series 90 series 90ry - cablescancablescan.com/download/manuals/archive/series 90...high voltage...

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CABLESCAN

SERIES 90 & SERIES 90RY

REFERENCE MANUAL

SECfION 4.0

TEST

October 7, 1993

4.0 Test Page ii

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4.0 Test Page iii

• TABLE OF CONTENTS

INTRODUCfION .................................................................................................... 1

DISCUSSION .................................................................................................. 1

TEST SCREEN ............................................................................................... 2

KEYBOARD OPERATION ........................................................................ 2

TEST MODES ........................................................................................................... 3

TEST ................................................................................................................. 3

LOOP TEST ..................................................................................................... 6

LOAD PROGRAM ........................................................................................ 8

TEST OPTIONS ............................................................................................ 10

PARAMETERS ............................................................................................ 11

• USER LOG IN .............................................................................................. 13

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4.0 Test Pageiv

4.0 Test Page 1

INTRODUCTION

DISCUSSION

Test modes are used to perform tests on completed assemblies. The assemblies can be tested in a variety of ways depending on the settings of the test options. This section covers loading and running single and loop tests. Test options also are discussed, but for a complete description refer to the Options section.

Before a test can be run, the assembly to be tested must be connected to the Series 90. This requires a test fixture for holding the assembly, interface wiring and connection for each electrical test point of the assembly, and adapter cabling to connect the test points from the scanner board connectors to the interface wiring.

Use interface cabling that can be quickly disconnected at the fixture end when changing fixtures. This eliminates excessive wear on the Series 90 scanner board connectors. In applications where the tester is used on a number of fixtures, a ZIF (Zero-Insertion-Force) type of connector is recommended. The ITT Cannon DL series is an example of a ZIF type connector. For the Series 90 the DLl-156 can be used to accommodate the two 64-pin connectors on each scanner board. The DL2-96 can be used with the Series 90HV to accommodate the two 32-pin connectors on each high voltage scanner board.

The Test screen is entered through the Run category window from the main screen. From the main screen, move the category highlighting bar to the Run selection, which then displays the Run window as shown below.

Cablescan Series 90 / Series 90HV

[ Run

Test Sui ld Statistics

User Log In

Print Program

Copyright 1992, CABLESCAN, INC.

System Options

i"""'"'------------------- 8:05:30 Use intensified letters to make your selection.

Use Mouse or Arrow Keys to Select, ... ..1 Enter' to Execute. Fi for Help

to

4.0 Test Page 2

TEST SCREEN

A Test screen is displayed when Test is executed from the Run category of the main screen. The Test screen is used for running the Test modes. The Test Modes window is shown below.

Cablescan Series 90 I Series 90HV CONDITION CIRCUIT INFORMATION

[ program name MEASUREMENT MIN

TEST MODES

Test Loop Test

MAX

Load Program

Test Options Parameters

User Log In

The Test Modes window provides selections for six test or test-related operating modes:

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Test, Loop Test, Load Program, Test Options, Parameters, and User Log In. Test and Loop Test perform the actual tests on connected assemblies. Test Options and Parameters provide windows to change how tests are performed; normally they are used for setting up • special test conditions. Changes made from these windows default back to the original settings when a program is loaded or when returning to the main screen. User Log In allows an operator to log in for access, when using passwords.

After testing is complete, pressing ESC reopens the Test Modes window. Pressing ESC when the Test Modes window is opened displays an Exit Test Modes prompt window for returning to the main screen.

KEYBOARD OPERATION

Keys used when the Test Modes window is opened and while testing from the Test screen have the functions as defined below:

TEST MODES WINDOW T Test E Loop Test P Load Program o Test Options M Parameters L User Log In ESC Exit Test Modes

TEST SCREEN ENTER Start a Test or Continue ESC Halt Test ESC Return to Menu Screen Keys Numbers & Letters - Serial # + Increment Serial or Job #

Fl F2 F3 F4 F5 FlO

Decrement Serial or Job # Help - Display Key Definitions Open Job Number Window Probe - Identify Mode Print Test Results Print Label Hide Serial Number Window •

4.0 Test Page 3

TEST MODES

TEST

When Test is selected on the Test Modes window, one complete scan is performed on the assembly under test. Each continuity is compared against the wire list program loaded into the Series 90. If a program has not been loaded prior to executing Test, the Series 90 will automatically execute the Load Program mode described later in this section. After the wire list program is loaded, the selected mode is run. How the test is performed and how the test results are displayed depend on the test options. For details on the test options see the Options section.

High Voltage Tests

When a high voltage test is selected to be run on the Series 90HV, the low-voltage continuity and shorts tests are run first. The high voltage test is then run only after the tests passed. High Voltage tests are controlled by passwords for operator safety. If a high voltage test is attempted before passwords are enabled, the test stops and a high voltage warning message is displayed and a password prompt window is opened. To run the high voltage test, type "HANDS OFF," verify that no one is touching the harness, and press ENTER. Passwords can be used to allow only certain operators to run high voltage tests, or the prompt window can be eliminated for well controlled test areas. For details on setting up passwords, see the System section.

RUNNING A TEST

1. Attach the assembly to be tested to the interface fixture.

Note: Before a test can be performed, a wire list program must be created and saved on disk. This can be performed using the Learn-Known-Good function or entering a program through the keyboard using the Program Editor. Details on these two functions are located in the Programming section of this manual. A separate Programming Manual is provided for using the Program Editor.

2. Move the highlighting bar to Load Program, using the down arrow, and then press ENTER.

3. Load program, following the instructions provided later in this section on the Load Program mode. When the program has been loaded, the program name will

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be at corner of the screen. This will be

test determined by the options

anew

4.0 Test


TEST PASSED

[ program name MEASUREMENT MIN MAX

Page 4

6. If a high voltage test is being run on a Series 90HV, the following warning message will be displayed.



!!! WARNING !!! HIGH VOLTAGE Test in Progress

Enter User HV Password

Password:

MAX

7. If the Password window opens, enter the password that enables high voltage testing. If passwords have not been enabled, type HANDS OFF, and press ENTER.

8. Detach assembly from test fixture.

9. To test another assembly of the same configuration, attach it to the fIXture and press ENTER. Each time ENTER is pressed after the end of a test, a new test is performed.

10 If the serial number option is enabled, a Serial Number Entry window will open to allow a new serial number to be entered. (The + and - keys can be used to increment or decrement the current serial number.) To retest the assembly press ENTER without changing the serial number.

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4.0 Test Page 5

11. After tests are completed, press ESC to return control to the Test Mode window.

12. Observe that if an error is located during one of the tests, the error is displayed. The tester can be programmed, through the Test Options, to pause either after displaying each error or after displaying a page (screen) full of errors, as shown in the following screen. To continue testing after the pause, press ENTER. Pressing ESC while paused terminates the test.

Cablescan Series 90 / Series 90HV CONDITION CIRCUIT INFORMATION


OPEN A1J4-68 037-10 (circuit label for above open)

SHORT A1J4-70 A1J4-68 A1J4-69

OPEN J4-J J3-A (circuit label for above open)

OPEN J4-B J3-C (circuit label for above open)

158 Circuits Tested

TEST FAILED: 3 Opens, 2 Shorts

*** TEST FAILED *** Test time: 2.32 sec.

MAX

11. lfthe Pause option is set to Pause on Error, the tester stops after displaying each error. To continue the test, press either ENTER or footswitch or, if the error is an Open, connect the open circuit to continue the test.

12. If the Output to Printer option is set to F4 ONLY, a hardcopy of the test results may be printed by pressing F4.

13. When all tests using the current loaded program have been run, press ESC. Control is returned to the Test Modes window.

14. To exit the Test screen and return to the main screen, press ESC from the Test Modes window.

LOOP TEST

When Loop Test is selected, the tester scans the connected assembly not just once, but repeatedly to detect intermittent connections. Each continuity is compared against the wire list program loaded into the Series 90. If a program has not been previously loaded prior to executing Loop Test, the Series 90 will automatically execute the Load Program mode described later in this section. The Loop Test mode is similar to the Test mode, except that after each test is completed, a new test is automatically started. At the bottom of the screen a count of the number of tests completed and the number of tests failed are displayed. How the test results are displayed depends on the test options. For details on the test options, see the Options section.

RUNNING LOOP TEST

1. Attach the assembly to be tested to the interface fixture.

Note: Before a test can be performed, a wire list program must be created and saved on disk. This can be performed by using the Learn-Known-Good function or by entering a program through the keyboard using the Program Editor. Details on these two functions are located in the Programming section of this manual. A separate Programming Manual is provided for using the Program Editor.

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2. Move the highlighting bar to Load Program, using the down arrow, and then press • ENTER.

3. Load program, following the instructions provided later in this section on the Load Program mode. When the program has been loaded, the program name will be displayed at the top right corner of the Test screen. This program will be used for comparing continuities and other test results during Loop Test.

4. Scroll up to the Loop Test selection and press ENTER, or press the letter L. The Test Modes selection window will close and the test results will be displayed, as shown below. The options selections determine the format of the test results and what action is to be taken after an error.

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4.0 Test Page 7

5. Observe that if no error has been detected after a loop test, the ''Tested:'' counter (at the bottom of the screen) will be incremented by one and the "Failed:" counter will remain unchanged.

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OPEN

SHORT

OPEN

OPEN

A1J4-68 037-10 (circuit label for above open) A1J4-70 A1J4-68

A1J4-69

J4-J J3-A (circuit label for above open) J4-B J3-C (circuit label for above open)

MAX

FAILED - ESC to quit/Any key to continue Tested: 5 Fai led:

Each succeeding test is automatically started, displaying any discrepancies and incrementing the counters accordingly after each test.

To suspend the Loop Test, press the ESC key. Pressing ESC a second time terminates the Loop Test, returning control to the Test Modes window .

Observe that if an error is located, it is displayed. The tester can be programmed to pause either after displaying each error, or after a page (screen) full of errors. To continue the test after a pause, press ENTER. If the Pause is set to Pause on Error, and the tester stops after displaying an error, unlike the Test mode, connecting an open circuit will not continue the test. The test can be continued only by pressing ENTER.

8. To change the test options, press ESC to suspend testing and press ESC a second time to returned to the Test Modes window. From the Test Modes window select Options.

9. To exit the Test screen and return to the main screen, press ESC from the Test Modes window .

LOAD PROGRAM

Load Program retrieves test programs from disk and loads them into the tester's memory. The test programs are stored with 24-character file names. Programs can be grouped as individual directories. Using separate directories helps to locate a program when a large number of programs are stored on the work station. Directories can be used to group programs by job, application, operator, etc.

LOADING A PROGRAM

1. From the Test Modes window, scroll the highlighting bar down to Load Program and press ENTER. (Load Program can also be executed by pressing P.) When the Load Program mode is executed for the first time, a Directory List is displayed. The next time a program is loaded, the Directory List will be bypassed.



I TEST MODES

I Test t

Series 90 Directory List gram

Delta Production 01/24/1983 17:41:00 ions Delta Incoming Receiving 04/06/1987 07:32:12 rs Omega Final Tests 04/11/1990 10:52:26

In

Use Mouse or Arrow Keys to Select, ~ Enter to Execute. F1 for Help

2. Scroll down to the desired directory and press ENTER. A directory also can be selected by typing in the directory name and pressing ENTER. As the name is typed, the highlighting bar automatically moves in response. The Directory List window will then be replaced with a Directory window, listing programs within the selected directory, as shown in the screen below.

3. To select a different directory press ESC, and the Directory List window will open again enabling a new directory selection.

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4.0 Test


( program name MEASUREMENT MIN MAX

I TEST MOOES

I Test st

Directory: Delta Production gram

5210932 Assembly 02125/1984 16:40:59 ions 5210945 Cable Assembly 05/07/1988 06:31:11 rs 5290234 Adapter Harness 03/10/1989 09:51:25

In

Use Mouse or Arrow Keys to Select, .~ Enter to Execute. F1 for Help

Page 9

4. Within the Directory window, scroll down to the desired program name and press ENTER. The program also can be selected by typing the name and pressing ENTER. After the program is loaded, the name will appear in the upper right corner of the screen and the Directory window will close. A test can then be run using the loaded program. All tests run in the Test and Loop Test modes use the displayed program. When the program is loaded, the options and parameters are set according to the program and default settings. Any changes in the options or parameters remain in effect for the displayed program until Load Program loads another program. The options and parameters can be returned to the original program settings by reloading the program.

5. To load a different program, execute Load Program from the Test Modes window. The Directory window for the previously selected directory will open.

6. To load a program from a different directory, press ESC. The Directory List window will replace the Directory window. Pressing ESC a second time will terminate the Load Program mode.

4.0 Test Page 10

TEST OPTIONS

Test options settings determine how a test is to be run and how the test results are to be displayed or printed. There are three ways to set test options;

1. Selecting the Options category from the main screen. 2. Programming the test options from the Editor. 3. Temporarily changing the Test Options from the Test Modes window.

Test options that were initially set during programming, or when the program was loaded, may be temporarily changed with the Test Options mode through the Test Modes window. This allows special tests to be performed without permanently changing the program. Once the program is reloaded, the options return to their initial settings. For additional information regarding Options see the section on OPTIONS.

CHANGING TEST OPTIONS

1. From the Test Modes window, scroll the highlighting bar down to Test Options and press ENTER. (Test Options can also be executed by pressin~ 0.) The right hand column of the Test Options window indicates the current settmgs of all listed options. Some options can be set to either YES or NO, while other options have more choices. Selection windows will open for options with three or more choices .

Cablescan Series 90 / Series 90HV [ program name CONDITION CIRCUIT INFORMATION MEASUREMENT MIN MAX

----------------~ TEST OPTIONS

Test Method Test Continuities Test Shorts Test Unused Points Retest

Output Output to File Output to Printer Include Options Data

Print Label Pause Start-up Delay Log. Test Data Serial NUJi)er Job/Batch NUJi)er

Editing Test Options. Esc to Exit

OPTIMIZED YES YES

NO YES

ERRORS ONLY OFF OFF

NO

OFF ON ERROR

0.0 OFF

NO NO

TEST MODES

Test Loop Test Load Program


User Log In

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2. To change Test Method from Optimized to Sequential or Sequential to Optimized, press t~e 0 key for Optimized or the S key for Sequential. Pressing any other letter key will toggle the selection between Optimized and Sequential for each press of the letter key.

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3. To change an option from YES to NO (or NO to YES), scroll down to the option and press the Y key for YES or the N key for NO. Pressing any other letter key will toggle the selection between YES and NO for each press of the letter key. •

4.0 Test Page 11

4. To change Output, Output To Printer, Output To File, or Pause, scroll down to the desired option and press ENTER. A small window will open displaying the choices. Scroll to the desired choice and press ENTER. (Pressing ESC closes the window without changing the option.)

5. To change Start-up Delay, scroll down and type the number of seconds between 0.1 and 9.9, and then press ENTER. To edit a number already in the field press ENTER. This places the cursor in the number field.

PARAMETERS

Parameters settings establish the values used for testing an assembly. Primarily, they define the resistance values for accepting or rejecting a circuit during test. Continuity Threshold defines the maximum resistance a circuit can have before it is rejected. Shorts Threshold defines the minimum resistance value two isolated circuits can have before thev are rejected. Parameters are also used to display the number of test points programmed for test, to display which points are to be used for lamps (or relays), and to add delay during test.

There are three ways to set parameters;

1. Selecting the Options category from the main screen. 2. Programming the test parameters from the Editor. 3. Selecting the Parameters from the Test Modes window.

Test parameters that were initially set during programming, or when the program was loaded, may be temporarily changed with the Parameters mode through the Build Modes window. This allows special tests to be performed without permanently changing the program. Once the program is reloaded, the parameters return to their initial settings. For additional information regarding Parameters, see the section on OPTIONS.

CHANGING TEST PARAMETERS

1. From the Build Modes window, scroU the highlighting bar down to Parameters and press ENTER. (Parameters can also be executed by pressing M.) The right hand column of the Parameters window indicates the current setting of each parameter.

To change a parameter, scron down to

4.0 Test


PARAMETERS

Continuity: Threshold Current Max Voltage Dwell Time

Isolation: Threshold Voltage

~:fl U~ime Start Point Number of Points Lamp Start Point Number of lamps

Editing Parameters. Esc to Exit


100 0 5.1 rnA

<5.1 V 0.0 s

10 len 5.1 V 1.0 kV/s 0.0 s

1 4096 4097

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TEST MODES

Test loop Test load Program


User log In

Page 12

4. Observe that if an out of range value is entered for a parameter, a warning window displaying the valid range will appear followed by the selection window shown below:

Continue Edit Cancel Edit Leave Unanswered

Selecting Continue Edit returns the cursor and out of range value to the line so it can be further edited. Selecting Cancel Edit returns the original value and returns the cursor to the next parameter line. Selecting Leave Unanswered leaves the line blank and returns the cursor to the next parameter line.

5. If after making changes, you decide to return the parameters to the values that were current before the window was opened, press F7. The Parameters will close and control will be returned to the Test Modes window.

6. To close the Parameters window, press ESC. A Keep Changes window with Yes/No prompt will appear as shown below:

Keep Changes

INo Yes

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7. To keep changes, place the cursor on the Yes response, and then press ENTER. To close the window without keeping changes, arrow up to the No response and • press ENTER.

4.0 Test Page 13

USER LOG IN

The User Log In selection is used to enter a user name and password. User names and passwords are programmed from the main screen to control access to the various selections of the Series 90. User names are included on test result printouts and stored along with test and build data. A user name may be entered for printout purposes without a password if passwords are not enabled.

LOGGING IN

1. From the Build Mode window, scroll the highlighting bar down to User Log In and press ENTER. (User Log In can also be executed by pressing L.) A Login window will open as shown below:

I LogIn I

I User name:

I Password:

2. Type your user name and press ENTER.

3. If passwords are enabled, type your user password and press enter. If a wrong password is entered, the window will remain open.

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