USER`S MANUAL(ver4.4) CABLE HARNESS TESTER
Contents
1. USER S MANUAL ver4 4 OF CABLE HARNESS TESTER MODEL PHTM320 PHTM640 PHTM960 BY FUTURA APSOL PVT LTD 1212 B 2 Apte Road Shivajinagar PUNE 411 004 TELE FAX 020 2553 1832 E MAIL info futuras com www futuras com Software Version PHTM GEN 5 5 and PHTM_320_4k_2 5 19 12 2012 N A c Cable Harness Tester Models PHTM320 PHTM640 PHTM960 Packing List Cable Harness Tester 1 no This User s Manual 1 no Mains cord 1 no similar to PC mains cord A pair of multimeter test probes for board check and continuity check Learn lock key for learning a harness Cable from tester to board rig as per number of points or connectors Futura s Serial Cable A CD containing DOS as well as windows based PC software for serial communication with tester and other details Enter Serial Number of Tester 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 1 IMPORTANT NOTES 1 1 Safety notes 2 Changes in Various versions 2 INTRODUCTION 2 Description of the system 2 2 Specifications 2 3 Tester 2 3 Testing Features 2 3 2 General Features 2 3 3 Harness Data Circuit Data 2 3 4 Input Output cards I O cards 2 3 5 Keyboard2. Pushing might damage the connectors on I O cards or on the board of the tester Check proper earthing at the power supply input of the Cable Harness Tester Warranty void if equipment is opened by unauthorized person 1 1 Changes in this versions 1 2 3 1 2 3 4 1 2 1 1 PHTM GEN 3 0 Label data size has been increased to 4k 4096 bytes Facility to scan two operator codes On label operator codes can be printed by variables 9 B amp C PHTM GEN 4 4 Provision for second relay is made in software If Hardware for second relay is present in the tester then second relay can be used First relay can be set as relay on pass or relay on fail as per the requirements But Second relay will be compulsory on after harness pass PHTM GEN 4 6 New variable i e U is added for label printing U followed by two characters will represents single byte hex value For ex UAA i e OxAA At every QU following value will be sent to the printer port Le in above example hex AA will be sent to port At every harness fail if relay on fail setting is enabled then harness name will be sent On the serial port by default serial settings PHTM GEN 4 7 New modification in variable i e U For ex UAA 1 For every date character hex value mentioned will be sent before that character This modification will be applicable to PHTM label variables such as Time Serial number etc for ex 9U23 2 6000 6
3. 2 How to add card Switch off tester Remove mains cord Remove these 2 screws near edge Back view of tester Previous card Remove this plate with PCB Remove these screws and remove covering plate Keep holding painted blocks from inside Assemble new I O card using blocks and screws provided Take new card and assemble with removed plate in the tester in the same way Insert card in the slot using guides provided in the tester with 15 pin connector at the top Feel the card fitting firmly in the connector Connect Mains cord and switch On tester Check all points with board check 48 7 3 Connections Of new CPU Following photos indicate internal view of PHTM CPU and all its connections Front view of tester Here CPU PCB is located 10 pin Connector from IO cards FRC connector for Display FRC connector from motherboard Program Module of CPU CPU overview 8 BASICS OF TROUBLE FREE OPERATION PROPER USE OF TESTER The following basic procedures are essential for safe and trouble free operation of the system Installation and operation of the tester or system according to the directions in the manual Power supply 230 V AC 50 Hz 1096 with proper earthing Use of CVT for power supply fluctuations Packing tester properly while shifting from one location to other Supporting cable
4. 9 U 2 PHTM GEN 5 0 or PHTM 320 4K 2 0 During harness testing if extra point settings is enabled and extra point is occurred Then tester will once display error and declare harness is failed and goes for waiting into testing of new cycle PHTM GEN 5 5 PHTM 320 4K 2 5 1 W is added in label printing variable User details with maximum 16 bytes can be added through serial port and will be printed via W On every power on if valid user details are present then displayed on LCD Installation of PHTM960 1 PHTM960 is similar to PHTM640 except a Maximum number of I O cards can be 15 i e 960 points b Keyboard Learn lock key Display Buzzer continuity and board check terminals are separated in a hand held enclosure called MMI Man machine Interface unit 2 Along with tester find enclosed MMI unit and 26 way flat cable of length 1 5 m a Place the tester at a suitable location preferably under the table b Connect MMI unit to the tester using flat cable provided At the back side of MMI unit and tester indicators for connections are provided 3 Connect cables to board Switch on supply to the tester Rest of the connections are similar as earlier To facilitate tracing of assembly and testing operators facility to enter their codes and printing them on label is added Two operator s codes are to be entered Operator Code length should not be more than 8 characters On power off operator codes are not remembered O
5. by user by Learning Test Parameters 5 DC Q current in mA Tester I Os 37 pin 2 nos for points 32 points in each 37 pin D connectors 4 numbers for 64 point LEDs 16 in each 37 pin D F connectors 3 numbers for tray LEDs 16 in each Terminated at back side of tester User interface 4 key touch pad sealed keyboard Facility to connect PC keyboard 16x1 large character LCD display with backlit Output on Pass is Buzzer audio Relay no potential contact rating 230V 5A and a LED Operation HAA64 has Three modes viz assembly setup and analyse Assembly mode guides the operator through assembly In setup mode component selected component s data and its name can be changed In change data data for one step can be edited or a complete new data can be entered Name of component can be changed through PC keyboard In analyse mode data for selected component can be displayed self test can be carried out and fixture rig board can be checked Assembly is carried out as explained in function above Programming new data Programming of a new data needs completely wired fixtures and point numbers where terminals will be inserted Once new data is selected data starts from step number 1 Step number will be displayed on the left hand of display In any step First available tray s LED will be on Required tray LED can be made on using up and down keys Only unselected or available tra
6. does not check it again Circuits mode can be selected on power on the nets tested in one pass if all are found correct passes harness For MSSL Circuits mode only Testing can be Automatic Auto or manual In auto mode TEST key is to be pressed once After passing a harness displays Remove Cable On removing harness from board displays Put Cable Starts testing automatically when a harness is mounted In manual mode TEST key is to be pressed for each testing Mode selection is done once by pressing LRN key when power is switched on In manual mode testing is faster Useful for harness with fewer points on testers with more points Tests extra point which is not in circuit program harness data but is on harness It can be skipped by pressing LRN key when power is switched on To be set once Facilitates two stage testing For example for fuse box First stage complete harness and second stage only fuses Does not test for extra points in second stage Switches a relay contact of 230 V AC 5A capacity on for settable time 1 to 10 seconds on for any application as stamp printing etc Options available while placing order o Small buzzer on each fault o Instead of removing complete harness to start next test start on removing a point o First stage testing twice and second once o In second stage check only for open points makes second stage program wr
7. lock key for learning a harness Cable from tester to board rig as per number of points or connectors Serial Cable with models PHTM320 PLUS and PHTM640 A CD containing DOS as well as windows based PC software for serial communication with tester and other details OO 000 0 0 0 Check for major damages in transport such as removal of certain parts bends dents etc and inform FUTURA accordingly 3 2 Installation Connect the tester with your rig as per stickers provided on rig as well as the controller Connect D type connectors at proper positions such as CON 1 2 etc The number and connectors will depend on the number and points Fix the D type connectors using small flat head screw driver Connect mains cord in socket provided tester and switch on the tester 4 OPERATION 4 1 Operating Instructions Key Definitions Key operations are as follows For any wrong key pressed message will be displayed Key LRN Learn from mounted harness Key TEST Test mounted harness and show results Key Analyse for analysis Key A Next selection command menu number Key V Previous selection command menu number Key 1 Enter accept the selection command menu number Refer figure for graphic representation of keys and menus and submenus 20 FUTURA Keys Menus and submenus Setup mode LRN pressed during power on au
8. printing option is selected and printer is not connected or is offline display will be printer not ready 4 6 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 settable time 1 to 16 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 40 4 7 Buzzer On passing a harness a ringing buzzer sounds for 3 seconds Buzzer s tone and volume can be controlled from presets at the back side Different tones can differentiate passed harnesses and to avoid confusion 4 8 Interfacing barcode scanner reader Function To read bar code on each harness before testing using a bar code reader is added A tester match this bar code with the stored one and continues if both match else displays BARCODE ERROR This ensures testing correct harness as selected program A barcode scanner with serial port can be connected to tester Serial scanner needs external power supply voltage Tester cannot supply power to barcode scanner Settings of a bar code reader are 2400 band 8 bit data 1start 2stop bits and even
9. the fault is removed The tester will pass the harness only if it finds correct harness as per selected test mode circuit by circuit or all circuits When a harness is passed in auto mode of testing tester displays REMOVE CABLE meaning remove cable harness from the rig Tester will keep on checking if the harness is removed completely When harness is removed completely the display will be PUT CABLE i e indicating that there is no harness on the board and operator should mount harness Now the harness is to be mounted Once tester finds a circuit mounted on rig it starts testing the harness and displaying first occurred fault Hence test key is required to be pressed only once to start the test Now only the next harness is to be mounted To leave test mode Analyse A key can be pressed If a harness name is entered for that cable number tester will display name in place of cable When a harness is passed in manual mode tester keeps displaying PASS and next test starts only after pressing test key Two stage testing While testing selected cable number program is taken as stage 1 and next cable number is taken as stage number 2 Tester checks for complete correctness of harness in stage 1 if correct gives a small beep along with display PASS 1 meaning stage 1 passed Then immediately starts checking for stage 2 While testing stage 2 tester only checks correct connectivity of program It does not chec
10. 0 CALIBRATION OF FUTURA S CABLE HARNESS TESTER MODEL PHTM320 11 OTHER CABLE HARNESS RELATED PRODUCTS 10 1 Harness Assembly Aid Tester HAA64 10 2 One To One Continuity Tester with Parts Counter CT121 12 FUTURA S PROFILE 1 IMPORTANT NOTES 1 1 Safety notes Safety Notes Please read before putting the system into operation This system has been checked for safe and correct functioning before being shipped In order to keep this safety the user has to pay attention to the corresponding notes and advice of the operating manual Before connecting test samples to the instrument check for strictly separation of the sample from power Any connection of the test sample to power can be dangerous for the operator and can damage electronics Before connecting test samples to the instrument check for static charges of the test sample fixtures and operator which are to be eliminated Otherwise the test electronics can be damaged Any external continuity meter like buzzer bulb or multimeter should be strictly avoided Use of these will damage the test electronic While changing the board removal and fitting of D type connectors on the back side of the tester or centronics connector on the board 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
11. 1 1 Harness Assembly Aid Tester HAA64 Function Harness Assembly aid is a tool useful for harness assembly sub assembly Basis of HAA64 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 fray and inserting terminals in housings at proper location i e points During assembly in a step HAA64 guides operator to pick parts from proper tray by glowing corresponding LEDs Then HAA64 glows LED at first point where terminal is to be inserted and blinks LED at point where next terminal is to be inserted Once correct insertion is done point s LED stops blinking and HAA64 moves on to next point in the same step If insertion is wrong then HAA64 will keep displaying fault like open and short and will not go to next step unless correct connection Once a step is complete HAA64 will move on to next step An audio signal along with relay output and visual signal will be given out when all steps are over HAA64 will start assembly of new component only when old one is removed 56 Each step is programmable for tray and points of choice Complete system consists of HAA64 a set of trays with LED at each tray along with numbers a fixture with LED at each point along with numbers Technical Specifications Power Supply 230V ac 10 AND or OR 12 V DC 800 mA Number of programmable steps 99 with 48 number of trays and 64 number of points programmable
12. 1 DATE WILL BE PRINTED AT 2 TIME WILL BE PRINTED AT 3 WEEK WILL BE PRINTED AT 94 MONTH WILL BE PRINTED AT 5 YEAR WILL BE PRINTED ITEM 01234 Futura Time 92 Date 91 Year 5 Week 93 Month 24 Pass EXAMPLE BAR CODE THIS WILL BE COMPARED WITH SCANNED LABEL NOTE EXTENSION OF FILE SHOULD BE LBL START AND END WITH NAME CAN BE OF MAXIMUM 32 CHARACTERS SAMPLE BAR LABEL Harness EXAMPLE OF HARNESS NOTE EXTENSION OF FILE SHOULD BE LBL START AND END WITH NAME CAN BE OF MAXIMUM 16 CHARACTERS SAMPLENAME General points to remember for PC connectivity e For DOS based execution files required on the drive are transl l exe receive exe transmit at Copy all these files from the floppy ro CD provided to the PC e Data to be entered should be in non document ASCII text mode using any editor word processor e Start the data entry by character and end also by a character Any matter before and after will be considered as comments and can be used to write details of harness Always use correct COM serial port By default serial port chosen is COMO If it is to be changed then open file transmit At in an editor and last line which stands for com port 0 for COMI and 1 for COM2 Change as per requirement and save in text mode only Do not modify any other data as these are the settings for serial communication Alway
13. 121 has two modes viz Setup and Test In setup mode test mode and selected component s database can be altered Available test modes are Circuits Circuit by circuit and parts counter In all circuits mode tester should find all correct connections in one pass while in circuit by circuit connection can be random and momentary It is useful for fixtures with limit switches and without locks Parts counter helps in counting parts Change Data facilitates selecting a Component out of 25nos and changing last circuit to be tested and changing name of component through PC keyboard Last Circuit informs tester to test upto last circuit CT121 finds and displays faults such as open and short along with faulty circuit numbers On correct connections sounds buzzer changes relay state and glows LED for 23 seconds and asks component to be removed Testing starts again only when component is removed CT121 is enclosed in a rugged enclosure for continuous use industrial environment 12 FUTURA S PROFILE Futura Apsol Pvt Ltd Visit www futuras com for details Sr No Futura s Products en Testers for cable wiring harness 1 1 Cable Harness Tester 320 points with serial parallel 1 2 Cable Harness Tester 640 points with serial parallel 1 3 Cable Harness Tester 960 points with serial parallel And MMI unit 1 4 Cable Harness Tester for 1024 points with serial pa
14. 2 3 6 Rig 3 INSPECTION AND INSTALLATION 3 1 Unpacking the equipment 3 2 Installation 4 OPERATION 4 1 Operating Instructions 4 2 Setting tester to test Key LRN 4 3 Interfacing with PC 4 4 Testing and Test Results 4 4 Testing 4 4 2 Error types and reporting 4 5 Interfacing Printer 4 6 Interfacing Relay output 4 7 Buzzer 4 8 Interfacing barcode scanner reader 4 9 Analysis 5 Discription of menus and user general instructions 5 Power on learn menus 5 2 Normal LRN menu 5 3 Analyse Menu 6 TROUBLESHOOTING 6 1 On power on there is no display 6 2 Display is NO CARDS 6 3 After passing a harness tester displays Remove Cable Even after removing cable tester does not display Put Cable 6 4 How to increase number of points i e capacity of tester 6 5 Tester shows point after selecting a cable number 6 6 Tester remains in receiving mode even after transmitting data from PC 6 7 Erratic behavior of tester Suddenly displays a point number which is not in the circuit Suddenly shows any error Displays card etc 6 8 After pressing Test key tester displays Receiving and hangs 7 HOW TO 7 1 How to replace I O card 7 2 How to add I O card 7 3 How to Press Replace Memory IC replace program EPROM 8 BASICS OF TROUBLE FREE OPERATION PROPER USE OF TESTER 9 RIG BOARD WIRING FOR FUTURA S CABLE HARNESS TESTER MODEL 1
15. CONTINUITY the red and black terminals on the front panel are to be used as two probe points Please refer the attached front panel diagram A pair of probes is also provided Continuity checking can be stopped by pressing any key To check rig board or cable from tester to board or I O card use this mode In check board mode the display will be BOARD 0000 The red terminal on the front panel is to be used as a probe point Please refer the attached front panel diagram A pair of probes is also provided As soon as the probe is touched to a point on the board display will be BOARD XXXX where XXXX means the corresponding I O number Board checking can be stopped by pressing any key In change cable mode cable number can be changed In this mode display will be CABLE NUMBER XX where XX stands for current selected cable number It can be changed using and keys and 1 key accepts the cable number In 2 stage testing if one stage is complete and second stage is not complete this option is not available In display data mode harness data is displayed First of all POINTS nnnn will be displayed Where nnnn are the number of points for the selected cable number The learnt data or net list as it is called can be displayed in this mode Points will be displayed one after another with a fixed delay At a time one point is displayed When the net is complete NEW is displayed After end of data O
16. VER will be displayed And tester will return to command mode In receive operator codes mode tester is ready for reception of 2 operator codes from barcode scanner After scanning operator codes it will be saved in temporary memory and can be printed on label by amp 9C After power off operator codes will be vanished 42 5 Description of menus and user general instructions 5 1 Power on learn menus After pressing LRN key on power on and key position on LRN Auto testing Testing will be done in auto mode Manual testing Testing will be done in manual mode Skip Extra pnt Disable extra point testing at harness testing Check extra pnt Enable extra point at harness testing Relay on pas Enable relay after passing harness up to settable time Relay on fail Disable relay after passing harness Set Relay on time Relay on time can be set between 1 to 10 seconds in this mode by up or down key This time will be saved in the memory so that can be retrieved after power off 5 2 Normal LRN menu To enter in to this menu before pressing LRN button key position must be on Learn position if not entry will be disabled While pressing any other key than LRN key ensure that key position should not be on LRN position otherwise operation will be failed with display KEY LOCK ON LERAN e Test Data Processing of test data e Label Data Receive label data from pc e Harness Name Receive Harness name from pc
17. as its own power supply working on mains supply The tester is a very handy unit and can be shifted from rig to rig very easily 2 3 5 Keyboard Keyboard is a sealed keyboard with six numbers dome type keys It should be pressed gently More than one Test keys are provided as it is used frequently life of keyboard increases Keyboard should never be pressed by nail 2 3 6 Rig As the testing time reduces to one to five seconds the harness mounting time on the rig becomes very significant All the harness points are to be mounted on the rig If connectors are used in a harness then time taken is very less We have developed some parts which take less efforts and time mount them on rig these points are to be brought to the D type connectors tester The errors give numbers as per D type connector s connection The same numbers are to be put on rig for easy identification of the cable Some other visual aids such as colored strips are also on rig for ease of finding location on the rig 3 INSPECTION AND INSTALLATION 3 1 Unpacking the equipment The equipment is packed in a corrugated box along with special packing to avoid transit damages Retain the packing material which is specific to your equipment Following is the list of items packed Cable Harness Tester 1 no This User s Manual 1 no Mains cord 1 no similar to PC mains cord A pair of multimeter test probes for board check and continuity check Learn
18. cuit Application can be a fixture with limit switches a connector or a coupler with open ends It does not check midjoints Tester can test for maximum of 48 96 circuits cables Last circuit to be tested is user programmable Set up allows programming of last circuit component name Last circuit can be stored for 25 different components CT121 also has parts counter to count parts on a harness using a limit switch probe Numbers of parts are programmable for 25 different harnesses along with harness name Maximum parts counted are 99 Technical Specifications Power Supply 230V ac 1096 AND or OR 12 V DC 800 mA One to One Tester Number of circuits to be tested 48 circuits i e 96 points on one module card expandable to 96 circuits using additional card Last circuit to be tested programmable by user Refer document for circuit connections Test Parameters 5 DC current in mA Tester I Os 25 pin D RA PCB mountable connectors 2 nos for from 48 circuits and 2 nos for to 48 circuits Terminated at back side of tester Parts Counter Maximum number of parts counted 99 Ninety Nine Input from a probe with limit switch using 9 pin D type connector at pin numbers 1 and 2 User interface 4 key touch pad sealed keyboard Facility to connect PC keyboard 16x1 large character LCD display with backlit Output on Pass is Buzzer audio Relay no potential contact rating 230V 5A LED Operation
19. d as displayed to cable M on board Rig F on tester use brd chk Connector no Pin no Printed Connector Pin No Printed on on connector No connector 1 1 8 1 1 2 1 15 1 2 3 1 7 1 3 4 1 14 1 4 5 1 6 1 5 6 1 13 1 6 7 1 5 1 7 8 1 12 1 8 9 1 4 1 9 10 1 11 1 10 11 1 3 1 11 12 1 10 1 12 13 1 2 1 13 14 1 9 1 14 15 1 1 1 15 16 2 13 1 16 17 2 25 1 19 18 2 12 1 20 19 2 24 1 21 20 2 11 1 22 21 2 23 1 23 22 2 10 1 24 23 2 22 1 25 24 2 9 1 26 25 2 21 1 27 26 2 8 1 28 27 2 20 1 29 28 2 7 1 30 29 2 19 1 31 30 2 1 32 31 2 18 1 33 32 2 5 1 34 33 2 17 2 1 34 2 4 2 2 35 2 16 2 3 36 2 3 2 4 Number card 36 Centronics Connector connected to as displayed cable M on board Rig F on tester use brd chk Connector no Pin no Printed Connector Pin No Printed on on connector No connector 37 2 15 2 5 38 2 2 2 6 39 2 14 2 7 40 3 13 2 8 41 3 25 2 9 42 3 12 2 10 43 3 24 2 11 44 3 11 2 12 45 3 23 2 13 46 3 10 2 14 47 3 22 2 15 48 3 9 2 16 49 3 21 2 19 50 3 8 2 20 51 3 20 2 21 52 3 7 2 22 53 3 19 2 23 54 3 6 2 24 55 3 18 2 25 56 3 5 2 26 57 3 17 2 27 58 3 4 2 28 59 3 16 2 29 60 3 3 2 30 61 3 15 2 31 62 3 2 2 32 63 3 14 2 33 64 3 1 2 34 Above details be used to repair correct or to make a new cable from tester to board rig It can also be used to add ne
20. e Read Barcode Save barcode from pc e Set Date and Time Receive date and time from pc e Set or Reset 2 Barcode on Enable or Disable 2 barcode mode 5 3 Analyse Menu e Check Continuity Checks continuity in this mode use probes e Display Data Displays harness data present at that cable number 43 Change cable number Navigates through cable number 1 25 and selects it Pass count Displays Pass count Board check Checks board at every point Operator codes Facility to scan two operator codes 6 TROUBLESHOOTING Futura Apsol Pvt Ltd is not responsible for any modifications done in tester circuit without consultation with Futura or by an unauthorized person General CHT tester is thoroughly tested before leaving the factory It is recommended that in case CHT fails the user should follow the troubleshooting guide before contacting FUTURA Proper use will prevent CHT from failures Frequently Asked Questions FAQs 6 1 On power on there is no display Check for loose power supply cable i e mains cord input mains plug as well as socket eCheck Fuse 750mA normal If burnt replace with spare one available in the fuse holder 6 2 Display is CARDS eSwitch off the supply press the I O card s Switch on the supply eswitch off the power supply remove I O card s and clean the edge connector on card s using trichloroethylene or CTC Insert the I O card s properly and check the teste
21. e setup harness data date time label data barcoded number harness name two barcode on flag etc TEST Start testing of harness Enter Accept command Keys Meaning A Analyse continuity board check and display count change cable number display harness data Next command number v Previous command number Cable Harness Tester PHTM320 Front Panel Futura Apsol Pvt Ltd Pune 411 004 India DOC NAME Cable Harness Tester HTM320 front panel DOC NO HTM320FP DRN BY GSR DATE 18 4 03 DIMIN SCALE MOD MOD MOD PAGE OF 15 pin D type M Points 1 15 DS pin D typ Points 16 39 gt 25 pin D type Points 40 64 Futura Apsol Pvt Ltd Pune 411 004 India I O cards Presently 2 nos Tester capacity 128 points Each card for 64 points Provision for 5 I O cards in PHTM320 and 10 in PHTM640 Fuse also an additional fuse is given inside Mains power Mains supply Input Switch Relay output Potential free 230Vac 5A Cable Harness Tester PHTM320 640 Back Panel DOC NAME Cable Harness Tester HTM320 640 back panel DOC NO HTM320BP DRN BY GSR DATE 18 4 03 DIMIN SCALE MOD MOD MOD PAGE 1 0F 1 2 2 Specifications Function The Cable Harne
22. echanical Dimensions 388 mm x 260 mm x 222 mm 2mm Weight Approximately 7 5 Kgs Rust and scratch proof Powder coated 2 3 Tester The tester is digital signal controller based unit Refer Figure 1 2 for a view of tester It has facility to connect five add on cards One card is the minimum configuration and it can test a harness with 64 points By adding one card the capacity can be increased by another 64 points in the same manner maximum capacity can be 320 640 points with 5 10 cards The tester stores the data into memory and compares it with the tested data If any error is found it reports through the 16 character LCD display It also recognizes the key pressed and functions accordingly PHTM320 PHTM640 PHTM960 Maximum number of points 320 640 960 Max 5 I O cards Max 10 I O cards Max 15 I O cards In step of points 64 64 64 Maximum Number of harnesses stored in 25 25 25 EEPROM or battery backed RAM Enclosure Size approx in mm 388 L 260 D 222 H 2 500 L 260 D 222 H 2 500 L 260 D 222 H 2 2 3 1 Testing Features Tester will display the first occurred fault and will be scanning the harness continuously and hence keeps on displaying the first occurred fault Tests and displays open point open net shorted net interchange i e miss location and extra point By default tests net by net starts with first net if found correct
23. ed error Tester can analyse and report four types of errors as follows Open point OPEN If a point xxxx is completely open look at point xxxx Interchange LOCN xxxx yyyy If location of a point xxxx is wrong or interchanged and is fitted to point yyyy Interchange xxx1 yyy1 xxx2 yyy2 If interchange has occurred between two nets of two points each tester cannot locate exact interchanged point It displays both possible interchanges Open group OPEN xxxx In case of two point net from xxxx to yyyy or if some wires with point from a circuit starting with point xxxx get disconnected Check only for Short group SHORT xxxx yyyy etc If a circuit net with first point xxx get shorted with a circuit net with first point Extra point EXTRA If a point is not in the net list but it is connected to tester 4 5 Interfacing Printer A standard centronics port on DB25 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 abel 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 25 different data can be stored in tester s memory For each cable type 1024 bytes are reserved
24. er based stand alone unit and Hence testing speed has been enhanced as compared to older version Time taken to test depends on factors such as selected mode auto manual extra point test number of points etc Minimum test system consists of Harness tester with mounting board rig Complete test system consists of tester a mounting rig solid state Floppy PC printer or stamping unit Harness tester is connected to the Rig Jig through D type connectors Any point on rig can be connected anywhere meaning there is no From and To concept This simplifies the rig wiring to a great extent This concept also facilitates in indirect saving of space by accommodating different types of harnesses on the same mounting rig While designing the rig care should be taken that all the end points or mountings of all harnesses are taken on the board Each mounting is connected to the tester A harness is mounted at particular mountings while learning the data as well as testing The harness to be tested is mounted on the rig and then tested through tester The errors can be seen on tester s LCD display Learn Lock Key provided to be used to unlock Learn can be pressed after unlocking only Prevents unauthorised changes in data Terminals for probes provided Red Manual Continuity board check Black Manual continuity Keyboard with 6 nos dome type keys LRN Learn Load chang
25. er on Page 2 No of stages x No key Change no of stages Enter m B of stages x Up Down Enter Clear Count 05 Seconds Enter Count Cleared Label printing off Label Printing on Print Label 5 Seconds Off Print Label 5 Seconds Enter Enter Print Label on Print Label off Enter Cleared PUTURA Power on Page 3 Barcode matching a incu Matching on Match Barcode 5 Seconds Bar Reader on Enter Bar Reader on Enc m d Command required settings are over and ready to accept command like test or learn or analyse FUTURA Test Data Enter Board to Data Enter Learn Enter Learning P 2 Bar DN Set2 Reset 2 Bar On PC To Hrn Data Enter Receiving Enter Enter DN UP 2 Baron 2 Bar off Hrn Data To Printer Enter Sending we DN UP DN UP Hrn Data To PC Enter Sending Label Data Enter Receiving DN UP Set Date Time Enter Receiving N UP Read Barcode FUTURA 2 Baron 2 Bar off Enter Receiving Bar 1 Receiving Receiving Bar 2 B cu d DN UP Disable Barcode Enter Bar Reader Off DN UP Harness Name Enter Receiving Test starts testing selected harness FUTURA Keys Menus and submenus TEST Starts testing selected harness stops at first fault displays faults Buzzer relay on pass A Le ANALYSE Check Continuity Enter Continuity DN UP Dis
26. for label 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 week 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 92 is to be placed etc To print special characters or bar codes first of all printer has to be finalized Label or bar code printers accompany label printing software which generates an ASCII 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 In Printing of labels Following are special characters to be used 1 Date Complete date in dd mm yy format Q2 Time hr mm ss 23 Week 94 Month 25 Year 6 6 Serial number numbers between 26 26 indicate serial no size Maximum serial no size allowed is 9 Foe ex 600001 26 5 00001 digit serial no is initialized special case 6000000 only six digits allowed for making compatible with old HTM For entering serial number enter 2 nos less than the first label as it prints sample label 7 Repeated serial number 8 Date 29 Not applicable A Not Applicable B Operator Codel Operator code 2 If label
27. iting as any two shorted points Random data entry of second stage 2 3 2 General Features Self test by pressing any key and switching on power without harness mounted on the rig board Tests for any shorted points on the board and displays shorted points if any Else displays Pass and switches on relay and sounds buzzer Based on digital signal controller based advanced technology which increases speed reliability and performance e Printing of labels on passing a harness on any parallel port printer Label s text is user programmable maximum of 4096 characters with real time date time week month and year Option can be set on or off after selecting Harness under Test which is remembered by tester e Read barcoded label on a harness before testing each harness compare it with loaded barcode and test only if both match Option can be set on or off after selecting Harness under Test which is remembered by tester Two barcode option is also available read two different barcodes before testing each harness compare them with loaded barcodes and test only if both two match Option can be set on or off through LRN menu A harness named up to maximum 16 characters e Printing of harness data on a printer e Uploading harness data to PC Check continuity of a harness manually Check rig board as a part of periodic performance check Download harness data label data harness name barcode etc f
28. k for extra points Displays faults in the harness as per stage 2 program When stage 2 also found correct first a small beep and PASS 2 will be displayed then a long beep and PASS XXX where 15 the pass count for selected cable number Now display will be REMOVE CABLE and CABLE as usual On PASS a no potential relay contact of capacity 230V 5 Amperes is provided The contact is on for selected time when a harness is PASSED This can be used to activate stamping unit or a label printer can be connected to print necessary labels by switching on the option ringing buzzer on PASS is provided with volume as well as tone control to identify PASS signal Volume and tone control can be adjusted using a small screw driver from the back side of the tester NO POINT will be displayed if TEST key is pressed without data in the memory of the selected harness number While viewing the errors user can test harness again by pressing TEST key Test key operation In Auto mode of operation once in Test mode Test key pressed again will not be acknowledged Only A key will be acknowledged manual mode for every test Test key is to be pressed VIMP Key lock should be on Lock while testing 4 4 2 Error types and reporting Tester will display the first occurred error and will be scanning the harness continuously and hence keeps on displaying the first occurr
29. n PC with minimum Windows 95 as operating system using setup exe This will create futura as group TCHT version 1 01 is executed as any other windows program Selection of correct communication port com port is important Connect PC to tester using serial cable 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 tester end Y end is connected to a COM port on PC To load from PC to tester a file has to be created For harness data filename extension required is hrn and for others extension required is lbl 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 test file and it should have proper extension Set tester in appropriate receiving mode For DOS based execution run trans l exe or tmssl exe program in DOS mode Where it will ask for filename Give the filename and press enter Data being transmitted will be displayed on the PC screen and after receiving the data tester will be ready to accept any command Data can be verified by using display data mode After receiving a label data if printer is connected tester will print one label to verify For windows based execution TCHT will ask to select task and then to select file For harness data only hrn files will be displayed and for others only will be displayed TCHT can also be u
30. n every power on these have to be entered loaded Operator codes are entered through barcode scanner connected at the back side of tester to serial port Communication parameters for operator barcode scanner are same as that for label barcode scanner i e 2400 band 8 bit data Istart 2stop bits and even parity Scanning is in Analysis mode i e on pressing key In label printing prints first operator code and prints second operator s code Operating sequence e Label data has 9 B and C at proper places where operator s codes are to be printed e Label data is transmitted to tester in the same way e When operator code is to be changed A key is pressed Display is Check Continuity Down Arrow key displays Operator codes e Enter accepts command and display is Receiving code 1 e First operator s code is to be scanned by barcode scanner e Display is Receiving code 2 e Second operator s code is to be scanned by barcode scanner Both codes are displayed e Tester displays command e Tester is ready for any command 2 INTRODUCTION 2 1 Description of the system Futura s Cable Harness Tester CHT is designed to test Cable Harnesses Cable Looms Cable Forms CHT locates interchanged connections shorted connections open connection and extra points CHT facilitates two stage testing of harnesses CHT is a 16 bit Digital Signal Controll
31. number which is not in the circuit Suddenly shows any error Displays card etc e Check for proper earthing at the power supply input point of tester It should be proper voltage in L and N and similar voltage in L and earth and less than 8 V in N and earth 6 8 After pressing Test key tester displays Receiving and hangs e It means barcode reader option is switched on To switch off press LRN up or down till display is disable barcode Press enter display will be bar reader off 6 9 After passing of harness tester displays No Points or instead of Remove Cable e Chek no of stages selected for the respective cable number if 2 stages are set then make stages 1 6 10 After passing of harness tester remains Pass xxx instead of Remove Cable e Check mode of testing if Manual mode is set change it to Auto mode Through power on learn key 6 11 Tester is not getting powered e Check the condition of fuse if found burnt then replace it with additional fuse given with socket 46 7 HOW 7 1 How to replace I O card Switch off tester Remove mains cord Remove these 2 screws near edge Back view of tester If it cannot be removed then Remove this plate with I O PCB remove this second plate first by Remove PCB from plate and replace with new PCB and 47 7
32. o data DATA TO PRINTER meaning data to printer HRN DATA TO PC meaning gt data to PC Same commands can displayed by pressing in reverse order command is accepted by pressing J key Board to data command will ask LEARN To learn the harness data put known good harness on the rig Press J to accept the learn command Now display will be LEARNING POINTS nnnn Number of points learnt is nnnn Hence if nnnn is less than the actual number of points points are missing due to some reason After that COMMAND will be displayed and tester will come in to idle position PC to data will load a data from file on PC to the selected harness number through serial cable Press J to accept the command and now the display will be RECEIVING meaning receiving this ensure using correct port COMI correct cable given with the tester correct software on PC More details are in the following sections Run programme in DOS mode on PC where it will ask for filename Give the filename and press enter Data being transmitted will be displayed on the PC screen and after receiving the data tester will be ready to accept any command Data can be verified by using display data mode Windows based programme also can be used If two stage data is transmitted from PC to tester 2 stage testing is automatically set and need not be set through keyboard It will be set as per data transmi
33. parity And data can be 1 to 16 digits in length and only bar code in ASCII without any other characters Testing should start without harness During testing when test key is pressed display will be RECEIVING and waits for bar code data on RS232 Once received compares with stored bar codes If a match is found then continues testing if codes do not match then displays bar error When harness is tested and passed display will be REMOVE CABLE Bar code should be scanned only when message is Receiving Tester will not recognise if scanned otherwise Label printing option if required should be made on and remains on even if program is changed through bar code reader until it is switched off If tester is in two barcode on mode then before testing it will scan two different barcodes and enters in to testing only when both barcodes matches 4 9 Analysis In analysis mode i e key A available functions are CHEK CONTINUITY to check continuity CHECK BOARD to check board COUNT to display pass count CHANGE CABLE NO to change cable number and DSP DAT to display data OPERAOTR CODES to receive operator codes and V keys facilitate selection of functions and on pressing J key accepts that function In case of count display J key is not required 4l To manually check continuity in a harness use this mode In continuity checking mode display is
34. play Data Enter Board 0000 Display Harness Data DN UP Count NNN Pass Counter DN UP Change Cable number Enter Cable No 00 DN UP Check Board Ente Rig Cheking Operator Codes Enter Read through scanner 4 2 Setting tester to test Key LRN Learn Lock key position For LRN key operation tester checks for key switch on Learn position For any other key operation tester checks for key switch not on Learn position If it is then displays Key lock on learn and then command Sequence of operation should be Key switch on Learn Press LRN key Display is TEST DATA Bring back key switch on LOCK position Press other keys Key switch is put on LEARN to learn or change the data On pressing key LRN display will be TEST DATA meaning test data By pressing A keys displays will be SET OR RESET TWO BAR LABEL DATE TIME READ BARCODE DISABLE BARCODE HARNESS To accept test data command press 1 Accepting test data means now test data can be learnt from the board as or data can be received from a file in PC or data can be printed on a standard centronics printer or data can be transmitted to PC for storage Initially display will be BOARD TO DATA meaning board to data Press A for next commands and the displays will be TO HRN DATA meaning PC t
35. r 6 3 After passing a harness tester displays Remove Cable Even after removing cable tester does not display Put Cable e Jt means that tester finds some points internally shorted even if harness is removed e Conduct self test after removing harness from the board Tester will display shorted points Check these points on the board e If problem persists separate board from tester at board end and conduct self test Check for shorted points from tester to board e If problem persists remove cable from back side of the tester and conduct self test Check for shorted points and replace appropriate I O card Refer 5 10 1 How to replace I O card 45 6 4 How to increase number of points i e capacity of tester e Capacity of PHTM320 is maximum 320 points and PHTM640 is maximum640 points e If tester has less number of cards than its maximum capacity it can be increased by adding an I O card in the next available slot Refer section 5 10 2 How to add I O card 6 5 Tester shows point after selecting a cable number e Press memory IC 24c512 in tester in which all programs are stored 6 6 Tester remains in receiving mode even after transmitting data from PC e Check connection of serial cable Y end to PC and single end to tester e Replace serial cable e Check communication port number selected and connected and working COM port com2 6 7 Erratic behavior of tester Suddenly displays appoint
36. rallel CHT Enhancer attached 1 5 Add on I O card for 64 points 1 6 Testing Rig to mount harness One to one continuity tester with parts counter 2 1 One to One continuity tester for 48 circuits 2 2 One to One continuity tester for 96 circuits 2 3 One to One continuity tester for 6 circuits 2 4 One to One continuity tester for 10 circuits 2 5 Clip Assembly Aid 2 6 One to One continuity tester for 32 circuits Harness Assembly Aid Harness Assembly Aid for 64 points and 48 trays 3 2 Harness Assembly Aid for 64 points and 48 trays with pull test 3 3 Harness Assembly Aid for 96 points and 96 trays with 10 pull test Data Collectors converters 4 1 Gauge Link 4 2 RF to RS232 converter 4 3 Solid State Floppy Automatic Test Equipments Systems for 5 1 Transformer cut toroidal cores 5 2 12V DC fans 5 3 Relays 5 4 Timers 2 9 Capacitor discharge welds 5 6 Fuel gauge 5 7 HT Coil 5 8 Pick up coil 5 9 Cockpit dashboard 60 Switch Testing 6 1 Switch Harness tester without load 6 2 Combiswitch tester switch test with load 6 3 Switch test endurance 6 3 1 Programmable load power supply 6 3 2 Waveform Capture Computer Peripheral 7 1 Printer sharer A
37. rom a PC Using DOS as well as windows based software Relay on time is settable through software 1 to 10 sec 2 3 3 Harness Data Circuit Data Tester stores harness data in its memory which is retained even on power off Type of memory used is EEPROM Earlier BBRAM Battery Backed RAM was used Harness data can be loaded either by self learning or downloaded from PC s serial RS232 port The tester can store data for twenty five harnesses Harness data in Cable number 0 cannot be stored on power off Hence tester can test twenty five fixed types of harnesses and one general type of harness The tester counts the number of points learnt or loaded from PC and displays them to help learning as well as loading Tester also displays and compares the stored number of points and actual number of points in a net list programmes when a cable number is selected If they are not same the tester displays error and disables test key This facility confirms the correctness of data in memory 2 3 4 Input Output cards I O cards I O cards are connected to main controller unit and controller controls them all Controller finds out the number of cards present and then displays results accordingly Add on card can be added at any time without changing hardware or software At one edge of I O card two D type 25 pin male connectors and one D type 15 pin male connector is provided These are the points to be connected to rig Tester h
38. s connected to I O cards at the back side of tester so that I O cards are not pulled Fastening of all dust covers of connectors at I O cards to hex nuts of I O cards Using proper tool to set tone and volume control Using key provided to unlock Leann s lock and not using tools like screw driver Using built in manual continuity checker for checking continuity of harness only and not for any other purpose Using keyboard properly Pressing single key at a time Pressing keys using fingers and not nails tools etc Taking care not to damage keyboard physically 9 BOARD WIRING FOR FUTURA S CABLE HARNESS TESTER MODEL PHTM320 As Future s Cable harness tester does not have from and to concept for wiring the board or rig it is very easy and simple to wire a rig Refer to the attached figure for connector details Each I O card has three connectors specified as 15 pin D type M 25 pin D type M 2 nos For wiring the rig required connectors are the opposite connectors Hence for 64 points required connectors are 15 pin D type 1 number and 25 pin D type 2 numbers The I O point s number 1 to 64 is numbered as shown The meaning is that if a terminal on harness is connected to I O point number 5 on card through rig then while showing fault or net list or board check that point will be referred to as point number 5 In Future s PHTM320 each and every point acts as from or to Hence to wire the rig circui
39. s put the receiving item in receive mode first and then press ENTER to transmit data Connect the cable correctly as marked on cable Harness Data e Harness Data files should have extension FILENAME HRN First number should be number of points in the following harness data If this number and actual number of points do not match then tester gives error Data is to be entered net by net each net separated by a carriage return and line feed i e press ENTER after every net only End the data with on the last line Each point is separated by a space i e type space between each points Any other character will not be recognised by tester Label Data date time barcode harness name etc e Files should have extension FILENAME LBL Label Data can be an edited file or a pure ASCII file generated by a label printing software Preferably file size should be less than 200 bytes for each harness 4 4 Testing and Test Results 4 4 1 Testing Press TEST key and wait till display CABLE after that mount the harness to be tested on the rig The display will be PASS nnnn with audible beep sound for good harness along with the count or directly errors details in following section will be displayed for faulty harness For a faulty harness the tester will stop at first occurred fault and test the same harness repeatedly and keep on displaying the same fault It proceeds only when
40. sed to create and edit hrn as well as files Details of TCHT screen and sample files are as follows m FUTURA ELECTRO DESIGNERS Select Task here TE Asa YA 2 9 chip Gy Exploing Csbe ELECT 94 Sample files Harness Data FILE EXTENSION SHOULD BE HRN THIS IS DUMMY DATA FOR A HARNESS NOTE HASH CHARACTER AT THE START AND END FIRST LINE IS NUMBER OF POINTS EACH POINT IS SEPARATED BY A SPACE NEXT LINE STARTS ONLY FOR NEW NET CIRCUIT NO SPECIAL CHARACTER HERE IN NET CIRCUIT POINTS IN ASCENDING SMALL TO BIG ORDER ALL STARTING POINTS OF NETS CIRCUITS IN ASCENDING ORDER 35 167790 245 8991 120 190 211 234 256 278 280 290 300 540 555 600 601 602 623 350 78 9 10 11 23 13 15 56 This is second stage 34 amp 126507790 39 Date Time FILE EXTENSION SHOULD BE LBL 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 HASH CHARACTER AT THE START AND END For Example On date 3 rd January 2000 and time afternoon 3 07 09 String will be 030100150709 For 2000 and onwards enter year in two digits only Tester will print year in four digits ddmmyyhhmnss 8030100150709 Label Data EXAMPLE OF LABEL DATA NOTE EXTENSION OF FILE SHOULD BE LBL BLANK LINE WILL BE PRINTED AS BLANK LINE AT
41. ss Tester tests a harness under test by checking each point with each other point compares the net list with the stored net list and displays the result If the net lists match then displays PASS else displays the faults and the associated number Faults searched for and analysed and displayed are open point open group short group location interchange and extra point Net list is stored by learning a good harness or from PC through serial It also has a analyse function for continuity checking board checking displaying pass count changing cable number and displaying the learnt data e Power supply Supply Voltage 230 V AC 50 Hz 10 Power consumption Maximum 10 Watts Fuse 750 mA normal e Inputs Test voltage 5 V DC Test current In mill Amperes e User Inputs Keyboard input Dome type dust proof keys with good tactile feedback Number of operations One million Number of keys 6 nos e User Output Display Output Display used 16 character LCD display with backlit Buzzer audio output on pass with tone and volume control Potential free Relay output up to 230V AC 5A load Piezo Buzzer for continuity Interfaces PHTM320 PHTM640 PHTM960 Printer Centronics parallel port for printers Can print learnt data and label on Pass PC Standard RS232 serial at 2400 baud no parity 8 bit data 1 start 2 stop bits through a PC e Environmental Working temperature 0 50 e M
42. sses These are connected to the tester Many points can be made parallel by proper selection Different templates for different harnesses can be made for easy mounting Each template has visual indications for mounting the harness The only important point is that while testing the harness has to be mounted in the same way as it is mounted while testing Different harness data is stored at different memory locations This data i e net list is noted down and cross checked before the testing starts Now the test system is ready to test multiple harnesses For testers with more than one card the I O points are above 64 i e in second card points are 65 128 third card 129 192 fourth card 193 256 and fifth card 257 320 The sequence of points is same as that shown in figure i e for 1 64 points Only that number of in the tester is to be found then find the point number from 1 64 say p and add 64 n 1 to p and the addition gives exact point number This way Cable Harness Tester PHTM320 can be connected to the rig and fully points are to be added per number of cards present to get actual point If point in n th card utilized Connection details for I O card to 36 centronics connector i e cable wiring details from tester to board Number I O card 36 Centronics Connector connecte
43. t of harness is not taken into consideration and any point can be connected anywhere While learning the tester takes care of the circuit One most important point to consider is that each and every terminal on the harness has to be connected to the tester through rig Layout of harness on the rig size of the rig position of tester etc can be as per one s convenience After wiring of the board visual indications at each mounting point can be pasted The details such as wire color wire number from the drawing corresponding number associated with tester it should be prominent etc can be pasted The final board check can be done to ensure correct connections of rig to the tester Now the complete harness test system is ready The master harness is mounted properly Cable number where the harness data is to be stored is selected and the data is learnt Learnt data is seen on display using analysis and display data function and is noted down First step is to confirm number of points as expected This data is the net list of the harness The noted data is cross checked for required data by checking wire color Now the test system is ready for testing harnesses Another advantage of PHTM320 is that since it does not have from and to concept one rig can be designed to mount different types of harnesses For this purpose all the required harnesses are to be collected and a board is designed to have all the end points of the harne
44. to Me manual MANUAL TESTING Enter AUTO TESTING Enter SET MANL TESTING SET AUTO TESTING Skip Extra point testing CHECK EXTRA PNT Enter En SET CHECK EXTRA SET SKIP EXTRA KIP EXTRA PNT ter FUTURA LRN pressed during power on Relay on fail Relay on pass RELAY ON FAIL RELAY ON PASS Enter Enter SET RELAY ON FAIL SET REALY ON PASS Printer Ready CHK PRN READY SKIP PRN READY nter Enter ON OFF No k diii Set relay on Enter time Up or Down Relay on time xx Proceeds for further Enter operation Proceeds for further operation FUTURA Analyse key pressed during power on without harness mounted on the rig board Self Test mode Tests for any shorted points on the board No shorted points Shorted points found Displays pass relay and buzzer on Displays error and shorted points Operation Halted To restart Continues with normal operation Switch off and on again PUTURA Power on Page 1 Keys Menus submenus Power On FUTURA VER XX Cards xx All Circuits Enter Set Circuits Cable No 00 DN UP Cable Number increments decrements upto maximum minimum If Harness Name is stored displays name instead of Cable No Enter No point if empty memory Compares actual number of points and stored ones If match found Points nnnn number of points in memory for selected cable number Else Points Error FUTURA Pow
45. tted from PC If 2 stages are on and a cable number is selected tester displays no points in second stage also If two stage data is transmitted from PC to tester 2 stage testing is automatically set and need not be set through keyboard If label printing is on for a cable number serial number can be cleared and made to print from 000001 for regular and O01 for Tester asks CLEAR SERIAL NO if ENTER is pressed serial number is cleared and display is CLEARED Data to printer will print the net list or stored data for selected harness number on a standard printer which is used with PC Same cable can be used to connect printer to the tester where printer connector is marked Data to PC will transmit the data for selected harness number to PC through serial port Serial cable should be connected from PC to tester Before pressing J on tester run program receive exe on PC in DOS mode Enter the non existing filename to store the data PC will display the received data and store it in the file 4 3 Interfacing with PC To load harness data label data date barcode harness name etc PC has to be interfaced with tester Harness data can be transferred from tester to PC Load software from floppy or CD provided with tester DOS based programs are transl l exe or tmssl exe to transmit from PC to tester and receive exe from tester to PC Windows based program is TCHT It has to be installed o
46. uto 4 1 3 2 Printer sharer Auto 2 1 7 3 Printer data switch manual 1 2 7 4 Printer data switch manual 2 2 7 5 Printer data switch manual 4 1 Electronic Scarecrow EBU 8 1 Electronic Scarecrow for animals 8 2 Electronic Scarecrow for birds 8 3 Electronic Scarecrow for animals and birds 8 4 Electronic Scarecrow deluxe Tapeless Recorder 9 1 Music on Hold TLR90 9 2 TLR90 with recording 9 3 Museum Guide 10 Electrical Test System for Automobiles ETSA 11 Automobile Regulator Calibrator 12 Electronic Shouter 13 PC based Harness Assembly Training 61
47. w mountings points to the board with centronics connectors on board rig Similar configuration is used for higher numbers 10 CALIBRATION OF FUTURA S CABLE HARNESS TESTER MODEL 320 Since the certification such as ISO QS IS etc are important the calibration of the testing equipment is also important 1 As the tester compares data or connections of a standard harness with the connections of Harness under Test calibration is not required 2 PHTM320 does not measure any absolute quantity hence calibration is not required 3 To confirm functionality of the test system i e test equipment along with test rig following procedure can be repeated after fixed period say 3 months or 6 months To check the contents of memory display data in analysis mode is used and the data is confirmed against the data net list written down by hand after initial learning procedure of the harness or printed data attached in user s manual if the board is supplied by Futura It will be a good practice to file the master data for each harness Time taken will be 5 minutes for each harness type Tools required are none B To check functionality of the equipment and the board check board facility in analysis mode is used and every point on the board is checked Time taken will be 10 15 minutes Tools required are test probes provided with the equipment 11 OTHER CABLE HARNESS RELATED PRODUCTS 1
48. y LEDs will be on Once selected to programme the same enter key is pressed Now again first available tray s LED will be on for selection Hence a step can have more than one trays After completing selection of trays in that step escape key will switch to learning circuit for the step Now first available point LED will be on Selected point will be end or starting point of circuit It can be selected by using up and down Once finalized remaining terminals are to be inserted at respective locations As soon as terminals are inserted corresponding LEDs will be on After insertion of complete circuit key will store circuit data in memory It completes programming of a step Immediately tester will move on to next step To stop programming escape key is pressed twice Editing a step asks to select a step to be edited and then same steps as programming a step are to be followed Self Test In self test all LEDs will glow one by one for visual inspection and tester searches for all points open If open then passes self test else asks to remove component Escape is used to change current mode to parent mode Only while programming it changes from tray to points HAA64 is enclosed in a rugged enclosure for continuous use industrial environment 58 11 2 One To One Continuity Tester with Parts Counter CT121 Function One to One continuity tester is to test point to point continuity of a cir
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