USER`S MANUAL One To One Continuity Tester with Parts Counter
Contents
1. meaning shorted circuit numbers xx and yy 2 1 2 Ckt by Ckt Testing of continuity from circuit 1 upto last circuit for the selected component number Checks each point and considers correctness of each point even if continuity is found momentorily Checking is not done sequentially Passes if all points are found correct Finds out and displays open faults Keeps displaying first fault located On every pass counter is incremented After passing displays Remove Component and after removing displays Mount Component Starts testing even if one circuit found connected After displaying error no key will be accepted and faulty harness will have to be removed Open xx meaning open circuit number xx Since tester displays Mount Component if all circuits are found open here care should be taken that at least one fixture should be of locking type and will be locked throughout testing Hence Testing will start after mounting component in this fixture and Mount Component display will appear after removing component from this fixture 2 1 3 Parts Counter It counts parts on shorting pin numbers 1 and 2 of 9 pin D type connector provided at the back side When all parts are counted any key pressed will indicate that counting is complete Count will be compared with stored count and pass will be displayed if matched else Count Error will be displayed for 3 seconds and will start counting again To end testing2. speaker Power On switch and input socket fuse and SPARE FUSE CRTs 81 96 CRTs 6580 KR O Q Parts counter probe Relay output P NGNO TONE CKTs 49 64 CKTs 33 48 CKTs 17 32 CKTs 16 0 0 12 V GND 12V 37 pin D type F connectors for CKTs External 12 V DC supply terminals and use end terminal for board Futura Apsol Pvt Ltd Pune India Continuity Tester One to One CT121 Front and Back panel details Drawn by GSR on 14 6 2001 Doc No CT121 PD drawing not to scale 3 Operation 3 1 Front and Back panels Front Panel 4 keys keyboard 16 1 LCD display with backlit and PC keyboard socket Back Panel Mains input socket with fuse and spare fuse Mains power on switch Relay output terminal strip 9 pin D type connector for parts counter probe 12 V DC 800 milli Ampere alternate power input Tone and volume control of buzzer 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 Tester displays FUTURA VER for 2 seconds last selected test mode for 3 seconds last selected component number and its data for 5 seconds and START TEST Use keyboard on front panel for further functions as required Refer to section 3 2 for display meanings and keys to be used Relay Relay will be normally off and will be on for
3. 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 Menus and submenus Menu name and keys accepted Start Test up down Enter Setup up down enter Change Component up down enter Escape Change cable number Change data up down enter Escape Change last circuit Change test mode up down enter Escape All Circuits up down enter Escape Ckt by ckt up down enter Escape Parts Counter up down enter Escape Name Component up down enter Escape PC Keyboard entry To accept Enter on Keyboard 2 Description of menus 2 1 Start Test Starts testing in selected test mode for selected component number 2 1 1 All Circuits Testing of continuity from circuit 1 upto last circuit for the selected component number Passed only if ALL CIRCUITS are found correct in one pass Finds out and displays open and short faults Keeps displaying first fault located On every pass counter is incremented After passing displays Remove Component and after removing displays Mount Component Starts testing even if one circuit found connected After displaying error any key will not be accepted and faulty harness will have to be removed ce y Fault display will be Open xx meaning open circuit number xx short xx with yy
4. Escape is to be pressed again when error is displayed Required count is programmed for 25 components along with component name Test mode will end with Escape key 2 2 Setup In Change Component mode set up facilitates selecting component number out of 25 nos Keys up and down will change component number and enter will accept displayed numbers In Change Data mode set up facilitates changing last circuit number of parts for parts counter For continuity checking and parts counter same database is provided in EEPROM Keys up and down will change last circuit number display and enter will accept displayed numbers In Change Test Mode mode setup facilitates selecting test mode from All Circuits Ckt by Ck and Parts Counter Keys up and down will change modes display and enter will accept displayed mode In Name Component setup facilitates entering name of a component Blinking cursor will be at the first position of component name Alphanumeric name can be entered if PC AT keyboard is connected Maximum number of characters in a name can be 10 numbers Enter key on keyboard will save the name Any key on keyboard will come out of setup mode without saving PASS LED Indicator PC Keyboard connector LCD Display FUTURA FUTURA VER 1_7 A ENTER 4 keys sealed keyboard
5. 3 seconds on Pass Relay output is provided on back side on a terminal strip Pole NO and NC are all available for use Parts counter probe is to be connected to connector provided with tester 12 V DC also can be used to supply power to tester Input is using terminals on back panel Open wire or multimeter probes can be used for input 3 2 Displayed messages their meanings and keys to be used START TEST Start Testing Enter starts testing up down next menu Escape no change SETUP Want to change settings Enter displays CHANGE TESTMODE up down next menu Escape to SETUP CHANGE COMPONENT Want to change selected component Enter displays currently selected component and its data up down next menu Escape to SETUP CHANGE DATA Want to change selected component s data last circuit Enter displays currently selected component and its data up down next menu Escape to SETUP CHANGE TESTMODE Want to change test mode Enter displays existing test mode up down next test mode Escape to SETUP NAME COMPONENT Want to name selected component name using PC Keyboard entry Enter displays blinking cursor at first position and selected component s data up down next menu Escape to SETUP ALL CIRCUITS Select test mode continuity check for all c
6. Last circuit to be tested is user programmable Set up allows programming of last circuit harness name to be stored in EEPROM using PC key board Last circuit can be stored for 25 different harnesses Futura s one to one tester also has parts counter to count parts on a harness using a limit switch probe Number of parts are programmable for 25 different harnesses along with harness name Maximum parts counted are 99 It is a microcontroller based tester 1 2 Technical Specifications Power Supply 230V ac 10 AND or OR 12 V DC 4 V DC 2V DC Ripple lt 1 800 milli Ampere One to one continuity tester Number of circuits to be tested 48 96 circuits i e 96 192 points Last circuit to be tested programmable by user Refer document for circuit connections Test Voltage TTL Logic 1 level 5V DC Test Current In milliamperes Tester I Os 37 pin D F connectors 3 6 nos terminated at back side of tester Parts Counter Maximum number of parts counted 99 Ninety Nine Input A probe with limit switch using 9 pin D type F connector at pin numbers 1 and 2 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 Green LED on Pass User Interface functional specifications
7. USER S MANUAL OF One To One Continuity Tester with Parts Counter Model CT 121 48 96 VER 1_7 manual date 24 10 07 BY FUTURA APSOL PVT LTD 5 amp 6 B wing Mangalmurti Complex 117 A Sinhagad Road PUNE 411 030 TELE FAX 020 2425 1128 E MAIL info futuras com www futuras com oi Ge ee oS One To One Continuity Tester with Parts Counter Model CT121 48 96 Packing List One To One Continuity Tester 1 no This User s Manual 1 no Mains cord l no similar to PC mains cord Cable from tester to board rig as per number of points or connectors Cable for parts counter probe 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 Test 2 1 1 All Circuits 2 1 2 Circuit by Circuit 2 1 3 Parts Counter 2 2 Setup 3 OPERATION 3 1 Front and Back panels 3 2 Display meanings and keys used 4 POINTS TO REMEMBER 5 ONE TO ONE CONTINUITY CHECKER CONNECTIONS TO RIG FIXTURE BOARD 6 OUR OTHER PRODUCTS AND SERVICES GENERAL PRECAUTIONS Before using the equipment read the following carefully Following points are to be taken care of while using the equipment The
8. connector as or connector no or connector no MSSL 1 1 1 1 1 13 2 9 1 20 1 2 1 32 2 10 1 2 1 3 1 14 2 11 1 21 1 4 1 33 2 12 1 3 1 5 1 15 2 13 1 22 1 6 1 34 2 14 1 4 1 7 1 16 2 15 1 23 1 8 1 35 2 16 1 5 1 9 1 17 Not Used Not Used 1 24 1 10 1 36 Not Used Not Used 1 6 1 11 1 18 Not Used Not Used 1 25 1 12 1 37 Not Used Not Used 1 7 1 13 1 19 Not Used Not Used 1 26 1 14 1 8 1 15 1 27 1 16 1 9 2 1 1 28 2 2 1 10 2 3 1 29 2 4 1 11 2 5 1 30 2 1 12 7 1 31 2 8 MSSL Wiring or connecting of rig fixture to tester All cables provided along with tester are similar in connections as per above connection table To use for I Os pin numbers 1 3 5 7 9 11 13 15 of 18 pole connector no 1 of 37 pin connector connected at position CKTs 1 16 on back panel of tester are one end of circuits 1 to 8 and pin numbers 2 4 6 8 10 12 14 16 are other end of circuits 1 to 8 Similarly 18 pole connector no 2 are circuits 9 16 and 18 pole connector no 1 of 37 pin connector connected at position CKTs 17 32 on back panel of tester are circuits 17 24 Similarly 18 pole connector no 2 are circuits 25 48 Similarly remaining circuits can be used 6 OUR OTHER PRODUCTS AND ACTIVITIES 6 1 Cable harness Testers 6 2 Harness Assembly Aid 6 3 Switch Testing Equipments with without load 6 4 Custom built Automatic Test Equipment 6 5 Gauge Link 6 6 Cockpit dash board test equipment
9. ircuits in one pass Escape to SETUP up down next previous menu Enter displays SET ALL CIRCUITS for 3 seconds and displays current component number and its database from memory for 3 seconds and then SETUP CKT BY CKT Select test mode continuity check circuit by circuit Escape to SETUP up down next previous menu Enter displays SET CKT BY CKT for 3 seconds and displays current component number and its database from memory for 3 seconds and then SETUP PARTS COUNTER Select test mode counting parts Escape to SETUP up down next previous menu Enter displays SET PARTS COUNT for 3 seconds and displays current component number and its database from memory for 3 seconds and then SETUP PASS ZZZ On passing of component in any test mode ZZZ is counter which resets on every power on and component change MOUNT COMPONENT In continuity checking all circuits are open and waiting for mounting component Escape to TEST REMOVE COMPONENT In continuity checking tester expects all circuits to be open Escape to TEST COUNT ERROR In Parts counting mode Counting error CURRENT COUNT WW In parts count mode counts number of pulses and are displayed at WW Any key pressed once compares count with stored count During display COUNT ERROR any key to TEST If count matches displays pa
10. se 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 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 Pushing might damage the connectors on I O cards or on the board of 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 Check proper earthing at the power supply input of the Cable Harness Tester Warrenty void if equipment is opened by unauthorized person 1 INTRODUCTION 1 1 Function One to One continuity tester is to test one to one continuity of a circuit 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
11. ss for 3 seconds and starts counting again 4 Points to remember In circuit by circuit testing mode connections may not be sequential Tester will take care of random circuit numbers making continuity In circuit by circuit testing at least one fixture should be of locking type and will be locked throughout testing If not then tester will keep displaying MOUNT COMPONENT once it finds all circuits are open Counter for all test modes is same and is initialised on every power on and on entering test mode In parts counter if error occurs then pressing any key twice will put tester is TEST mode Component name can be of maximum 10 alphanumeric characters Component name will be saved only when enter key on PC keyboard is pressed Any other key on panel will not save name Parts counting probe is a limit switch activated When two pins are shorted count will be incremented Parts count input should not be connected to any external voltage or multimeter or active device If component name is not entered or saved earlier display will be COMPONENT On power on tester displays FUTURA for 2 seconds last selected test mode for 3 seconds last selected component number and its data for 5 seconds and TEST On entering test mode displays selected component number and its data for 5 seconds and starts testing 5 1 I O connections tester 37 pin D F Each Connector 37 pin D type M solder t
12. ype on rig side On Each 37 pin connector has 16 circuits indicates one end and indicates second end First connector has circuits 1 to 16 Second has 17 to 32 and so on Configuration in all connectors is the same as shown below Cable provided has one end as 37 pin D M connector and other end as 36 pin centronics M 36 pin F connector is mounted on the board I O connections are as below I O No Pin number on Pin number on T O No Pin number on Pin number on 37 pin D 36 pin 37 pin D 36 pin connector centronics connector centronics connector connector 1 1 1 9 9 9 1 20 19 9 28 27 2 2 2 10 10 10 2 21 20 10 29 28 3 3 3 11 11 11 3 22 21 11 30 29 4 4 4 12 12 12 4 23 22 12 31 30 5 5 5 13 13 13 5 24 23 13 32 31 6 6 6 14 14 14 6 23 24 14 33 32 7 7 7 15 15 15 7 26 25 15 34 33 8 8 8 16 16 16 8 27 26 16 35 34 37 pin D 36 37 Not connected NC 36 pin centronics 35 36 NC 5 5 For MSSL Cable from Tester to 18 pole MSSL F connector 37 pin D type solderable M connector 37 pin F connector on tester to 18 pole MSSL F connector 16 poles are used 37 pin M Pin number 18 pole F pin no as 37 pin M Pin 18 pole F pinno Connect on connector MSSL Connect number on
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