USER`S MANUAL Harness Assembly Aid / Tester with
Contents
1. 3 nos for 96 points 32 per connector Point LEDs 50 pin centronics F connectors 4 nos for 96 points 2 cables for each LED 24 LEDs per connector Tray LEDs 50 pin centronics F connectors 4 nos for 96 tray LEDs 2 cables for each LED 24 LEDs per connector Pull points 2 nos for each coupler 9 couplers 37 pin D F connectors 1 no Terminated at back side of tester General User input 4 key touch pad sealed keyboard viz Enter Up Down Escape Facility to connect PC keyboard for entering component name User output 16x1 LCD display with backlit Buzzer audio output on Pass Relay no potential contact rating 230V 5 A on Pass A 5mm LED on Pass OC PASS LED ELENE KEYBOARD D o Q a SPEAKER FRONT PANEL DETAILS Docuren inter User Interface functional specifications Keys Enter Accept command or menu Up Next command in menu or increment number Down Previous command in menu or decrement number Escape escape to previous menu or escape from test 1 ENTER ACCEPT COMMAND 2 UP NEXT COMMAND IN MENU OR INCREMENT A NUMBER a DOWN PREVIOUS COMMAND IN MENU OR PUTURA DECREMENT A NUMBER 4 ESCAPE ESCAPE TO PREVIOUS MENU KEYBOARD MENUS HAAP 96 VERSION NO t ACTION TAKEN ON COMPONENT SELECTED LABLE ON OFF STATUS START ASSEMBLY ANALYSIS od uP DISPLAY DATA SELF TEST BOARD TEST COUNT DISPLAY MEMORY CHECK CHECK ae SELF BOARD s DISPLAYS USER TEST ENTERED DATA CHANGE2. COMPONENT CHANGE DATA CHANGE LABLE LABEL ON OFF SET TIME CLEAR COUNTER TIME SETTING T JAN O Ds ONLY DATA DATA OAI A CLEARS COMP 1 CHANGE FROM PC TO LOADS LABLE pr amp TIME FROM PASS COUNT 1 TO9 SEC 7 o OFF COMP NO TESTER PC TO TESTE IN STEPS OF PRINTS NO LABLE 1 SEC FUTURA APSOL PVT LTD KEYPAD MENUS FOR HAAP 96 F raper X Menus and submenus Menu name and keys accepted Start Assembly up down Enter Setup up down enter Change component up down enter Escape Change data up down enter Escape Change label data up down enter Escape Label on off up down enter Escape Set time up down enter Escape Clear counter up down enter Escape Time setting up down enter Escape Analyse Display Data up down enter Escape Self Test up down enter Escape Board Test up down enter Escape Count up down enter Escape Display Memory up down enter Escape Mains Supply 230V AC 10 50 Hz with 500 mA fuse 5V DC 500mA supply Relay driver with relay Microprocessor oO vous On nes output on 3 way terminal strip On back panel Microcontroller CPU Buzzer driver with tone and volume control on Pass LED driver with LED on front panel 37 pin D F connectors with EEPROM data 96 I O LEDs on 4 nos 50 pin centronics F storage and necessar y connec
3. CONNECTION DIAGRAM 5 ae 25X2 BERG CONNECTOR FRONT VIEW S RAM PLATE LED CONNECTION DIAGRAM I O Connector 37 pin D type M solder type on rig side On tester 37 pin D F I O Conne Pin number I O Conne Pin number I O Conne Pin number No ctor on connector No ctor on connector No ctor on connector 1 1 1 26 1 32 51 2 10 2 1 20 27 1 14 52 2 29 3 1 2 28 1 33 53 2 11 4 1 21 29 1 15 54 2 30 a 1 3 30 1 34 55 2 12 6 1 22 31 1 16 56 2 31 7 1 4 32 1 35 57 2 13 8 1 23 33 2 1 58 2 32 9 1 5 34 2 20 59 2 14 10 1 24 35 2 2 60 2 33 11 1 6 36 2 21 61 2 15 12 1 25 37 2 3 62 Z 34 13 1 7 38 2 22 63 2 16 14 1 26 39 2 4 64 2 35 15 1 8 40 2 23 16 1 27 41 2 5 17 1 9 42 2 24 18 1 28 43 2 6 19 1 10 44 2 25 20 1 29 45 2 7 21 1 11 46 2 26 22 1 30 47 2 8 23 1 12 48 2 27 24 1 31 49 2 9 25 1 13 50 2 28 MSSL Wiring or connecting of rig fixture to tester Refer attached wiring diagram which gives details of wiring of I Os I O LEDs Trey LEDs and pull points FUTURA Haap g6 AC MAINS olooaad Asoo a a 3 0 fo x HO on ES 132 PRINTER a202 Q a O 60 09 otota0 a2000 04948 9 6 4 PON Q Q Q O 6 440 atate a 60000 9 6 a202 goa 00 H8 9 O P0705 0 o 0 o a econndoa d PON oono09g 0080 0 atate a 9 o 00 0800 9 e FULL TEST POINTS a 4 3 o BAD CHE w E Se g 4 5 TRAY LEDS u 4 u RAY
4. LEDS 4 m TRAY LEDS n 4 i SS Se a eee s e is jO LEDS j0 LEDS REAR PLATE DETAILS J Soainert Minber HAAP 96 f Tirran January 16 206 Al
5. for programmed time from 1second to 8 seconds If switch D is found open i e correct condition tester starts buzzer Buzzer will stop after pulling is stopped and switch A is open again If switch D is on during this programmed time tester displays FORCE gt 1200 FAIL and after 2 seconds REMOVE ASSEMBLY Now tester is in continuous checking mode 4 Harness Assembly Aid connections to rig fixture board Fixture wiring involves wiring of I O points I O LEDs and tray LEDs and pull points For MSSL Refer attached diagram for wiring of I Os and LEDs from 18 pole F connector Refer table folowing this section for detailed connector pin numbers 1 0 CONNECTIONS 1 CONN 1 1 0 s FROM 1 TO 16 2 CONN 2 1 0 s FROM 17 TO 32 3 CONN 3 1 0 s FROM 33 TO 48 4 CONN 4 1 0 a FROM 49 TO 64 5 CONN 5 1 0 s FROM 65 TO 80 6 CONN 6 1 0 s FROM 81 TO 96 I O LED TRAY LED CONNECTIONS PULL TEST POINT CONNECTIONS alal lalaa 7 ral oh NOTE NOTE 1 CONN 1 I OLED s FROM 1TO8 1 CONN 1 PULL PT FROM 1TO8 2 CONN 2 I OLED s FROM 9TO 16 2 CONN 2 PULL PT 9 12 CONN 12 1 OLED s FROM 89 TO 96 FOR TRAY LED s CONNECTOR NO 1 TO 8 ONLY ALL CONNECTORS VIEW FROM WIRE INSERSION SIDE FUTURA APSOL PVT LTD ite TESTER TO BOARD CONNECTIONS Docunant Number 4 1 Wiring of 96 I O points Three 37 pin D F connector are provided at the back panel of tester 37
6. PRINTED ITEM 01234 Futura time 4 date 1 year 3 month 2 pass 3 5 PC connectivity General points to remember for PC connectivity Data to be entered should be in non document ASCII text mode using any editor word processor Start the data entry by a character and end by a character for test data and end by for label data Always use correct COM serial port Use correct settings for serial communication Always put the receiving item in receive mode first and then press ENTER to transmit data Connect the cable correctly Solid State Floppy can be used to tranfer data from PC to tester Use Futura s serial cable and serial extension cable PC to SSF Y end to PC 25 pin end to SSF Serial extension cable not required PC to Tester Y end to PC 25 pin end to Serial extension cable 9 pin end to tester SSF to Tester Y end to SSF 25 pin end to Serial extension cable 9 pin end to tester 3 6 Interfacing Printer A standard centronics port on DB25 F i e 25 pin D type female connector is provided It can be connected to any standard centronics printer available such as dot matrix ink jet laser or bar code printers Label printing is added to print a label on every passed harness Data to be printed on every pass can be different for each cable number i e in case of CSTE 10 different data can be stored in tester s memory For each cable type 1000 bytes are reserved for labe
7. USER S MANUAL OF Harness Assembly Aid Tester with Pull Tester Model HAAP96 BY FUTURA APSOL PVT LTD version 1 2 1212 B APTE ROAD SHIVAJINAGAR PUNE 411 004 INDIA TELE FAX 020 2553 1832 2552 1395 E MAIL info futuras com www futuras com Harness Assembly Aid Tester Model HAAP96 Packing List Harness Assembly Aid Tester I no This User s Manual 1 no Mains cord 1 no similar to PC mains cord Cables from tester to board rig Cable for pull test points Futura s Serial Cable Serial Extension Cable N A o A MU N N A Cd with necessary programmes Important Note Preserve the packing sent along with the tester which is specially designed for protection of the tester during transportation In case tester is to be sent back to Futura use the same packing INDEX GENERAL PRECAUTIONS 1 INTRODUCTION 1 1 Function 1 2 Specifications 2 DESCRIPTION OF MENUS 2 1 Start Assembly 2 2 Setup 2 3 Analysis 3 OPERATION 3 1 Front and Back panels 3 2 Display meanings and keys used 3 3 Power On 3 4 Programming 3 5 PC Connectivity 3 6 Interfacing Printer 3 7 Interfacing Relay 3 8 Buzzer 3 9 Assembly 4 CONNECTING TESTER TO RIG 4 1 Harness Assembly Aid to rig 4 2 TO connection details 4 3 VO LEDs connection details 4 4 Tray LEDs connection details 4 5 Connecting Pull Test points GENERAL PRECAUTIONS Bef
8. a starts with and ends with between two lines of data All letters in small and none in capital Data format One line comment can be written here A Saart with maruti swift First Line is assembly name red net g ______________IName of First step in sequence Maximum 8 digits 1 2 3 _1___Trey LEDs in first step each separated by a space 0005 0006 0007 Step 1 net to be assembled and checked With coupler to be checked for pull test green net Out of four digits 4 first digit indicates pull test coupler number 0 is no pull test 2009 0017 8019 0020 Number to 9 indicates coupler number 1 to 9 for pull test Coupler number 2 Point number 9 or 3 black net 9 20 gt 15 0001 20 0004 0008 2010 Date Time dd date in 2 digits mm month in 2 digits yy year in 2 digits hr time hours in 24 hours format in 2 digits mn minutes in 2 digits ss seconds in 2 digits AT THE START AND AT THE END For Example On date 3 rd January 2000 and time afternoon 3 07 09 string will be 03012000150709 For 2000 and onwards enter year in two digits only Tester will print year in four digits ddmmyyyyhrmnss 03012000150709 Label Data EXAMPLE OF LABEL DATA NOTE AT THE END BLANK LINE WILL BE PRINTED AS BLANK LINE AT 1 DATE WILL BE PRINTED AT 2 MONTH WILL BE PRINTED AT 3 YEAR WILL BE PRINTED AT 4 TIME WILL BE
9. ble only from PC to SSF To load from PC to tester a file has to be created This can be generated by using any text editor EDD EXE is one editor in the CD Others like edit notepad can be used with care that file should be non document pure text file Set tester in appropriate i e test data or label data or date time receiving mode Execute terminal on PC Set baud rate 2400 data bits 8 parity none stop bits 2 and hand shaking none as shown below Select proper com port Click on connect Click on send file Select proper test data or label or date time file Click on open Selected file will be sent to tester or Solid state floppy whatever is connected While tester receives data LED on controller blinks Test Data can be verified by using display data mode After receiving test data tester displays ARRANGING DATA and SAVING and OK and SETUP After receiving label and date time displays SETUP Details of Terminal screen and sample files are as follows Set baud rate 2400 data bits 8 parity none stop bits 2 and hand shaking none as shown below Select proper com port Click on connect baud rate 2400 data bits 8 parity none stop bits 2 and hand shaking none ff Terminal 1 9b 20040204 by Br y aT z Sie J gest eree el T g g g Send File aen __sewMe r Sample Files Test Data Dat
10. display that point number All 128 points including pull points can be analysed 3 Operation 3 1 Front and Back panels Back Panel Mains input socket with fuse and spare fuse Mains power on switch Relay output terminal strip tone and volume control for buzzer Use keyboard on front panel for functions as required Refer to attached diagramof keypad menus for detailed keyboard operation Relay Relay will be normally off and will be on for 3 seconds on Pass Relay output is provided on back side on a terminal strip Pole NO and NC are all available for use Black terminal i e ground is to be used for board checking mode Connect power cord provided with tester which is similar to PC mains cord to the tester at socket provided on the back panel Switch on power using power on switch 3 2 Displayed messages their meanings and keys to be used FUTURA Power on messaage VER 1_2 firmware version number COMPONENT NAME XX Currently selected component name and number XX CHECK HARNESS If complete harness is to be checked after assembly START ASSEMBLY Start assembly SETUP Want to change settings Up down next menu Enter displays O xx yy Tester displays fault that xx and yy are open S xx yy Tester displays fault that xx and yy are shorted PASS nnn When assembly is completed and found correct and pass count nnn REMOVE ASSEMBLY When assembly is completed and pass is indicate tester prompt
11. e 0005 0006 0007 _________Step 1 net to be assembled and checked With coupler to be checked for pull test green net Out of four digits 4 first digit indicates pull test coupler number 0 is no pull test 2009 0017 8019 0020 Number 1 to 9 indicates coupler number to 9 for pull test Coupler number 2 Point number 9 or 3 black net 9 10 15 0001 20 0004 0008 2010 Label data To load data of online label to be printed from PC Label on off To select online label printing on off Set date amp time To load real time date and time from PC Clear counter Clears Pass counter Set pull time To set time for pull test For how much time tester should check pulled point for a force of 900 settable from 1 second to 9 seconds Display Data Displays stored data 2 3 Analysis Display Data To display stored data for selected component Self Test Self test checks for all 128 I O points open It includes all pull test points also Displays result PASS if all points are open else fail Then glows LEDs one by one Trey LEDs from 1 to 96 followed by I O LEDs from 1 to 96 Tester displays type of LED and LED number LEDs are to be visually checked tester will report fault if it finds shorted points Board Test check Board facilitates making a rig fixture and also to check fixture When Ground i e black terminal at the backside is touched at an I O point tester will
12. from presets at the back side Different tones can differentiate passed harnesses and to avoid confusion 3 9 Assembly Assembly will follow same steps as programmed Tester will glow all tray LEDs from which parts are to be picked up in the first step It also displays step number At the same time I O LED corresponding to starting point say endA will glow and that of first endB will blink Hence parts from these trays will have to be picked up and then end A will have to be inserted at location where LED glows Other end s of cable is to be inserted at endB i e blinking LEDs If it is inserted at proper location then first endB will stop blinking and next endB LED will start blinking At the same time all those LEDs will glow which are connected by this net even though the insertion is wrong Hence identification of correct insertion is that blinking LED stops blinking This will continue till all I Os in that step are connected properly Else display will show errors like open and short and LEDs will not stop glowing Once all steps are correctly assembled tester will display pass Assembly If start point is entered as 00 tester will function as normal HAA without pull test If start point is entered as xx at point xx tester displays FORCE lt 900 xx i e pull is less than 900 for point xx Once switch A is on display will be FORCE gt gt 900 i e first switch is found OK tester continues to check switch D
13. isplaying faults display will be description O xxx yyy Where xxx is the starting point of the net circuit Meaning in described test yyy point is open from xxx Similarly SHORT will be displayed Once a step is complete HAAP96 will move on to next step when all steps are over tester can check complete subassembly again if the option is selected on power on By default this option is not selected If complete subassembly is found correct in one pass then only teser will pass the assembly On pass an audio signal along with relay output and visual signal will be given out when all steps are over HAAP96 will start assembly of new component only when old one is removed 2 2 Setup Change component To change selected component i e to select component under assembly Change data Programming of new data New data can be programmed only from PC s serial RS232 port A file in a text editor is generated in the specified format and transmitted to tester In the file information required is harness name once each step name trey LEDs in each step separated by space coupler number for pull test along with point number Format is as follows All letters should be small letters E e Saart with maruti swift WW WY Y First Line is assembly name red net e Name of First step in sequence Maximum 8 digits 1 2 3 ________Trey LEDs in first step each separated by a spac
14. l data A complete label can be printed or if standard label is pre printed then only variable data can be printed Tester can print variables viz Date time month and year of testing To print these in label data at the place where date is to be printed 1 should be placed and for time 4 is to be placed etc To print special characters or bar codes first of all printer has to be finalised Label or bar code printers accompany label printing software which generates an ASCH file to be sent to printer for printing required data Same file can be used by a little modifications such as adding characters at the start as well as end of the data and adding character followed by required number at required places for printing date and time 3 7 Interfacing Relay output A potential free relay output with a capacity of 230V AC 5A is provided on a terminal strip on the back panel This contact will be change over on every harness passed for 3 seconds It can be used to glow a lamp or for hot stamping or for activating a pneumatic circuit or for activating a solenoid For inductive loads use of snubber circuit will prevent tester from malfunctioning P i e Pole and NO i e Normally Open get connected when relay is on and pole and NC i e Normally Closed get open when relay is on 3 8 Buzzer On passing a harness a ringing buzzer sounds for 3 seconds Buzzer s tone and volume can be controlled
15. ore using the equipment read the following carefully Following points are to be taken care of while using the equipment These will protect the equipment from malfunction and any damage Any external continuity meter like buzzer bulb or multimeter should be strictly avoided Use of these will damage the internal electronic delicate components The tester is designed to work for 230V AC with 10 of fluctuation If the voltage goes below the specified voltage the tester will not work as expected It is advisable to have a voltage stabilizer preferably a CVT While changing the board removal and fitting of D type connectors on the back side of the tester should be done with utmost care These connectors are polarised and hence should not be inserted in wrong direction There is a tendency to push the connector hard in the tester even if polarisation is incorrect Pushing might damage the connectors on the tester The tester has a long life and does not need much of maintenance if used carefully The maintenance is required for the rig or mounting board 1 INTRODUCTION 1 1 Function Harness Assembly Aid Tester is to help in assembling a harness correctly including pull test and check the same online It improves the process and minimises assembly errors It is programmable by user Once programmed it guides the operator assembler to insert terminals at correct location It also checks correct connection and displa
16. pin D M connector marked points is used Each wire is labeled with corresponding point number Each point number is connected to spring type probe pin on assembly fixture See table for more details 4 2 Wiring of 96 I O LEDs 4 nos 50 pin centronics F connector are provided at the back panel of tester 50 pin centronics M connectors marked I O LEDs are used Each LED requires 2 wires which are harnessed together One wire marked with 5VDC is connected to ANODE of LED and other marked with point number is connected to CATHODE of LED of corresponding I O point on fixture On connector printed pin 1 to 24 are cathodes and printed 26 to 49 are anodes 4 3 Wiring of 96 tray LEDs 4 nos 50 pin centronics F connector is provided at the back panel of tester 50 pin centronics M connector marked TLEDs is used Each LED requires 2 wires which are harnessed together One wire marked with 4 5VDC is connected to ANODE of LED and other marked with tray number is connected to CATHODE of LED of corresponding tray on fixture On connector printed pin 1 to 24 are cathodes and printed 26 to 49 are anodes 4 4 Wiring For Pull Test points 1 no 37 pin D F connector marked pull test points at the back side Pin1 is for 900 gms pin 20 for 1200gms of coupler 1 2 21 for coupler 2 and so on for 9 such couplers SIMILAR CONNECTIONS FOR REMAINING SEVEN 50 PIN 25X2 BOX TYPE BERG CONNECTORS 25X2 HERG CONNECTOR
17. s to remove the present assembly CHECK HARNESS Asks if complete harness is to be checked after completing assembly 3 3 Power on Tester displays FUTURA for 2 seconds firmware version number for 2 seconds last selected component name if entered earlier and component number for 2 seconds Display will be CHECK HARNESS meaning after completing subassembly again whole assembly is to be checked or not If Enter is pressed during this display mode of checking harness will be set and goes to assembly To skip this option press Esc key can be pressed Tester displays START ASSEMBLY If Enter key is pressed here then tester starts with step one of programme Escape key will skip assembly function and will be back to main menu 3 4 Programming It can be done only through PCs serial RS232 port As explained earlier To load test data label data date etc PC has to be interfaced with tester Copy software terminal exe from CD provided with tester to an appropriate folder Connect PC or Solid State Floppy to tester using Futura s serial cable along with serial extension cable on tester side provided with the tester The Y end i e end with 9 pin and 25 pin connectors is the PC end and other 25 pin connector end is the serial extension cable and 9 pin end is to tester end Y end is connected to a COM port on PC To load data in solid state floppy SSF connect Futura ca
18. tors circuitry 64 TREY LEDs on 3 nos 50 pin centronics F connectors 16 1 LCD alphanumeric Display with Backlit On front panel 4 keys sealed keyboard with touch keys On front panel Futura Apsol Pvt Ltd Pune India Block Diagram of Harness Assembly Aid model HAAP96 Drawn by GSR Doc No HAAP96 BD 2 Description of menus 2 1 Start Assembly Basis of HAAP96 is that harness assembly is done in steps Each step involves picking up a part either a crimped cable cable assembly or a grommet etc from a tray and inserting terminals in housings at proper location i e points checking it for terminal backout by pulling During assembly in a step HAAP96 guides operator to pick parts from proper tray by glowing corresponding LEDs Then HAAP96 glows LED at first point where terminal is to be inserted and blinks LED at point where next terminal is to be inserted If programmed for pull test waits for pulling of terminal sensed through fixture It will be sensed for the set time If pull test is not passed if pull is less waits if more displays fault and leaves test If pull test is passed tests continuity of inserted terminal Once correct insertion is done point s LED stops blinking and HAAP96 moves on to next point in the same step If insertion is wrong then HAAP96 will keep displaying fault like open and short and will not go to next step unless correct connection While d
19. ys faults online Pull testing facilitates checking of terminal back out problem with proper fixtures It is a microcontroller based tester A fixture for coupler pull test has 4 probes say A B C D with switches Each switch will be on on applying a force of 300 Switch heights will be arranged properly so as to get correct result To check terminal after insertion terminal is pulled manually On pulling switches get on Required force is between 900 to 1200 Hence First three switches A B C should be ON and D should be off for correct force Installation In addition to other circuit connections pull test connections are required It is necessary that all pull test points are in sequence A B C are connected in series Tester has 2 inputs to sense i e read switches ABC and D These are terminated on a 9 pin D type F connector as SWA GND SWD GND P E ae GND SW D GND M SWA Connections of probes are as above On 37 pin D connector at the back side of tester 1 2 Technical Specifications Power Supply 230V ac 10 Assembly Testing capacity Number of points in a sub assembly to be tested 96 points Harness circuit programming is by self learning 96 LEDs for 96 points Number of trays LEDs 64 nos LED Test Voltage TTL Logic 1 level 5V DC Test Current For continuity in milliamperes For LEDS5 milliamperes Tester I Os Points 37 pin D F connectors
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