Cablescan 64 Instruction Manual Download Page 5

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Model 64/64x2 Instruction Manual

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TABLE OF CONTENTS

SPECIFICATIONS .............................................................................................VIII

THE MODEL 64 CONTINUITY TESTER .............................................................. 1

Major Functions ........................................................................................................ 1

Tester Features ........................................................................................................ 2

Signature Codes ....................................................................................................... 2

User Labels............................................................................................................... 4

Program Storage ...................................................................................................... 4

PREPARATION..................................................................................................... 6

Unpacking................................................................................................................. 6

Initial Hookup ............................................................................................................ 6

Program Cartridge Installation.................................................................................. 6

Power Turn-on and Self Test.................................................................................... 8

Printer Hookup.......................................................................................................... 9

PC Interface............................................................................................................ 10

CONTROLS AND DISPLAYS ............................................................................. 11

Controls .................................................................................................................. 11

Key-selected Functions .......................................................................................... 11

Menu-selected Functions ....................................................................................... 14

Display .................................................................................................................... 17

OPERATING INSTRUCTIONS - CONTROL PANEL.......................................... 18

Learn Known Good................................................................................................. 18

Wire List Printing..................................................................................................... 19

Test ......................................................................................................................... 20

Error List ................................................................................................................. 21

Loop Test................................................................................................................ 22

Saving a Program ................................................................................................... 23

Loading a Program ................................................................................................. 24

Deleting a Program................................................................................................. 25

Sequential Build (SEQ Build).................................................................................. 26

Random Build (Random Build ................................................................................ 27

Wire Identification (Search) .................................................................................... 28

Clearing Working Memory (Clear Memory)............................................................ 28

Setting Baud Rate................................................................................................... 29

Printing User List .................................................................................................... 30

Summary of Contents for 64

Page 1: ...CONTINUITY TESTER ASSEMBLY AID MODEL 64 MODEL 64x2 Cablescan ...

Page 2: ......

Page 3: ...August 29 2005 MODEL 64 Model 64x2 INSTRUCTION MANUAL Part Number 5900384 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: ...lf Test 8 Printer Hookup 9 PC Interface 10 CONTROLS AND DISPLAYS 11 Controls 11 Key selected Functions 11 Menu selected Functions 14 Display 17 OPERATING INSTRUCTIONS CONTROL PANEL 18 Learn Known Good 18 Wire List Printing 19 Test 20 Error List 21 Loop Test 22 Saving a Program 23 Loading a Program 24 Deleting a Program 25 Sequential Build SEQ Build 26 Random Build Random Build 27 Wire Identificati...

Page 6: ...RATING INSTRUCTIONS KEYBOARD 31 Introduction 31 Entering Commands 31 Test Commands 32 Build Commands 33 Print Commands 34 Program Commands 35 MODEL 64 OUTPUT SIGNALS 38 CARE OF THE MODEL 64 39 Cleaning 39 Repair 39 Memory Backup Battery 39 Replacement Parts 39 PARTS LIST 40 ...

Page 7: ...odel 64 layout 3 2 Program Storage Locations 5 3 Program Cartridge Label Format 7 4 Top Panel Keys and Display 12 5 Program Storage Accommodations and Use 15 6 Sample Wire List Printouts 19 7 Sample Error List Printout 21 8 Sample User List Printout 30 9 Schematic Model 64 CPU Board 42 ...

Page 8: ...ric LCD 6 character test point labels PROGRAM STORAGE Internal Memory Battery backed CMOS RAM containing working memory area and 8 program locations without test point labels or 2 program locations with test point labels Removable Memory EEPROM cartridge containing 16 program locations without test point labels or 4 program locations with test point labels BATTERY LIFE 5 years POWER REQUIREMENTS 1...

Page 9: ...rmination points and verify terminations A serial interface is provided for connection to a PC for remote control or to a printer for printout of test information MAJOR FUNCTIONS Major functions of the Model 64 and Model 64x2 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 ...

Page 10: ...connected to the FOOTSWITCH jack An optional 80 column serial printer provides hard copies of Error Lists Wire Lists and User Label Lists when connect to the PRINTER SERIAL interface An external PC not supplied by Cablescan may be connected to the PRINTER SERIAL interface for remote control using TERM or TestRite software provided by Cablescan The Model 64 and Model 64x2 operates on 9VDC provided ...

Page 11: ... BUILD RANDOM BUILD ERROR LIST MENU RUN Cablescan Model 64 Model 64x2 Top Panel 63 64 1 2 J1 PRINTER SERIAL FOOTSWITCH 9VDC PROBE ENABLE 1 0 Model 64 Rear Panel PRINTER SERIAL 63 64 1 2 J1 FOOTSWITCH 9VDC PROBE ENABLE 128 127 65 66 J2 1 0 Model 64x2 Rear Panel Figure 1 Model 64 layout ...

Page 12: ...rd processor such as Word or Word Perfect When word processors are used the files must be saved with the Text only or ASCII option Instructions for Wire list and User Label off line programming are provided in Cablescan s TERM software manual PROGRAM STORAGE The Model 64 has memory accommodations for twenty four programs without User Labels or six with User Labels as well as a working memory for t...

Page 13: ...ORY PROGRAM CARTRIDGE RAM EEPROM WORKING MEMORY MEMORY LOCATION 1 MEMORY LOCATION 2 MEMORY LOCATION 1 MEMORY LOCATION 3 MEMORY LOCATION 2 MEMORY LOCATION 4 MEMORY LOCATION 8 MEMORY LOCATION 16 Figure 2 Program Storage Locations Program Storage Locations ...

Page 14: ...rify the power pack is labeled correctly for the intended operating voltage See table above 2 Plug the power pack into the AC power source 3 Make sure that the power ON OFF switch on the rear panel is OFF and then connect the output plug from the power pack into the connector labeled 9VDC 4 Turn power ON OFF switch to ON and observe that a message is displayed The Model 64 is ready for use If noth...

Page 15: ...the menu using Up and Down arrows until LOAD CARTRIDGE is displayed and then press MENU RUN 6 Scroll through the signature codes of the programs one at a time Check the signature code of each location against the code recorded on the corresponding locations of the cartridge label If no programs are present MEMORY IS EMPTY will be displayed Cablescan PROGRAM CODE 1 2 3 4 5 6 USE ERASABLE MARKER 7 8...

Page 16: ... are connected to the interface connector on the rear panel and then press the Up or Down arrow to step through the menu to reach SELF TEST 3 Press MENU RUN to initiate Self Test During self test the software version number of the tester will display If the unit passes self test the display will show Self Test Passed and the tone will sound if it fails the display will show one of the following OP...

Page 17: ...ON 5 Press the Up or Down arrow to step through the menu to reach SET BAUD RATE 6 Press 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 If the printer was not provided by Cablescan the following setup data are required Transmission to the pri...

Page 18: ...ow to 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 A greater than prompt should appear on the PC screen NOTE If the prompt does not appear press ESC Also...

Page 19: ... display advances to the next open pair of points Body conductance Wrist Strap or Probe can be used in locating the proper wire from a bundle The assembly sequence of the wire list is first programmed off line with a PC and then downloaded with optional PC software to the Model 64 Once in the tester the program can be saved to tester memory Random Build The RANDOM Build key is selected when the se...

Page 20: ...am created in LEARN KNOWN GOOD or downloaded from a PC ERROR LIST Initiates test of assembly 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 64 in wait state until next selection is made UP DOWN ARROWS Used for stepping up and down through menu to select a function Also used to...

Page 21: ...in memory If the test is successful the display shows Passed XXXX YYYY and the tone sounds If an error is encountered the points in error are displayed along with an indication of whether the error is an OPEN or SHORT Reset When RESET is selected the Tester assumes a wait state and it remains in that state until another mode is selected RESET also can be used to terminate a mode in operation ...

Page 22: ...est NOTE Functions in left column require use of ENABLE plug To select a menu function use the following standard procedure 1 Press Up or Down arrow to step through the menu until the desired function is displayed 2 Insert the ENABLE plug if the function is one listed in the left column above 3 Press MENU RUN to initiate the function Learn Known Good This function is used for scanning existing con...

Page 23: ...rogram for future use copy it into the available memory locations using either SAVE INTERNAL or SAVE CARTRIDGE function All test and assembly procedures are conducted from the Working Memory To use a program that is stored in memory copy it into the Working Memory using either LOAD INTERNAL or LOAD CARTRIDGE function All programs remain where saved SAVE and LOAD functions only copy them They are e...

Page 24: ... the case with Save Program For saving a program rather than erasing it use Saving a Program procedure which is discussed later Please note that Clear Memory must be used prior to Learn Known Good if User Labels are present and are not to be part of the learned program Set Baud Rate This function is used to select the baud rate of either 1200 for printing or 9600 for connection to a PC Print Wire ...

Page 25: ...cation are displayed Pressing MENU RUN restarts the test Each time a successful test is completed a loop count on the display increments by one Search This function is used to identify wires by touch It is useful in both assembly and troubleshooting With the wrist strap connected the operator may touch the ends of the wires and the display will indicate the point or points touched User Labels will...

Page 26: ...OWN GOOD is displayed 4 Press MENU RUN to initiate LEARN KNOWN GOOD The Model 64 will instantly scan the known good harness and store its configuration wire list in memory A signature code will be calculated and the display will show Learned Signature code 5 If printer is connected select and initiate PRINT WIRE LIST Notice that the printout also will bear the signature code shown on the display R...

Page 27: ...e Printer Hookup procedure 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 Sample wire lists are shown below WIRE LIST WITH TESTER POINT NUMBERS Signature 010066 Wire List Sequence From Point To Point 001 005 013 002 004 014 003 003 012 004 002 011 005 001 010 006 009 015 007 008 016 End of List WIRE LIST...

Page 28: ... is provided below 1 Load program to be used refer to Loading a Program procedure 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 When an error is encountered an O for open or S for short with the From To points will be dis...

Page 29: ...oad program to be used refer to Loading a Program procedure 3 Install harness to be tested 4 Press ERROR LIST The Model 64 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 ERROR LIST WITH TESTER POINTS Signature 010066 Error List Condition From Point To Point OPEN 003 01...

Page 30: ...step through the menu until LOOP TEST is displayed 4 Press MENU RUN to initiate the LOOP TEST mode During LOOP TEST the harness may be flexed to aid in finding intermittents 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 A short b...

Page 31: ...splay 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 You Sure 4 Press MENU RUN again to save the program After the program has been saved the display will show Saved signature 5 If you decide not to save the program press RESET instead of MENU RUN 6 If there is insufficient memory to save the ...

Page 32: ...oad procedure is provided below To select and load a program 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 function and the display will show the selected Load function and the signature for the last program that was selected with the load function Load Int signature or Load Cart sign...

Page 33: ...nd the display will show the selected Load function and the signature for the last program that was selected with the load or delete function Delete Int signature or Delete Cart signature 4 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 5 If you decide not to delete a program press RES...

Page 34: ...ly fixture 5 Press SEQ BUILD the Model 64 will proceed to check each programmed continuity according to the stored sequence 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 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 a...

Page 35: ... points 7 Make the termination if made correctly 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 Steps 6 and 7 above 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 intermit...

Page 36: ...thers the display will scroll through the numbers in succession CLEARING WORKING MEMORY CLEAR MEMORY This function is used for clearing User Labels from the working memory before running a LEARN KNOWN GOOD If User Labels previously loaded into the working memory along with another program are not cleared the labels will be attached to the test points for the new program generated with the learn mo...

Page 37: ... BAUD 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 function The display will show one of the following as the current setting Baud Rate 1200 Baud Rate 9600 4 To change the baud rate press the Up or Down arrow The baud rate will alternate between 1200 and 9600 ea...

Page 38: ...st is shown below in Figure 8 To select and run 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 Signature 010066 User List 001 J1 1 002 J1 2 003 J1 3 004 J1 4 005 J1 5 006 J1 6 00...

Page 39: ... allows you to view 24 lines of information on the monitor instead of just the single line on the Top 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 in two letters They are executed by pressing their two keys followed by an ENTER There are four categories of commands as shown below Test test related com...

Page 40: ...p Test Menu CT Continuous Test Self Test Menu TT Test Tester Test SC Same as TEST button on Top 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 Top Panel menu See section on Cont...

Page 41: ...er Command Command Description Random Build RA Random Assembly Seq Build SQ Sequential Assembly Search Menu SB Scan Body Random Build RA Same as RANDOM BUILD on the Top Panel See section on Controls and Displays for more details Sequential Build SQ Same as SEQ BUILD on Top Panel See section on Controls and Displays for more details Execution of this command begins at the first sequence step progra...

Page 42: ...scription Error List PE Print Errors Print Wire List PW Print Wire List Print User List PU Print User List Print Error List PE Same as ERROR LIST key on the Top Panel See section on Controls and Displays for more details Print Wire List PW Same as PRINT WIRE LIST selected from the Top Panel menu See section on Controls and Displays for more details Print User List PU Same as PRINT USER LIST select...

Page 43: ...ry CM command is typed followed by an ENTER the prompt Are You Sure is displayed Pressing the letter Y when the prompt Are you sure is displayed will erase the program and User Labels in working memory If you decide not to clear memory press the letter N Delete Internal Same as DELETE INTERNAL selected from Top Panel menu Delete Internal command DI is used to erase a wire list program from one of ...

Page 44: ...d is typed followed by an ENTER the signature of one of the programs in internal 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 pressed To load the program corresponding to the displayed signature press ENTER Load External Program Same as LOAD CARTRIDGE PROGRAM ...

Page 45: ...rking memory by copying it to an external cartridge EEPROM memory If the cartridge does not have sufficient memory to store the program MEMORY FULL is displayed If the program is to be saved to cartridge and the cartridge is indicated as full turn off power and replace cartridge If there is sufficient memory ARE YOU SURE is displayed To save the program press the letter Y Update the cartridge labe...

Page 46: ...pins 24 and 25 respectively A jumper is also provided for supplying 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 J2 J1 W3 W1 W2 W4 W5 Part number 5211046 LITHIUM BATTERY 3vdc J9 J6 REMOTE OUT...

Page 47: ...y for repair 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 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 fo...

Page 48: ...73 U3 3300267 IC 6551 ACIA U4 3300270 IC 74HC04 U9 3300273 IC 74HC00 U11 3300283 IC 74HC138 U10 3300284 IC MAX231 RS232 DVR RCV U1 3300299 IC TC5564PL 15 SRAM 8KX8 U6 3300303 IC 79L05 REGULATOR VR1 3300304 IC LM311 U2 3300307 IC MAX690 WATCHDOG TIMER U7 3300317 IC 27C64 UVPROM 8KX8 U5 4041025 RESISTOR 25W 5 100 R7 4041037 RESISTOR 25W 5 1K R8 R9 4041042 RESISTOR 25W 5 2 7K R3 4041043 RESISTOR 25W ...

Page 49: ...133 POWER JACK 7100134 PHONE JACK 7100135 BANANA JACK 7200105 6 CONNECTOR 1X6X 1 PIN J4 7200105 16 CONNECTOR 1X16X 1 PIN J2 7200568 CONNECTOR 34 PIN CARD EDGE J5 7200569 CONNECTOR 1X14X 1 PIN J3 7200570 CONNECTOR 1X16X 1 SOCKET P3 7200571 CONNECTOR 25 PIN D SUB J1 8300077 DISPLAY STAND OFF SCANNER BOARD ASSEMBLY 5211045 P N DESCRIPTION SYMBOL 3300034 IC CD4051B U5 U20 3300265 IC 74HC373 U2 U3 3300...

Page 50: ...Page 42 Model 64 64x2 Instruction Manual Figure 8 Schematic Model 64 CPU Board 1 of 3 Model 64 CPU Board Page 1 of 3 ...

Page 51: ...Model 64 64x2 Instruction Manual Page 43 Figure 8 Schematic Model 64 CPU Board 2 of 3 ...

Page 52: ...Page 44 Model 64 64x2 Instruction Manual Figure 8 Schematic Model 64 CPU Board 3 of 3 ...

Page 53: ...5900384 Rev D Cablescan ...

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