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Introduction

System Overview

The CheckSum Model G-50 Cable/Continuity Test System allows an IBM PC (or com-
patible) to efficiently test assemblies (such as cables and harnesses) containing up to 96
test points for shorts and opens. The System performs a continuity test from each point
to every other point in the assembly.

The CheckSum Model G-50 includes:

•

One Model SR-500 I/O Module that is installed into the IBM PC. All of the System
electronics are included in the SR-500

•

Two 50-Pin Ribbon Cables for connecting the SR-500 I/O Module to the cable or
harness

•

A diskette containing CheckSoft Software that executes on your IBM PC with
MSDOS

•

This Instruction Manual

The System can be expanded up to 768 test points with the addition of optional Model SR-
500 I/O Modules, each containing 96 test points.

The Model SR-500s can be connected directly to the test unit, or can be connected to
either a user-supplied or CheckSum-supplied fixture unit to facilitate ease in connecting
various test units to the System.

The optional CheckSum Model GS-850 Fixture can be used to provide an efficient means
of connecting a wide variety of cables to the Test System. It connects to one or two SR -
500s. Mating connectors are then installed on adapter boards that quickly attach to the
fixture via a zero-insertion force (ZIF) connector.

Figure 1 shows a block diagram of the System architecture when used with a Model GS-
850 Fixture System.

CheckSum Model G-50 Manual - Page 5

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Содержание G-50

Страница 1: ...Model G 50 Cable Continuity Tester INSTRUCTION MANUAL CheckSum LLC P O Box 3279 6120 195th Street NE Arlington WA 98223 360 435 5510 WebSite www checksum com ...

Страница 2: ...perational characteristics of the System are subject to change Check Sum LLC cannot take responsibility for any direct or consequential damages arising from use of this manual or the related products IBM PC IBM XT and IBM AT are trademarks of International Business Machines Inc MS DOS is a trademark of Microsoft Inc ...

Страница 3: ...heckSoft Software Installation 17 Fixture Installation 21 Operating Instructions Overview 23 Testing a Cable 26 Learning a Cable 32 Locating a Pin 41 Assembling a Cable 42 System Self Test 43 Configure Install System 45 Appendix A Wiring Diagrams Appendix B Sample Reports Appendix C In Case of Problems Appendix D Error Messages CheckSum Model G 50 Manual Page 1 ...

Страница 4: ...e 14 Operator Comments Entry Screen 36 Figure 15 Sample Text File 39 Figure 16 Pin Locating Display 41 Figure 17 Cable Assembly Display 42 Figure 18 Self Test Result Display 43 Figure 19 Self Test Failure Display 44 Figure 20 Configure Install System Menu 45 Figure 21 Report Configuration Menu 48 Figure A1 SR 500 I O Port Pin Out Ap 2 Figure A2 Cable Test Report With Failure Ap 3 Figure A3 Cable T...

Страница 5: ... invoiced at a nominal cost In such case an estimate will be submitted before the work is started if requested THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EX PRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WAR RANTYOFMERCHANTABILITY FITNESS ORADEQUACYFORANYPAR TICULAR PURPOSE OR USE CHECKSUM LLC SHALL NOT BE LIABLE FOR ANY SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES WHETHER...

Страница 6: ...CheckSum Model G 50 Manual Page 4 ...

Страница 7: ...PC with MSDOS This Instruction Manual The System can be expanded up to 768 test points with the addition of optional Model SR 500 I O Modules each containing 96 test points The Model SR 500s can be connected directly to the test unit or can be connected to either a user supplied or CheckSum supplied fixture unit to facilitate ease in connecting various test units to the System The optional CheckSu...

Страница 8: ...learning a known good cable Learning a cable from a text file Saving cable data to hard disk or diskette Pin or wire locating Cable assembly aids Test printouts Cable wiring printouts System self tests System configuration The CheckSoft Software Package also allows for assigning operator instructions and long pin and wire names that can be displayed to help repair faulty cables CheckSum Model G 50...

Страница 9: ...Figure 1 System Block Diagram CheckSum Model G 50 Manual Page 7 ...

Страница 10: ...CheckSum Model G 50 Manual Page 8 ...

Страница 11: ...0 connections PC control Jumperable I O port addressing Uses 32 byte address on the PC I O bus Default Base Address is 300 hex Internal computer power supply requirements Approximately 5 Watts 1 A 5 VDC Computer requirements One full length slot in an IBM PC XT AT PS 2 Model 30 or full compatible Two 5 VDC and two GND pins are provided in the pin out and may be jumper activated on the SR 500 Matin...

Страница 12: ...able from known good sample Learn cable from text file created independently Save learned file on disk Test learned cable Loop test cable for intermittents Self test of each I O pin and control circuitry Wire identification via probe Propagation delay compensation Assign special operator instructions Assign pin names Assign wire names Print test results Print wiring data CheckSum Model G 50 Manual...

Страница 13: ...ain the help of a qualified person to do the installation SR 500 I O Module Installation The first step of the installation procedure involves installing the SR 500 I O Modules in the PC Step 1 Remove the power cord from your PC and turn off the power to minimize safety hazards and to ensure that no damage is done to circuitry in the PC or in the SR 500s CAUTION Ensure that you have removed the po...

Страница 14: ...rs should be installed The BASE ADDRESS for all SR 500s should be identical If you have only one SR 500 ensure the BOARD SELECT jumper is installed for BD position 1 the leftmost pair If you have more than one SR 500 each should be jumpered sequentially There should never be more than one jumper installed on the BOARD SELECT strip Note The VCC jumpers on the BASE ADDRESS strip provide the capabili...

Страница 15: ...herboard connector Position the back end with the bracket of the SR 500 to the left to provide working room 3 Install the first of the two cables to JP 4 on the SR 500 Pin one typically indicated by a red tracer on the cable should be toward the bottom Install the end of the cable without the white handle and strain relief to the SR 500 Fully seat the cable by pressing the cable connector onto its...

Страница 16: ...Repeat steps 1 through 5 for each SR 500 that you are installing Step 6 Reinstall the cover of the PC Step 7 Reinstall power to the PC and boot it up CheckSum Model G 50 Manual Page 14 ...

Страница 17: ...Figure 3 SR 500 Installation CheckSum Model G 50 Manual Page 15 ...

Страница 18: ...CheckSum Model G 50 Manual Page 16 ...

Страница 19: ... using the software keys to be pressed are represented with their name surrounded by square brackets For example the Escape key is repre sented by ESC Hard Disk Drive Installation If you have a hard disk drive in your System drive C you will want to install the Check Soft Software onto it The installation procedure installs it in a new subdirectory called CHECKSUM Step 1 Start your computer and go...

Страница 20: ...tion If you do not have a hard disk drive in your System use this procedure Step 1 The first step is to back up the CheckSoft Software diskette Have a spare floppy diskette ready Insert the CheckSoft diskette into the disk drive Type DISKCOPY A B Enter Follow the instructions with the source disk being CheckSoft Software and the destination disk being your blank diskette If you need additional ins...

Страница 21: ...ft Software is running Alternatively you can save cable data on the same disk as the CheckSoft Software If you have a two drive System you can change the data path to be B with the System Setup Configuration menu Completing the Software Installation You will see the introductory directory the System menu Figure 4 System Menu Select F6 Configure Install System You will then see the configuration me...

Страница 22: ... containing CheckSoft Software is installed Press ESC to return to the System menu shown in Figure 6 Press F5 from the System menu to execute the System self test The self test verifies that all of the I O pins called ports on the SR 500s are operational If you need further instructions in the use of the self test refer to the System Self Test section of the manual If errors are reported refer to ...

Страница 23: ...15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 JP4 UUTGnd2 Port 79 Port 81 Port 83 Port 85 Port 87 Port 89 Port 91 Port 93 Port 95 Port 80 Port 82 Port 84 Port 86 Port 88 Port 90 Port 92 Port 94 Port 96 Port 31 Port 33 Port 35 Port 37 Port 39 Port 41 Port 43 Port 45 Port 47 Port 32 Port 34 Port 36 Port 38 Port 40 Port 42 Port 44 Port 46 ...

Страница 24: ...ed about the connections use the probing feature of the System to iden tify the appropriate port numbers Once you have completed fixturing you are ready to start testing cables Continue on to the Operating Instructions portion of this manual to learn how When you have become familiar with operation of the System refer to the section Learning an Assembly for allow ing the System to learn the connec...

Страница 25: ...CheckSum Cable Continuity Test System the first thing to do is to power up your computer If you do not have a hard disk drive insert your copy of the CheckSoft disk into the A drive Type in the sequence A Enter CABLE Enter If you have a hard disk drive in your computer and are presently in the CheckSum or root directory CHECKSUM or simply type CABLE Enter You will then see the System menu as shown...

Страница 26: ...ata file describing the cable and to display or print test results F2 is used if you want the System to learn the correct connections for a particular as sembly You can also use F2 to assign alphanumeric pin and wire names assign operator instructions assign a cable name learn about a cable from a PC file created separately save information about a cable on the disk or get a report about how a cab...

Страница 27: ...g properly F6 is used to change the configuration of your testing environment You can specify which disk and directory that cable data is to be stored in turn the beeper on and off specify the destination of printed reports and tell the PC how the hardware is configured In addition this option can be used to configure the reports generated by the System ESC allows you to terminate CheckSoft Softwa...

Страница 28: ...y loaded in memory At the end of the F1 line on the screen you will see a name in parentheses This is the name of the file that is currently loaded into memory If it is None no file has been loaded into memory If a cable name has been assigned to the data in memory it appears just before the file name in parentheses If a cable has been learned but not saved on disk it is valid to continue with the...

Страница 29: ... to eleven characters that do not include spaces or special characters such as colons or periods Errors that might occur are listed in Appen dix D F3 allows you to choose the data file from a list of those available on the disk that you have chosen This display is shown in Figure 9 Figure 9 File Selection List You may move up and down the displayed list with the up and down arrow keys or page up a...

Страница 30: ...e Test Failure display as shown in Fig ure 10 Figure 10 Test Failure Display The Type indicates whether an unexpected short or open type of error was encountered If it says Short that means that an erroneous short was encountered during the test Each error is reported once For example if a connection is expected from cable pin 4 to cable pin 7 and the connection is not present it is reported as an...

Страница 31: ...s pins 1 48 respectively On each cable the top pins 49 and 50 are either open ground or 5 V depending on the SR 500 jumpering The Pin and Wire Names are optionally assigned when the cable is learned Consequently they may be blank or contain up to a 16 character description Pressing ESC from the Test Failure display returns you to the Test Completed menu Pressing anything else continues the test Co...

Страница 32: ...tionally assigned in the Report Con figuration menu the Cable ID the optional cable name assigned when the cable is learned and the date and time It also contains the number of failures and an identity of the cable tester Even though a failure may have occurred more than once it is counted as a single failure only This prevents excessively long reports after intermittent testing Each failure is li...

Страница 33: ... and the yield as a percentage of the batch that passed the tests Finally the report contains the date and time and the tester identification Optionally the report can contain a list of the wiring for the cables tested Whether the wiring list is in cluded or not as well as its format is determined by the Report Configuration menu ESC Escape allows you to return to the main System menu to select a ...

Страница 34: ...System automatically learn the connections that are present Alternatively the information can be entered via a text file generated on your PC Once a cable is learned the System provides the capability of saving this information on a disk for future use This way you don t have to keep a known good cable around as a reference The System also provides a number of additional features to help you obtai...

Страница 35: ...f the F1 selection so that you are reminded that the connections have been learned Assigning Pin and Wire Names Selecting F2 from the Assembly Learn menu allows you to assign pin and wire names to the units that you are testing If you use this feature the reports and error messages that you get from the System will be much more useful to you There can be a pin name and wire name for each port of t...

Страница 36: ...st faster When you have completed entry of pin and wire names press ESC to move back to the previous menu If you press the F1 key you can use the probe to locate the port number With this fea ture you do not need to know the specifics of how the UUT is connected to your Con tinuity Test System Simply press F1 F1 toggles between probing on and off as indi cated by a mark at the bottom of the displa...

Страница 37: ...e are numeric they are incremented to the next numeric character Pressing F2 a second time disables auto increment Assigning Operator Instructions Selecting F3 from the Assembly Learn menu allows you to enter operator instructions Operator instructions are a way of giving information to the operator previous to each test The notes are presented to the operator and then a key is pressed to continue...

Страница 38: ...es in the direction indicated by the arrow key By turning lines on and off you can achieve most line drawings By redrawing over lines you can erase junctions to lines that you may have erased The drawing is saved with the spec data that you are creating at the time In addition the F2 key allows you to save the present screen to the disk for future recovery for ex ample if you would like to read it...

Страница 39: ...gning the Cable Name Selecting F4 from the Assembly Learn menu allows you to type in a descriptive name for the cable Any alphanumeric text up to 32 characters in length is allowed The cable name shows up in the File Select menu and on any cable reports that are generated Propagation Compensation Selecting F5 from the Assembly Learn menu allows you to set a propagation delay for the cable If your ...

Страница 40: ...veral keywords which are NAME ASSIGN TO FROM and COM The ASCII input file is of the form An exclamation point is used to start a comment Everything after it on the line is ig nored Blank lines are ignored NAME the cable name ASSIGN pin name wire name port Use of the Assign keyword is completely optional but can be used to associate pin names or wire names with ports This makes the rest of the file...

Страница 41: ...om Pin 1 to Pin 32 from Pin 2 to Pin 32 Figure 15 Sample Text File In Figure 15 a cable is described that has connections from Pin 1 to Pin 32 and also from Pin 2 to Pin 32 The cable s Pin 1 is connected to port 1 of the SR 500 Pin 2 to port 2 and Pin 32 to port 3 The signal at Pin 1 is named RTS and the signal at Pin 2 is named CTS The System figures out all of the resulting paths for you For exa...

Страница 42: ...ion menu Saving Cable Data on the Disk Selection of F9 from the Assembly Learn menu allows you to save the information about the cable you have learned onto a hard disk or floppy disk drive After selection of F9 you are prompted to enter a file name Enter a file name with up to eleven characters that do not include spaces or special characters such as colons or periods Your DOS manual describes va...

Страница 43: ...ty If a pin name and wire name have been assigned they are displayed as well You may either use the probe that comes with the Model GS 850 Fixture or your own probe The probe needs to be connected to the PC chassis to be effective since the Sys tem is searching for a grounded input The GS 850 probe jack is grounded for you by the ground cable to the computer When you move the probe to another pin ...

Страница 44: ...bly Display The System uses whatever cable definition is presently in memory If you would like to load another cable definition select F1 You may then type in the name of a file contain ing a file definition To perform an assembly probe the wire that you would like to connect You may either use the probe that comes with the Model GS 850 Fixture or your own probe The probe needs to be electrically ...

Страница 45: ...ing properly Since each port on the SR 500 is bidirectional the individual port outputs can be changed to each state and then be measured Consequently the self test can locate virtually all faults that might occur Note Ensure no cables are connected during the self test If cables are connected you may get incorrect test results To initiate a self test select F5 from the System menu When the test i...

Страница 46: ... Expected shows the desired test result Actual shows the measured value Tri State shows whether the output was tri stated or active at the time of the failure Bit shows which decimal bit position on the output byte has failed If you see massive self test failures it is likely to be an installation or compatibility prob lem If you see one or a few repeatable failures you can suspect an SR 500 hardw...

Страница 47: ...the SR 500s It also shows the present setting in decimal F2 defines how many SR 500s are installed in the System For more detail about these options see Solving Installation Problems in the Appendix of this manual Note If you have a large number of SR 500s in your system but are only using some of the lower numbered ones temporarily setting the number of I O modules to reflect the num ber of the h...

Страница 48: ... You may choose FILE TXT to send the output to a disk file by this name Note that if this option is used the file is saved in the same directory as the CheckSoft Software It does not use the data path After the file is saved you can leave CheckSoft Software and rename and or move the file with the DOS COPY command If you save more than once to FILE TXT the file is appended with the new data Becaus...

Страница 49: ...gh the various options until the display shows the printer port to which you have connected the foot switch F9 is used to save the configuration selections that you have made to the disk drive When you save the configurations each time you restart CheckSoft Software you will not need to reconfigure your System The configuration file is transparent to you It is named CONFIG CSM and is stored in the...

Страница 50: ...isting Consequently each connection is shown twice and as a result the report is much longer Full is valuable if you are using the report to help troubleshoot cables since it is easier to find the destination of each pin F3 is used to select whether the System asks the operator to type in the name of a batch prior to printing the batch report If this feature is enabled and the operator types in th...

Страница 51: ...special line of text in the respectively named reports You may enter a line of up to 32 characters If nothing is entered None is dis played and the reports do not contain this special line If something is entered it is placed in the header of the report left justified If the line contains a colon the information before the colon including the colon is placed in the left column and the information ...

Страница 52: ...CheckSum Model G 50 Manual Page 50 ...

Страница 53: ...AppendixA Wiring Diagrams CheckSum Model G 50 Appendix Page 1 ...

Страница 54: ...31 Port 33 Port 35 Port 37 Port 39 Port 41 Port 43 Port 45 Port 47 Port 32 Port 34 Port 36 Port 38 Port 40 Port 42 Port 44 Port 46 Port 48 Port 16 Port 18 Port 20 Port 22 Port 24 Port 26 Port 28 Port 30 Port 15 Port 17 Port 19 Port 21 Port 23 Port 25 Port 27 Port 29 Port 64 Port 66 Port 68 Port 70 Port 72 Port 74 Port 76 Port 78 Port 63 Port 65 Port 67 Port 69 Port 71 Port 73 Port 75 Port 77 Port ...

Страница 55: ...8 Cable Tester CheckSum Model G 50 Port Pin Name Wire Name Port Pin Name Wire Name 1 Pin 1 RTS 3 Pin 32 2 Pin 2 CTS 3 Pin 32 3 Pin 32 4 End of data Report showing unexpected opens from port 1 to port 3 and port 2 to port 3 It also shows a short from port 3 to port 4 Figure A2 Cable Test Report With Failures CheckSum Model G 50 Appendix Page 3 ...

Страница 56: ...e ID Cable PN 123 434 Failures 0 Test Date 9 10 90 Time 11 28 Cable Tester CheckSum Model G 50 Port Pin Name Wire Name Port Pin Name Wire Name Test Passed no failures End of data Figure A3 Cable Test Report With No Failures CheckSum Model G 50 Appendix Page 4 ...

Страница 57: ... Time 11 28 Cable Tester CheckSum Model G 50 Port Pin Name Wire Name Port Pin Name Wire Name 1 Pin 1 RTS 2 Pin 2 CTS 1 Pin 1 RTS 3 Pin 32 2 Pin 2 CTS 1 Pin 1 RTS 2 Pin 2 CTS 3 Pin 32 3 Pin 32 1 Pin 1 RTS 3 Pin 32 2 Pin 2 CTS End of data Figure A4 Cable Wiring Report CheckSum Model G 50 Appendix Page 5 ...

Страница 58: ...32 Cable ID Cable PN 123 434 Batch ID Order No 43 54W Operator Initials _________________ Number Tested 10 Failures 1 Yield 90 Test Date 9 10 90 Time 11 28 Cable Tester CheckSum Model G 50 Figure A5 Batch Test Report CheckSum Model G 50 Appendix Page 6 ...

Страница 59: ...than one SR 500 they must be at unique sequential addresses beginning with one The SR 500s do not use interrupts or DMA channels so there can be no conflicts in these areas If you still have problems there may be a conflict on the PC s I O channel The SR 500 uses 32 sequential byte addresses on the I O channel The default Base Address is 768 300 hex I O space up to 799 31F hex is used by the SR 50...

Страница 60: ...0 hex ADR7 128 80 hex ADR8 256 100 hex ADR9 512 200 hex Table A1 SR 500 Base Address Jumpers The base address is the sum of the above numbers for each of the ADR5 ADR9 jumpers which are REMOVED For example in the default case there are no jumpers on ADR8 and ADR9 so the Base Address is 256 512 768 The SR 500s all must be set to the same base address When you change the SR 500 base address you must...

Страница 61: ...0C0 0DF Math Coprocessor n a 0F8 0FF Joystick Game Controller 200 20F 200 20F Expansion Unit 210 217 n a Parallel Printer n a 278 27F Serial Port Primary 3F8 3FF 3F8 3FF Serial Port Secondary 2F8 2FF 2F8 2FF Prototype Card 300 31F 300 31F Fixed Disk 320 32F 1F0 1F8 Parallel Printer Primary 378 37F 378 37F SDLC 380 38F 380 38F Bisynchronous Com n a 3A0 3AF Mono Adapter Printer 3B0 3BF 3B0 3BF CGA A...

Страница 62: ...CheckSum Model G 50 Appendix Page 10 ...

Страница 63: ...ccess denied Error 12 Invalid file access code Error 15 Invalid drive number Error 97 Incorrect spec file revision Error 99 Not a valid spec data file Error 100 Disk Read error Error 101 Disk out of space Error 103 File Open error Error 150 Disk is write protected Error 152 Drive is not ready Error 156 Disk seek error Error 162 Hardware failure Table A3 File Error Messages CheckSum Model G 50 Appe...

Страница 64: ...CheckSum Model G 50 Appendix Page 12 ...

Страница 65: ... spec data for the batch Board Select A header on Model SR 500s that allows the installer to set the module s identity to the computer Each module has eight possible module select positions Each module that uses the same base address must have a unique module select position Cable Name An optional name that can be assigned to spec data that identifies the UUT The assembly name can be up to 32 char...

Страница 66: ...ule The electronics for the Test System that are in stalled in the PC Each SR 500 Module contains 96 ports for testing the UUT A single System can have up to eight SR 500s Model TR 3 Fixture An optional Bed of Nails Fixture that connects between the Model SR 500 Continuity I O Modules and the UUT This Fixture can be used for bare board or loaded assembly testing Model T 120 System Controller An IB...

Страница 67: ...tested The spec data in cludes information about each connection such as the port numbers and pin and wire names In addition the spec data includes the assembly name Test Report A report describing the outcome of testing a single UUT against its spec data This report includes information about each failed measurement e g port num bers pin and wire names the test threshold the facility name and tes...

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