 2 5 4 1 Engage ENABLE plug on rear panel 2 Select and initiate either SAVE INTERNAL or SAVE CARTRIDGE 3 The display will read Are You Sure 4 If it is decided not to save the program press RESET 5 To save the program press MENU RUN The program will be copied from the Working Memory into a memory location 6 After the program is saved the display will show S...

Page 18: ...3 5 4 1 Select and initiate either LOAD INTERNAL or LOAD CARTRIDGE 2 The display will show a signature code of a program stored in memory 3 Use Up Down arrows to step to the signature code for the desired program 4 If it is decided not to load the program press RESET 5 Press MENU RUN to load the program into the Working Memory 6 Verify signature code on display against the code for that location t...

Page 19: ...E plug on rear panel 2 Select and initiate either DELETE INTERNAL or DELETE CARTRIDGE 3 The display will show a signature code of a program stored in memory 4 Use Up Down arrows to step to the signature code for the program to be deleted 5 Press MENU RUN to delete the program the display will display Are You Sure 6 If it is decided not to delete the program press RESET 7 To delete the program pres...

Page 20: ...RROR LIST TEST RESET MENU RUN MODEL 256 1 1 Load program Figure 8 2 Connect harness to be tested 3 Connect printer per setup instructions in Preparation section 4 Press ERROR LIST 5 The Model 256 PC will perform a test of the harness and all errors will be printed or Passed XXXX YYYY will be printed for a successful test Where XXXX is the number of tests that have passed and YYYY is the number of ...

Page 21: ...BUILD ERROR LIST TEST RESET MENU RUN MODEL 256 2 8 1 Connect assembly fixture 2 Load program Figure 8 3 Connect wrist strap 4 Connect foot switch 5 Press SEQ BUILD 6 Follow the display in making connections When the From To point that is displayed is touched the tone will sound as an aid in identifying points 7 To bypass a step press SEQ BUILD or foot switch 8 When the assembly is completed OK is ...

Page 22: ...D ERROR LIST TEST RESET MENU RUN MODEL 256 2 9 1 Connect assembly fixture 2 Load program Figure 8 3 Connect wrist strap 4 Connect foot switch 5 Press RANDOM BUILD 6 The display will show Select Next Wire 7 Touch any wire at random and connect according to displayed From To points Repeat for all wires to be assembled 8 To cancel a displayed From To point press RANDOM BUILD or foot switch 9 When ass...

Page 23: ... observe that a message is displayed The Model 256 PC is ready for use If nothing happens check power source power cord connections and the fuse on the rear panel PROGRAM CARTRIDGE INSTALLATION Each Program Cartridge can store up to sixteen programs A label on the outside surface of the cartridge Figure 13 contains blanks for entering program names and signature codes This label is erasable so it ...

Page 24: ... Changing Power Setting 1 Turn power on at the unit by moving the power switch on the rear panel to ON the display will light up and the tone will sound 2 For self test of the basic Model 256 PC verify that no circuits are connected to the interface connectors on the rear panel 3 Press the up or down arrow to step through the menu to reach SELF TEST 4 Press MENU RUN to initiate Self Test If the un...

Page 25: ...s MENU RUN to initiate setting the baud rate 7 If the display reads Baud Rate 1200 press RESET to continue 8 If the display shows Baud Rate 9600 press the down arrow to change to 1200 and then press MENU RUN Data Format If the printer was not provided by Cablescan the following setup data are required Transmission to the printer is at 1200 Baud with 8 data bits 1 stop bit and no parity Pin assignm...

Page 26: ...e printer does not print after being set up according to the above procedure 1 Verify that printer Select light is On 2 Verify that the cable is wired according to the wiring diagram above 3 Turn power off and then on after making switch changes on the printer This enables the printer to read the new switch settings 4 Verify in the printer manual that pin 11 is used by the printer to control data ...

Page 27: ...o step through the menu to reach SET BAUD RATE 5 Press MENU RUN to initiate setting the baud rate 6 If the display reads Baud Rate 9600 press RESET 7 If the display shows Baud Rate 1200 press the down arrow to change to 9600 and then press MENU RUN 8 Execute TERM from the DOS prompt on the PC 9 A greater than prompt should appear on the PC screen NOTE If the prompt does not appear press ESC Also v...

Page 28: ... to disconnect the housing Do not remove any screws from center area of the bottom 4 Tilt front edge of housing front panel up to expose red and black slide switch on upper circuit board When tilting housing be careful not to over extend internal cabling 5 The red and black switch is labeled for two power settings and is currently set for the power source indicated on the outside of the unit Move ...

Page 29: ... is first programmed off line with a PC and then downloaded with optional PC software to the Model 256 PC Once in the tester the program can be saved to tester memory Random Build The Random Build key is selected when the sequence of assembly is not important In this mode the tester waits for the operator to select a wire and then displays the corresponding FROM TO points of the open circuit Body ...

Page 30: ...Uses continuities program created in LEARN KNOWN GOOD or downloaded from a PC ERROR LIST Initiates test of assembly under test and produces a printout of errors or prints Passed if no errors TEST Initiates single test of assembly and displays errors RESET Terminates current mode and places Model 256 PC in wait state until next mode selection is made UP DOWN ARROWS Used for stepping up and down thr...

Page 31: ...own Arrows The Up and Down arrows are used to select from the menu selectable modes Once a menu selection has been made the Menu Run key is pressed to initiate the mode selected The display shows each mode name arrived at during mode selection Menu Run The Menu Run key executes the menu mode that is selected by the Up Down arrows and shown on the display The Menu Run key is also used as an advance...

Page 32: ...mode Learn Known Good This mode is used for scanning existing continuities in a sample assembly and storing them as a program in the working memory As a program is stored it writes over any program currently in the working memory However User Labels are maintained if they are currently loaded in memory Labels can be cleared before learning by first selecting the Clear Memory function To save the c...

Page 33: ...he labels will be printed in lieu of the tester point numbers The wire list is printed in the order in which the circuits were learned or downloaded Print User List This mode prints the User Labels assigned to test points for the wire list loaded in the working memory Each test point may have up to 6 characters assigned Generally User Labels are use to relate test points to corresponding connector...

Page 34: ...ines scanner boards The error type open or short and the faulty points are displayed No test harness may be connected to the unit while in the Self Test mode DISPLAY The Model 256 PC employs a 16 digit alphanumeric LCD Liquid Crystal Display The display provides the user with mode status and From To points The From To points refer to test point numbers which may be interpreted using the table belo...

Page 35: ...wn good harness through interface wiring to the rear panel test connectors 3 Press Up or Down arrow to step through the MENU until LEARN KNOWN GOOD is displayed 4 Press MENU RUN to initiate LEARN KNOWN GOOD The Model 256 PC will instantly scan the known good harness and store its configuration wire list in memory along with a signature code for that configuration The display will show Learned Sign...

Page 36: ...e in the Preparation section 2 Press Up or Down arrow to step through the menu to display PRINT WIRE LIST 3 Press MENU RUN to initiate printing A sample wire list is shown below Signature 010066 Wire List Sequence From Point To Point 001 5 13 002 4 14 003 3 12 004 2 11 005 1 10 006 9 15 007 8 16 End of List The sample wire list shown below represents one when User Labels have been loaded into memo...

Page 37: ...the user may refer to Figure 5 To select and use TEST proceed as follows 1 Load program to be used refer to Loading a Program The Passed Tested counter is reset to 0000 0000 2 Install harness to be tested 3 Press TEST key TESTING will be displayed and one complete scan will be made 4 If test passes the following will be displayed Passed 0001 0001 5 An O for open or S for short with the From To poi...

Page 38: ...o be tested 4 Press ERROR LIST The Model 256 PC will perform a single test and will print a list of all errors or it will print Passed 0001 0001 if there are no errors 5 When test and printouts are finished disconnect harness Signature 010066 Error List Condition From Point To Point OPEN 3 12 OPEN 1 10 OPEN 8 16 SHORT 3 10 SHORT 8 12 Failed 0000 0001 The sample Error List shown below represents on...

Page 39: ...efer to Loading a Program 2 Install harness to be tested 3 Press Up or Down arrow to step through the menu until LOOP TEST is displayed 4 Press MENU RUN to initiate the LOOP TEST mode Each time a successful scan is completed a loop count on the display is incremented by one as shown below Loop 001 5 An O for open or S for short with the From To points will be displayed when an error is encountered...

Page 40: ...ave Program function proceed as follows NOTE Turn power off Power ON OFF switch on rear panel before removing or inserting a Program Cartridge 1 Insert Enable jack in the rear panel 2 Press the Up or Down arrow to step through the menu to display either SAVE INTERNAL or SAVE CARTRIDGE 3 Press MENU RUN to initiate the mode If there is sufficient memory to save the program the display will show Are ...

Page 41: ...the program cartridge A complete Load procedure is provided below Once familiarized the user may refer to Figure 8 To select and use the Load Program function proceed as follows 1 Press Up or Down arrow to step through the menu to display either LOAD INTERNAL or LOAD CARTRIDGE 2 Press MENU RUN to initiate the selected mode and the display will show the signature for the last program that was selec...

Page 42: ...ogram that was selected with the load or delete function Delete Int signature or Delete Cart signature 3 Press Up or Down arrow to display the signature for the program to be deleted from memory Each time the arrow is pressed the next program signature will display A Bottom of List message will appear after all programs have been displayed using the Down arrow A Top of List message will appear aft...

Page 43: ...y fixture 5 Press SEQ BUILD the Model 256 PC will proceed to check each programmed continuity according to the stored sequence 6 When a proper termination is not found in one of the sequence steps the sequencing will stop and the FROM and TO points will be displayed 7 An F will appear at the left of the display when the FROM point is touched and a T will appear when the TO point is touched Also as...

Page 44: ...e From To points 7 When the correct termination is made the tone will sound and the display will show Select Next Wire 8 Touch each succeeding wire in any order desired and make terminations as in Step 5 and 6 above 9 An F will appear at the left of the display when the FROM point is touched and a T will appear when the TO point is touched Also as soon as either the FROM or TO point is touched an ...

Page 45: ...s then the display will scroll through the numbers in succession CLEARING WORKING MEMORY CLEAR MEMORY This mode is required for clearing the working memory of User Labels before running a LEARN KNOWN GOOD If User Labels were previously loaded into the working memory along with another program the labels will be attached to the test points for the new program generated with the learn mode CLEAR MEM...

Page 46: ...aud Rate proceed as follows 1 Engage ENABLE jack on the rear panel 2 Press Up or Down arrow to step through the menu until SET BAUD RATE is displayed 3 Press MENU RUN key to initiate the mode The display will show one of the following as the current setting Baud Rate 1200 or Baud Rate 9600 4 To change the baud rate press the Up or Down arrow The baud rate will change between 1200 and 9600 each tim...

Page 47: ...n Print User List proceed as follows 1 Verify that a serial printer has been connected according to the Printer Hookup procedure in the Preparation section 2 Press Up or Down arrow to step through the menu to display PRINT USER LIST 3 Press MENU RUN to initiate printing A sample User List is shown below Signature 010066 User List 001 J1 1 002 J1 2 003 J1 3 004 J1 4 005 J1 5 006 J1 6 007 J1 7 008 J...

Page 48: ... operator to view 24 lines of information on the monitor instead of just the single line on the Front Panel display ENTERING COMMANDS Commands are entered at the system prompt To get the prompt press the ESC key on the Keyboard All commands are two letters that are executed by pressing their two keys followed by an ENTER There are four categories of commands as shown below Test test related comman...

Page 49: ...Test CT Continuous Test Self Test TT 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 After each error is displayed testing may be continued by pressing ENTER See Section on Controls and Displays for more details Loop Test CT Same as LOOP TEST selected from the Front Panel menu See section on Control...

Page 50: ...iption Random Build RA Random Assembly Sequential Build SQ Sequential Assembly Search SB Scan Body Random Build RA Same as RANDOM BUILD on the Front Panel See section on Controls and Displays for more details Sequential Build SQ Same as SEQ BUILD on Front Panel See section on Controls and Displays for more details Execution of this command begins at the first sequence step programmed into the wire...

Page 51: ...ommand followed by an ENTER Tester Function 2 letter Command Command Description Print Error PE Print Errors Print Wire List PW Print Wire List Print User List PU Print User List Print Wire List PW Same as PRINT WIRE LIST selected from the Front Panel menu See section on Controls and Displays for more details Print Error List PE Same as ERROR LIST key on the Front Panel See section on Controls and...

Page 52: ...ory If you decide not to clear memory press the letter N Delete Internal Delete Internal command is used to erase a wire list program from one of the storage locations in the Internal RAM memory When the DI command is typed followed by an ENTER the signature of one of the programs in memory is displayed Pressing the letter D advances through the list displaying the next program signature each time...

Page 53: ...m Use Load External Program command to load a stored program from the external cartridge memory into the working memory When the LX command is typed followed by an ENTER the signature of one of the programs in memory is displayed Press the letter D to advance down the list of programs or press the letter U to advance up the list The next program signature will display each time the letter is press...

Page 54: ...to the PC version Programs stored on cartridges are directly compatible and can be loaded and run on the Model 256 PC TEST POINT DISPLAYS When displaying point numbers the standard Model 256 displays a number that is in reference to the connector pin numbers on the rear of the tester The first digit of the point number display refers to the connector number 1 through 4 The last two digits refer to...

Page 55: ...ge programs The signature code is displayed after the program is loaded or saved Model 256 PC The Model 256 PC uses a signature code for selecting a program in lieu of a program location number The tester automatically select an available location in memory when a program is saved and does not copy over existing programs A delete program function has been added to erase an existing program Care mu...

Page 56: ...upplying 5vdc at pin 23 The pin assignment and the labels used on the CPU board are as shown below Function Standard Jumper Setting Alternate Jumper Setting Pass Fail W1 Pin 24 W4 Pin 24 End of Test W2 Pin 25 W5 Pin 25 Ground Pin 7 Pin 7 5vdc W3 Pin 23 W3 Pin 23 NOTE Early Model 256 and Model 256 PC testers were originally setup as shown under the Standard Jumper Setting The Alternate Jumper Setti...

Page 57: ...eled from 1 to 4 representing the scanner board number The Model 256 PC has two scanner boards as shown in figure 2 The top scanner board is board number one and requires a jumper across jumper pair number 1 The bottom board is scanner board number 2 and requires a jumper across jumper pair number 2 These jumpers are factory set However it may be necessary to move the jumper if the tester is disas...

Page 58: ...f equivalent rating and quality NOTE Please read Warranty in the front of this manual MEMORY BACKUP BATTERY If it is determined that the backup battery is faulty do not attempt replacement of the battery Battery replacement must be done by Cablescan Inc REPLACEMENT PARTS The following part numbers are provided for use in ordering replacements from Cablescan Model 256 PC 5211027 Cartridge Labels 86...

Page 59: ...C 1488 U1 3300151 IC 1489 U2 3300185 IC 6809 MICRO U5 3300213 IC 79M05 REGULATOR VR3 3300265 IC 74HC373 U6 3300267 IC 6551 ACIA U4 3300270 IC 74HC04 U8 3300273 IC 74HC00 U3 3300282 IC 7912 NEG V REG VR2 3300283 IC 74HC138 U9 3300299 IC TC5564PL 15 SRAM U12 3300304 IC LM311 U10 11 3300317 IC 27C64 UVPROM U13 4025054 RESISTOR 50W 5 6 2 R23 4041025 RESISTOR 25W 5 100 R3 4041035 RESISTOR 25W 5 680 R24...

Page 60: ...U13 7100132 JACK MICRO PHONE ENABLE J3 7100134 JACK PHONE FOOTSWITCH J8 7100135 JACK BANANA PROBE J9 7200105 6 CONN 1X6 0 1 STRIP J2 7200380 26 CONN 26P HEADER 90 J6 7200461 CONN 8P MOLEX HEADER 156 J7 7200568 CONN 17 35P CD EDGE 90 J5 7200571 CONN 25P D SUB RECPT 90 J1 7200578 CONN 16P SOCKET STRIP J4 SCANNER BOARD ASSEMBLY 5210869 P N DESCRIPTION SYMBOL 3300034 IC CD4051B U1 4 6 9 11 14 3300034 ...

Page 61: ...Model 256 PC Instruction Manual Page 53 Figure 20 Schematic CPU Board 1 of 3 ...

Page 62: ...Page 54 Model 256 PC Instruction Manual Figure 20 Schematic CPU Board 2 of 3 ...

Page 63: ...Model 256 PC Instruction Manual Page 55 Figure 20 Schematic CPU Board 3 of 3 ...

Page 64: ...Page 56 Model 256 PC Instruction Manual Figure 21 Schematic Scanner Board 1 of 3 ...

Page 65: ...Model 256 PC Instruction Manual Page 57 Figure 21 Schematic Scanner Board 2 of 3 ...

Page 66: ...Page 58 Model 256 PC Instruction Manual Figure 21 Schematic Scanner Board 3 of 3 ...

Page 67: ...NOTES ...

Page 68: ...Cablescan 5900379 REV G ...

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