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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.

Before attempting to operate your model of the Series 90, be sure to read this manual until you
understand it. Then, when first using your Series 90, follow the manual as closely as necessary
to achieve proper operation. When you eventually develop mastery of the system, you will
continue to turn to the manual as a reference.

Information in this manual supports a second volume, "Series 90 Software Manual."

If you have a question or problem regarding this manual, please contact Cablescan.

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Summary of Contents for 90 Series

Page 1: ...Cablescan Series 90 SETUP MANUAL 90 90 ...

Page 2: ......

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: ... 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 USE OF ...

Page 5: ... the Unit 6 Power Cords 6 Series 90 Series 90HV System Controller INterfacing 7 Rear Panel 7 I O Board 7 Series 90 90HV Connection Procedure 8 Basic System Hookup 8 Adding Expansion Cabinets 9 Series 90L4 Series 90H8 Scanner Control 10 Series 90L4 H8 Connection Procedure 10 Adding Scanner Boards 11 Series 90E9 Series 90E32 Cabinets 11 Series 90HV23 Cabinet 12 Series 90L4 H8 Cabinet 13 Low voltage ...

Page 6: ...nector Kit 19 5211037 Cable Assembly 19 5211038 Cable Assembly 19 5211088 Connector Kit 19 Remote Signals 21 Signal Timing 21 Output Connectors 22 Vacuum Fixture Operation 22 TestDiag 23 The TestDiag Program 23 Starting TestDiag 23 TestDiag Opening Screen 24 Control Menu 24 Title Bar 24 Control Menu 24 Menu Bar 25 Status Banner 25 Test Results Window 25 Status Bar 25 TestDiag Menus 26 File Menu 26...

Page 7: ...pplication 31 Test Descriptions 31 Enable 31 System Status 31 Short Test 31 Sense Line Test 31 Raw FET On Test 31 Raw FET Off Test 31 Resistor Bank 31 High Voltage Tests 32 Application 32 Test Descriptions 32 Enable 32 High Voltage Gen 32 High Voltage Dis 32 High Current Select 32 Scanner Relay 32 High Voltage Select 32 High Current Gen 32 Scanner Relay Res 33 Isolation Amplifier 33 Controller Lea...

Page 8: ...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 40 Maintenance 40 Repair 40 Handling Circuit Boards 40 Shipping and Storage 40 Replacement Parts 41 Specifications 42 Appendix A Scanner Resistor Bank 44 Appendix B Calibration Boards 45 ...

Page 9: ... Multiple Expansion Cabinet Hookup 9 9 Series 90L4 H8 Cable Connections 10 10 Series 90E9 Scanner Board Locations 11 11 Series 90HV Scanner Board Locations 12 12 Series 90L4 H8 Scanner Board Locations 13 13 Scanner Board Jumpers 14 14 Low voltage Scanner Board Layouts 15 15 High voltage Scanner Board Layouts 16 16 Low voltage Cable Assembly 5210917 03 17 17 Low voltage Cable Assembly 5210982 18 18...

Page 10: ...y certain models read the portions pertaining to your model Before attempting to operate your model of the Series 90 be sure to read this manual until you understand it Then when first using your Series 90 follow the manual as closely as necessary to achieve proper operation When you eventually develop mastery of the system you will continue to turn to the manual as a reference Information in this...

Page 11: ...ystem controller You can create and store your test build programs on disk You also can obtain and store test programs through the learn known good process or you can import test programs from other sources SERIES 90L4 SERIES 90H8 The Cablescan Series 90L4 and Series 90H8 Figure 3 are low and high voltage models respectively that are used on small assemblies and require use of your PC as the contr...

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: ...V 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: ...accommodate high voltage scanner boards There is only one model the Series 90HV S23 with a 23 board expansion cabinet It may be ordered with 1 to 23 high voltage 64 point scanner boards Additional 23 board expansion cabinets may house partial or full complements of scanner boards System Controller Optional Printer Monitor Keyboard Expansion Cabinet Expansion Cabinet Expansion Cabinet Assembly Unde...

Page 15: ...0 E9 Nine scanner boards with 128 test points each yielding 1152 maximum possible test points per cabinet Series 90 E32 Thirty two scanner boards with 128 test points each yielding 4096 maximum possible test points per cabinet Series 90HV One expansion cabinet model is available for the Series 90HV Series 90HV E23 Twenty three scanner boards with 64 test points each yielding 1 472 maximum possible...

Page 16: ...t of the Series 90 90HV is shipped with a three wire grounded power cable When the cable is connected to a three wire grounded power receptacle it connects the chassis of the unit to ground WARNING Continuity of the grounding circuit is vital for the safe operation of the units Never operate the Series 90 system through an ungrounded power connector or with the grounding conductors disconnected Po...

Page 17: ...tions The remaining slots are covered with blank panels Additional boards may be installed in these empty slots for special applications Note Depending on the CPU board used in your system controller the 15 pin monitor connector may be located vertically on the left most slot instead of next to the COM1 port as shown above I O Board The Cablescan I O Board is a high speed communication board used ...

Page 18: ... power connector male on rear panel of system controller to an AC receptacle 3 Connect color monitor power cord from INPUT power connector male on color monitor to AC receptacle The color monitor may have an attached cord 4 Connect mouse to top PS 2 connector MOUSE on System Controller 5 Connect keyboard to bottom PS 2 connector KB on System Controller KB MOUSE PRINTER USB COM1 COM2 MONITOR SPKR F...

Page 19: ...ource of trouble is poor connections Adding Expansion Cabinets 1 To add a second expansion cabinet remove terminating plug from OUTPUT connector on the first expansion cabinet 2 Connect the female end of another 9 conductor cable part number 9100069 to the OUTPUT connector of first expansion cabinet and male end to INPUT connector on second cabinet 3 If the second cabinet is the last in the chain ...

Page 20: ... 9 and as described below 1 Verify power switch on rear panel is in OFF position 2 Connect power cord part number 9200016 from power connector male on rear panel to an AC power source 100 to 220V 3 Connect PC serial port to and tester serial port with 9 conductor cable 9100069 4 Connect PC to appropriate power source in accordance with PC instruction manual Grounding the Unit The Series 90L4 90H8 ...

Page 21: ...s are installed from the bottom left and upward When the top slot is filled the next board is inserted into the right hand column at the bottom with additional boards continuing toward the top If more capacity is needed after the last slot has been filled a new cabinet must be added Refer to Adding Expansion Cabinets earlier in this section When top right slot is filled a new cabinet can be added ...

Page 22: ... must be added Refer to Adding Expansion Cabinets earlier in this section Scanner 32 Test Blank slots 2 Blank Panels Control Points with panels Board removed Two boards shown leaving twenty one empty slots Figure 11 Series 90HV Scanner Board Locations NOTE Make sure that the terminating plug is installed on the 9 pin output connector on the rear panel A time out error message will be displayed whe...

Page 23: ...ries 90L4 or Series 90H8 is contained in one cabinet configuration Series 90L4 64 Test Points per connector 128 Test Points per board Scanner Control First Scanner Board Board Series 90H8 32 Test Points per connector 64 Test Points per board Scanner First Scanner Control Board Board Figure 12 Series 90L4 H8 Scanner Board Locations NOTE The Series 90L4 low voltage scanner boards must have jumpers i...

Page 24: ...be installed in one of two locations on the three pin connector Each scanner board except for the last board in the cabinet must have a jumper connecting the center pin to the pin toward the center of the board On the last board move the jumper so that the center pin and the pin toward the outside of the board are jumpered This pin is labeled LAST BD When multiple expansion cabinets are required t...

Page 25: ...nt 64 Pin 64 Point 192 Scanner Board 1 Scanner Board 2 Pin 1 Point 1 Pin 2 Point 2 Pin 1 Point 129 Pin 2 Point 130 J1 J3 Pin 63 Point 127 Pin 63 Point 255 Pin 64 Point 128 Pin 64 Point 256 Pin 1 Point 65 Pin 2 Point 66 Pin 1 Point 193 Pin 2 Point 194 J2 J4 Series 90 L4 Vertical Board Layout Point 63 Pin 63 Pin 63 Point 191 Pin 64 Point 64 Pin 64 Point 192 Point 1 Pin 1 Pin 2 Point 2 Point 129 Pin ...

Page 26: ...is located in the upper left corner The second pin is located in the upper right corner See Figure 15 for the proper location and orientation of the connectors Note When making interface cables be careful to use these locations and avoid using the pin numbers stamped on the DIN connectors Scanner Board 1 Scanner Board 2 Pin 31 Point 95 Pin 31 Point 127 Pin 1 Point 1 Pin 2 Point 2 Pin 31 Point 31 P...

Page 27: ... cable can be used by stripping back its unterminated end and soldering it to the mating connectors for the assembly under test It can also be used to terminate a different type flat cable connector which will then mate to a discrete version of the connector such as a D type that is mounted either on the interface fixture or an adapter cable This is the same cable assembly as 5210917 03 shown in F...

Page 28: ...MP literature for termination tools Low voltage Interface Cable Assemblies CS P N Description First End Connector Second End Connector 5210914 3 64 conductor flat cable 7200481 no connector 5210917 3 64 conductor flat cable 7200481 7200446 5210982 64 conductor Harness Board discrete 7200449 no connector Cablescan to AMP Conversion Table Cablescan Part No Description AMP Part No 7200426 64 pin latc...

Page 29: ...ble Assembly The 5211037 is an eight foot discrete wired high voltage cable assembly It has a 32 pin male DIN connector 5211036 on one end and the second end is unterminated This cable can be used to terminate mating connectors for the assembly under test or a connector to interface to a test fixture See Figure 18 Pin 1 Pin 2 5211037 Figure 18 High voltage Cable Assembly 5211037 5211038 Cable Asse...

Page 30: ... pin DIN male connector 100 932 124 Strain Relief 100 000 071 Housing 100 000 064 Cablescan to ITT Cannon Part Number Conversion Cablescan Part No Description ITT Cannon Part No Cable End Connector Components 5211061 96 pin ZIF connector plug DL2 96P 96 pin ZIF connector shell kit DL2 J S 96 pin ZIF connector handle 2040016 000 Contacts for ZIF connectors 030 2410 001 Panel mount Connector Compone...

Page 31: ...ING signals return to a logic high state A PASS FAIL test status signal is output and occurs approximately 2 ms before END OF TEST transitions to low If the test passed the signal remains high If the test failed the signal transitions to a logic low External circuits can use END OF TEST to latch the PASS FAIL test status signal The PASS FAIL output is held for approximately 2 ms after END OF TEST ...

Page 32: ...ded on the parallel port Series 90S9 Series 90S32 Series 90HV23 Series 90L4 Series 90H8 Pin Numbers Function Pin Number Function 1 2 3 Ground 1 Pass Fail 4 6 15 N C 2 3 4 5 6 7 8 5 Execute Test 9 12 13 15 N C 7 8 5vdc 10 Footswitch 9 Inverted Pass Fail 11 Execute Test 10 Pass Fail 14 End of Test 11 Inverted End of Test 16 Testing 12 End of Test 17 5vdc 13 Inverted Testing 18 19 20 21 14 Testing 22...

Page 33: ...tDiag Menus STARTING TESTDIAG To understand TestDiag you should be familiar with basic Windows techniques such as choosing commands and resizing windows Refer to Microsoft Windows documentation To run TestDiag follow the instructions below 1 Click the Start button and then point to Programs A pop up menu with various files and folders will open 2 Move the pointer up or down this menu to TestRite f...

Page 34: ...t Results Window Status Bar Control Menu TestDiag Screen As shown on the TestDiag screen there are six main items Title Bar Control Menu Menu Bar Status Banner Test Results Window and Status Bar These six items are described below Title Bar The Title bar contains the Application name TestDiag and the Control Menu Control Menu The Control menu has three buttons Minimize Maximize Restore and Close T...

Page 35: ...ground is displayed when the tester is ready to run a test Testing light gray background is displayed while the tester is performing a test and results are being sent to the Test Results window Aborted red background is displayed when a test in progress has been cancelled A test is cancelled by selecting the Reset command Pass green background is displayed after all circuits have been tested and n...

Page 36: ...the 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 DiagnoseSystem The Diagnose System command initi...

Page 37: ...nals The Series 90 provides external signals for use in controlling external devices and equipment Refer to the Remote Signals section earlier in this manual for locations and timing of the signals TestDiag does not test the I O Signal Port After selecting the Tester Type and the Communication Port click the OK button and the Tester Settings window will close A warning window will open if the Test...

Page 38: ...ew Menu contains only one command Status Bar The Status Bar switches between on and off each time the Status Bar command is selected A check mark appears to the left of the Status Bar command to indicate when it is turned on Help Menu The Help Menu is a standard Windows menu At this time there is no help index available for TestDiag however the current version of TestDiag can be viewed by selectin...

Page 39: ...tage Series 90 testers High voltage Tests are special tests that are performed on only the high voltage Series 90 testers When the tester type is set to Series 90 the High voltage Tests is grayed out When the tester type is set to Series 90HV none of the Test check boxes are grayed out However a group of tests Low Voltage or High Voltage can be disabled grayed out by unchecking the Enable check bo...

Page 40: ... in this dialog box can be used to force the firmware to be downloaded Warning Interrupting the tester or PC during download can cause the download portion of the EEPROM to corrupt If this happens a new EEPROM must be installed on the Scanner Control Board Contact the factory CapacitanceOffsetFunction Capacitance Offset Function measures the amount of capacitance in the system This value is used a...

Page 41: ... AD Reference Voltage 2 0V Voltage 5 0V Voltage RAM on the controller card Scanner Assign Errors ShortTest Short Test performs shorts tests between all test points on the scanner boards Interface cables must be disconnected during diagnostics SenseLineTest Sense Line Test verifies isolation and noise levels for each test point RawFETOnTest Raw FET On Test verifies FET On condition for each test po...

Page 42: ...ut requiring each test to be unchecked Enable can be unchecked while running only the low voltage tests on a high voltage system High VoltageGen High Voltage Generator verifies the output voltage and the speed of the high voltage generator It measures the read back voltage and the ramp up time HighVoltageDis High Voltage Discharge verifies that the high voltage discharge circuit is functional It m...

Page 43: ...age select relay is activated to connect the scanner boards ShortingBarSize Shorting Bar indicates the number of points that have shorting bars installed Shorting bars typically are made by connecting all the pins on a mating connector together If only one connector is used for the test the Shorting Bar Size should be set to 32 one connector During a test requiring a shorting bar the test will pau...

Page 44: ...ag Running the Low Voltage components test selection verifies the operation of all test points in the system 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 Measurement accuracy is verified using several resistance values connected across s...

Page 45: ... Diag button in the center of TestDiag window Keep hands clear while test is being run 8 A message box opens prompting to remove shorting bars and resistor banks Remove all connections and click OK 9 TestDiag performs several tests on various circuit components Verify that Passed is displayed after each of the following tests Shorts Test Sense Line Test Raw FET On Test Raw FET Off Test 10 TestDiag...

Page 46: ...e displayed click Close button 6 Click the Diag button in the center of TestDiag window Keep hands clear while test is being run 7 System Status test will run first Verify test passed 8 TestDiag pauses and displays a message box prompting to remove shorting bars and resistor banks Remove all connections to the scanner boards and click OK 9 TestDiag performs several tests on various circuit compone...

Page 47: ...ircuit components Verify that Passed is displayed after each of the following tests Scanner Relay Test High Voltage Select Test High Current Generator Test Scanner Relay Resistance Test 17 TestDiag pauses and displays a message box prompting to install a 100 MΩ resistor between test point 1 and test point 57 Install Calibration board using connectors opposite side marked Shorting Bar 18 Click OK a...

Page 48: ...el of the expansion cabinet and remove the four screws on the bottom of the cabinet nearest the sides 3 Slide the top cover forward until it just clears the front of the unit Do not over extend the cover since the front panel switch is wired to the main chassis 4 Reach up and disconnect the switch harness then fully remove the cover 5 Locate the power supply and fuses on the front of the card cage...

Page 49: ...n the power supply board as shown in Figure 21 below Use replacement fuse with the same rating as the one installed Replacing the fuse with a higher rated fuse can cause permanent damage to the power supply scanner control board and scanner boards 4 Reinstall rear panel Rear Panel Inside View of Rear Panel LAMP FUSE PROBE LAMP POWER SERIAL PORT SERIES 90L4 SERIES 90H4 PIN LAYOUT PIN LAYOUT 1 2 129...

Page 50: ...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 HANDLING CIRCUIT BOARDS If a circuit board is to be handled outside the cabinet anti static measures must be employed Any person handling the board must wear an anti static 1 megohm wrist strap connected to ground The wrist strap supplied w...

Page 51: ...for all low voltage models 5210948 Scanner Control Board for H4 H8 High voltage 5211023 Scanner Control Board for HV23 High voltage 5211023 01 Series 90 Installation Manual 5900407 TestRite Software Manual for Series 90 5900408 TestRite Software Series 90 upgrade 5211107 Series 90 E32 Thirty two board expansion cabinet 5210972 Series 90 E9 Nine board expansion cabinet 5210963 Series 90 H23 High vo...

Page 52: ...1 0 amp ISOLATION Shorts Threshold 10 kΩ to 9 5 MΩ 10 kΩ to 9 5MΩ 5 vdc 5 MΩ to 1 000 MΩ depends on test voltage TEST VOLTAGE 5 vdc or 200 mvdc 5 vdc to 1500 vdc or 200 mvdc RAMP TIME N A 40 volts to 10 kvolts per sec RESISTANCE TEST 1 Ω to 9 5 MΩ 10 1Ω 1 Ω to 9 5 MΩ 10 1Ω CAPACITANCE TEST 1 000 pf to 10 000 μf 20 1 000 pf to 10 000 μf 20 DIODE TEST Polarity voltage drop Polarity voltage drop DWEL...

Page 53: ... additional board SYSTEM CONTROLLER 466 MHz Celeron 64MB RAM 7 5 GB Hard Drive CD ROM Drive 1 44 MB 3 5 Floppy Disk Parallel Serial Ports Wheel Mouse Windows NT TestRite Software Dimensions 6 0 x 23 5 x 15 0 inches 15 2 x 59 7 x 38 1 cm Weight 26 lbs 11 8 kg DISPLAY CONTROLS 17 inch VGA Color Monitor 101 key AT style keyboard User Labels 16 character Circuit Labels 32 character BODY CONDUCTANCE Le...

Page 54: ...rteen The values and corresponding connector locations are shown below R1 3 32Ω R2 39 2Ω R3 82 5Ω R4 392Ω R5 1kΩ R6 3 92kΩ R7 12 1kΩ R8 43 2kΩ R9 121kΩ R10 267kΩ R11 475kΩ R12 825kΩ R13 3 32MΩ 1 5 9 13 17 21 25 29 33 37 41 45 49 53 64 R1 3 32Ω R2 39 2Ω R3 82 5Ω R4 392Ω R5 1kΩ R6 3 92kΩ R7 12 1kΩ R8 43 2kΩ R9 121kΩ R10 267kΩ R11 475kΩ R12 825kΩ R13 3 32MΩ R14 100MΩ 1 5 9 13 17 21 25 29 1 5 9 13 17 ...

Page 55: ...k is connected to one set while the second set of connectors is used as a shorting bar During high voltage testing one of the tests requires all test points of each connector to be shorted or connected together SHORTING BAR J4 TP1 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 J1 100M 5211117 High Voltage Calibration Board Part Number 5211117 SHORTING BAR J2 TP1 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 ...

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Page 57: ...5900407 Rev D Cablescan ...

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