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Horizon Programming Manual

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1. 1 z 5 6 BE eter Esc Low Uoltage Settings H Flex Dis Scan Star Conductor Res Sk Max Fixed HC Stimulus on Min Isolation Min Res 190K Min More Options Do you a Voltage Drop Tes Select Conductor Res from the Low Voltage Settings menu In the Specify Continuity Type menu select Fixed HC If you would like to measure the conductor s voltage drop select Yes Selecting No will to measure the conductor s resistance If No is selected then set the Maximum Conductor Resistance Q and select Enter Enter the Minimum Conductor Resistance Q and select Enter The settings are updated If Yes is selected then set the Maximum Conductor Voltage Drop V 4 62 Horizon Series Tester Programmer s Manual Basic Programming and Testing Select Enter Enter the Minimum Conductor Voltage Drop V a Low Voltage Settings H The settings are updated Flex Perm Scan Star Conductor Res 4 2 Fixed HC stimulus Min Isolation Min Res 160K Min More Options If the test program is set for 2 wire measurement then this message menu will be displayed he fixed 1A HC sourc
2. Checking the High Current Source Mode Auto current Enter the value m 1000 1 lear ENES sers ess ez o Esc Checking the High Current Source Mode Auto Current 1000mA Source On Checking the High Current Source Mode Auto Current 1660mA 999m i lO4mU Resist lO4mi Source On 4 Checking the High Current Source Source On Enter the Vout value UI 28 0 1 Elear 4 5 BS Em m nter su Select Current Enter the maximum current of the HC Source in your machine either 500mA or 1A Select Enter Using the Calibration Tool place an ammeter between the jacks Select Source On Check the ammeter reads the correct current The shaded portion of the screen shows the Horizon measurements Compare those with your meter s measurements Select Source On to turn off the High Current Source and then select Mode Mode set to Manual makes the Max Volt option available Select Max Volt Enter the maximum voltage the High Current Source can sustain 28V Select Enter Horizon Series Tester Programmer s Manual 11 Appendix Calibration Verification Checking the High Current Source Mode Current Max Vol
3. 3 System Setup 3 1 3 1 DE 3 3 3 2 Inputs 3 3 3 3 Time and Date 3 4 3 4 G neral Set p Functions rA n ERU He 3 5 3 4 1 Installing software Options sene 3 6 3 4 1 1 Install Advanced NetList 2 8 8 3 6 3 4 1 2 Install TCL Scripting Package seen 3 7 3 4 1 3 Uninstall Advanced NetList Editor or TCL Package 3 8 3 4 1 4 Default Language deest 3 9 3 4 2 Digital Hand Held Probe Smart Probe sees 3 9 3 4 3 Remote RS232 Options Bar Code Reader Setup 3 10 3 5 Scar ire e 3 12 3 6 Service 2 3 7 Outputs 3 8 Passwords 3 8 1 Setting Up Passwords od Op 3 20 3 8 2 Disablingi eren 3 21 3 9 AGING EXPANSION BOXCS 3 22 3 10 PANT SwiteheS 3 23 4 Programming and Testing 4 1 4 1 erroe Loro ps 4 3 42 Learning the Cable 4 3 4 3 Testing Your 4 7 4 4 Controlling the DIAQIOSHCS rera 4 9 44 1 Altering the results displayed before 5 sss 4 9 442 Alter the results
4. Capacitors DC Diodes AC Hipot HC Source DC Hipot Cancel ake sure there are no capacitors connected to the dacks The system will perform capacitance calibration ENTER THE VALUE OF THE EXTERNAL REF CAPACITOR 0 441 nF 2 3 E1222 wes one ees 9 E 7 Esc 441 nF Measured C 442pF Tolerance Check calibration using external reference components Resistors DC Capacitors Diodes AC Hipot HC Source DC Hipot Connect the diode to the Jacks Diode Open To verify capacitance measurement select Capacitors The first step is to allow the Horizon to measure the capacitance of the jacks so their value is not computed as part of the component to be measured Measure the capacitance of your component using an extremely reliable tool such as a bridge Enter the measured value Connect the component to the external jacks on the calibration board and the Horizon measures the value comparing it to the reference value entered The tolerance between the two values is reported Press Ok to return to the Check calibration using external reference components menu Select Diodes to verify the Horizon detects polarity and forward voltages through the diode junction The Hor
5. This sample report indicates that there was excess leakage anc leakage at pin 19 and 25 at connector 1 on J1 The Horizon measures and reports the leakage current JL Reported Results FAIL In this example an arc occurred during a MASS HiPot test FAC arc during mass hipot arc arc Netia End of Report Lene UNE NN 4 60 Horizon Series Tester Programmer s Manual Basic Programming and Testing Sac ape mags hipot Arc locations can only be reported during a MASS HiPot if the fault is reoccurring If the arc occurs only once the system will report it but will not give a location If you run a LINEAR HiPot the location will always be identified Ss In this example the arc occurred during a LINEAR HiPot ae fast AC Neti4 2 13 0hm arc Neti 16 165M0hm Neti 157 Gee Hesse All failures are identified with an asterisk AC Het2l 7 26G0hm 2 212 4 14 7 AC HiPot More Options Ramp Ramp Down amp Current Neutralization Ramp The slope of the charge and discharge of a PUT can be controlled by selecting Ramp from the DC Hipot Settings menu Select either Ramp Up or Ramp Down to enter the desired value Programmable range 01V to 10kV per second for both Ramp Up and Ramp Down Neutr
6. You are now given the option to alter the global settings to Linear should you wish to continue editing the local High Voltage variable Select Yes to accept the change Selecting Hipot will remove the check mark and this net will not be HiPot tested Notice however that you can actually specify different HiPot test settings for different parts of the cable In the example cable that s exactly what we chose to do setting a different voltage and duration to be used for this net and this net only but leaving the leakage limit the same Select Ok to return to Edit Net s Settings Cancel returns with no action taken The display has now changed to indicate that this net is using Custom settings to define its Hipot test parameters Select Ok to go back to the Edit Net menu Cancel returns with the previous parameters intact You may wish to use the Label function to document the changes you have made to this net Repeat these steps as necessary to modify the required nets When you have finished select Ok to return to Set Test Parameters As before select Ok from this menu to save your cable record Horizon Series Tester Programmer s Manual 4 57 Basic Programming and Testing Test Program as CBL File datab cables main testca 5 cbl For greater detail see section 9 CABLE TEST CABLE 83 6 NET STAR J1 1 12 THRESHOLD 61 J3261 125 ACHIPO
7. 3 4 Insertion Delay 3 12 K Kelvin Measurement Programming With Fixture 5 52 Switches 5 64 L Labels een b nee 2 7 Learning Your Cable 4 3 Logging Reports to File 7 3 M Mass HiPot Routine See Appendix C Miswires 4 22 4 61 N Netlist Custom Hipot Settings 4 56 Labels reete tenen 2 7 nominal continuity current 4 64 7 Opens reete ns 4 20 i 3 20 Fall ERA 3 20 HV On iEn 3 20 PASS pP 3 20 Test Over iei 3 20 P Palm Switches Autohipot 3 23 Enclosure Switch 3 24 One Palm Switch 3 24 One Temporary 3 24 Start 3 23 Two Asynchronous 3 24 Two Synchronous 3 24 Two Temporary 3 24 3 20 Printer Setup 7 4 Printing Reports 7 3 Programming Capacitors 5 30 Chain Scan 4 18 DG Hipot 4 36 Flex Test ede eee 4 26 Flying Leads eoe tds 5 4 Froe t 5 4 Gold
8. 6 3 Quad 2 5 6 4 Resistance Tare 6 9 Signature Components 6 5 Single Wide 2 5 6 4 Testing Your Adapter 6 10 Text File Formats 9 34 INDEX Advanced Netlist Editor 4 14 9 3 Assembly Aid Tools Group Scan 4 31 Group Sorting 4 33 Pin Eocator on 4 35 SI p 4 30 Assembly Aid Tools 4 29 Auto Diagnose 7 6 3 23 Backups sse 8 3 Other removable 8 3 C Calibration See Appendix D Calibration Verification See Appendix D Capacitance 3 13 Capacitors Autoleatn iden 5 30 Editing Thresholds 5 32 Electrolytic Components 5 38 ooo et 5 39 Hipot 5 5 38 Manual Programming 5 35 CDA inei te aue 9 3 Chain 4 18 Cumulative Fault 4 9 D Date 3 4 DG Hipot 4 36 Adaptive
9. Flex Ferm Scan Star Conductor Res SOOmU HC Stimulus OU Min Isolation Min Res Min If Voltage Drop is selected the dialog at the left is displayed The Maximum Conductor Voltage Drop V enter the Minimum Conductor Voltage Drop V and the nominal continuity current must be entered The continuity test will be performed using the high current programmable source The maximum voltage drop entered at the step above will be used to qualify the continuity test Select Ok to accept the settings and return to the Set Test Parameters menu Horizon Series Tester Programmer s Manual 4 65 Basic Programming and Testing Test Program as CBL File datab cables main testca 6 cbl For greater detail see section 9 CABLE TEST CABLE 4 7 NET CONTINUITY 0 0 5 J1 C1 12 HCRES 1 J3 C1 12 QUICKISOLATION NET STAR IL eiio THRESHOLD 61 J3 116 NET POSITION J1 J1 C1 14 ADAPTER HA 116 J3 C1 14 POSITION J3 NET NET J1 C1 15 Tl pa J3 C1 15 NET NET ILGI T zy 11 1 2 J3 C1 16 NET NET J1 C1 17 Jlgocl 3 ol JgJ3CL 3 NET NET J1 01 18 J1 C1 4 73 1 18 93 124 NET NET J1 C1 19 Ul Jd3 Cl 19 23 C1
10. 8 3 8 1 1 Performing BACKUPS 8 3 8 1 2 Performing Restores acd aida ated er e e 8 5 8 1 3 5 eco i a ren 8 6 9 Creating and Editing Nets from a Text Editor 9 1 9 1 Horizon 1500 Test File Format eiiis eene tnihi aaraa a theta tates 9 3 9 1 1 Introduction odere teta e a irte oca ies 9 3 9 1 2 Test Program ID 2 4 9 5 9 1 3 Adapter Interface Section sss 9 6 9 1 4 TestiParamelters o ea een AR M te cte Re es 9 10 9 1 4 1 Low Voltage Test Parameters sse 9 10 9 1 4 2 High Voltage Testing Parameters sse 9 14 9 1 5 Bild Ad acit edo dts 9 17 vi Horizon Series Tester Programmer s Manual Table of Contents 9 1 6 Print Options LER 9 20 9 1 7 eth ine adele 9 1 8 Netist m tO ie IAN eam 9 1 9 Components 92 Adapter iain arresto para a ede ead ette peat d deae 9 34 APPENDIX A Horizon Specifications APPENDIX B Troubleshooting Your Horizon APPENDIX C Mass HiPot Examples APPENDIX D Calibration Verification Glossary of Terms Index Horizon Series Tester Programmer s Manual vii 1 INTRODUCTION my CABLETEST Introduction 1 2 Horizon Series Tester Programmer s Manual
11. The display shows the Directory location and the Part Number for the last cable tested If this is the product you want to test select Test Now otherwise press Select and choose the proper cable Insert the proper adapter s After the proper adapters are installed the system automatically sequences to Connect Product To Start 5 54 Horizon Series Tester Programmer s Manual Advanced Programming Insert your product The Horizon will detect when the product is inserted and automatically start If your product Passed passes the green Pass light will be lit and a positive tone Failed we s will sound if it fails the red Fail light will be lit and a Start Test Negative tone will sound If for some reason the test does not automatically start or you have disabled the automatic start feature selecting Start Test will force the test process to start Select Cancel when finished testing 5 8 Switches 5 8 1 Introduction The Horizon can test cables and harnesses with embedded switches The basic philosophy is that each time a switch changes position the cable has changed its configuration As a result the learning process steps you through each of the switch positions as the Horizon learns the configuration for each position Then during the testing phase the operator duplicates the process Switches can
12. 1 17 J 4 2 2 4 5 6 7 8 9 9 HAHAHAHHA 7 Space Bar lear Locating Pin 1 E From the Select Tool menu select Pin Locator Enter the pin range for the first Group Pin ranges can be ascending or descending depending on your preference or need If you wish to select non sequential pins you can do so by separating them with commas e g 1 3 5 7 You may also select ranges that are non sequential you need only separate the ranges with a comma e g 1 5 8 20 Select Enter to continue There are two methods to sequence through a range of pins Automatic or Manual By selecting Auto check mark present once a pin is successfully probed the scan sequences to the next pin Be aware this may cause problems should you probe the pin and loose its location you will then need to select Prev to return scanning that pin In the manual mode once you have located the required pin select Next to sequence to the next pin in your selected Horizon Series Tester Programmer s Manual 4 35 Basic Programming and Testing Enter pin or pin 5 6 7 8 9 9 Space Bar Elear Step 6 Final Verification range Once you have probed the final pin in the range if you select Next or if you are automatically sequencing you will retu
13. K a 5 v D OONAN BEBE oT Gece s a v 9 a Edit Net s Settings IM Hipot Settings AC Hipot Settings Conductor Res Default Default Default Default Kelvin Default Highlight the Kelvin net you wish to verify Select Open to view all of its connections All four test points are included within this net In this example the 1 1 1 and J3 C1 1 are a Kelvin node as are J1 C1 4 and J3 C1 4 The connection between these two nodes is the product under test To verify this connection the net must be Kelvin Select Ok to return to the Edit Net dialog Select Edit to view the nets parameters The Kelvin option is checked the net is Kelvin 5 7 2 Testing a Cable using Kelvin The procedure for testing a cable using Kelvin testing is the same as testing any other cable or harness For more details consult Section 4 Test Configuration File Name datab cables MAIN KELUIN CEL Part Number IKELU IM eu l Tools Reports Select Test Now Batches Cancel a Insert the Adapter s IM J2 i HA HA 116 116
14. 193 NET NET J1 Cl 6 20 J3 C1 6 J3 C1 20 NET NET dicli 2 J33Cl 217 NET NET 71 01 8 J1 C1 22 93 518 93 61 22 NET NET Ji2Cl1 237 23 1 9 93461 23 NET NET J3 C1 10 J3 C1 24 NET NET JLC Lle J1 C1 25 Il 5 END 4 6 Horizon Series Tester Programmer s Manual Basic Programming and Testing 43 Testing Your Product On the Main Menu select Test The Test Configuration dialog appears Note that this module is not password protected since it is a run only function system and or test parameters cannot be modified added or deleted Test Configuration H File Name a les MA INS TESTCABL Part Mumber TEST CABLE Rev 1 Tools Reports Select Test Now Batches Cancel Refresh Delete gt Cancel Select Part Number rt Number L SESECOND Rew 1 Refresh Delete Back 1 OK 4 SD 1 Select element bu tuping m TEST CABLE 5 REU 1 3 4 5 ER 7 2 9 9 LJ File Name les MAIN TES TCABL CB Part Number TEST CABLE Rev
15. Edit Search New Save F2 Save as Change dir DOS shell Exit Alt X Modify Existing Cable Learn Hew Cable Default Learn Hew Cable Custom Advanced Netlist Editor OE NVA CABLE 5 1 THRESHOLD 61 ADAPTER HA 116 POSTITION J1 ADAPTER HA 116 POSTITION J3 Once you have edited the file as necessary select lt Alt F gt to pull down the File menu then lt S gt or lt F2 gt to save and lt Alt X gt to exit and return to the Horizon client software Please review section 9 for greater text editing details Exit returns you to the Program Cable menu 4 9 Basic Low Voltage Testing Options Continuity and Isolation The low voltage parameters of your product can be tested either by the default Quick Scan method or using a Measured method 4 9 1 Quick Scan The Horizon Quick Scan method is the default learning and measurement method for both Continuity and Isolation tests Horizon Series Tester Programmer s Manual 4 15 Basic Programming and Testing The method utilizes a hardware scan to determine whether any opens or shorts exist within the product you are testing It is because of this hardware scan that Quick Scan is quick The effective thresholds for the tests are as follows less than 3000 greater than 80kO Continuity Isolation Should you wish diff
16. Bar ear Set Test Parameters H Name Prompt Adapters Low Voltage Components High Uoltage More options Net List Print Test Now 1 As the Horizon learns your product a status screen keeps you informed about its progress The NetList for the cable is learned After the NetList has been learned you are asked to Enter the Part Number and a keyboard is displayed You can use any combination of alpha and numeric characters as well as other valid ASCII symbols such as parentheses amp etc for your part number At this point your cable is completely programmed to test all standard low voltage tests shorts opens and mis wires using the quick scan method You do not need to specify anything else However the Horizon has significantly greater capabilities as well These include generating an in depth capacitance and resistance profile of your product performing AC or DC HiPot testing testing for with embedded components and the ability to perform each or all of these tests on selected nets Each of these functions is described in depth in a separate section of this manual Consult the appropriate section if you want to set up any of these additional or extended tests Select Ok and the Save Cable Record dialog appears Save Cable Record
17. I 2 0 2 5 4 ag 2 4 Space Bar Etear ee Enter the operator ID YOUR NAME IE 9 2 0 HAHAHAHAA HBE EIE le Space Bar Etear IDANE e Reference values setup password ind icated ack of your manual to the manual for Enter the password 1 lear 4 5 6 BS pes p Enter REF RESISTORS REF CAPACITORS PASSWORD Modify the Reference Values By selecting Header you can enter this information where relevant or disable their function entirely By selecting Company you can enter this information or disable it By selecting Operator 1 0 you can enter this information or disable it When selected a check mark present next to it then information entered will be included in the printed report otherwise it will be omitted Selecting REFERENCE VALUES from the Calibration System Setup menu and the message to the left appears TE Do not alter the Reference Values unless they match the values measured on the Calibration Board Pressing Ok the Horizon prompts you to enter the appropriate password Your password is supplied when you purchase your calibration verification kit Select REF RESISTORS to alter their reference
18. Learn Cable Insert the sample product then press OK to continue ER Enter Part Humber MEE 7 9 0 Space Bar Elear a Set Test Parameters NEE Pronpt Adapters Low Voltage High Voltage Components Net List More Options Print Test Now Cancel From the Main Menu of your Horizon select Program Cable From the Programming Cable menu select Learn New Cable Default Place the appropriate adapter for the terminated end of your product Once detected select OK to continue You need not place the product onto the adapter at this point The learn process is required to create the pin list for terminated end of the product Select OK to continue Enter an appropriate part number for the product you are about to assemble Select Enter to continue You need not enter any further parameters Select OK to save the learned product 4 30 Horizon Series Tester Programmer s Manual Basic Programming and Testing Save Cable Record Tu 4 Cancel Programming Cable Modify Existing Cable Learn New Cable Default a Main Menu Ii Thu Sep 11 1997 01 40 Test Self
19. is essential to disable the Kelvin toggle before probing this special case adapter If not the system will learn the shorted points as Kelvin points Horizon Series Tester Programmer s Manual 6 15 Adapters Adapter as ADP File 5 datab adapters shorted adp ADAPTER SHORTED SIGNATURE 3 00000000 3 00000000 SIZE 1 VERSION V4 2 24 CONNECTOR 18 19 20 B 21 D 22 E 23 F 28 G 6 H 7 2 15 6 6 Editing existing Adapter Never edit or alter an adapter file if it has been used to learn a product If you alter an adapter after creating a test program you will need to relearn the product Programming Adapter Select Modify Existing Adapter to edit an adapter Modify Existing Adapter Learn New fidapter Test Adapter Advanced Netlist Editor If you want to edit some or all of the adapter s settings move the arrow keys to highlight the desired adapter then select Ok The Adapter Settings menu will be displayed Cancel OK 6 16 Horizon Series Tester Programmer s Manual Adapters EA SPECIAL From this menu you can edit any or all of the programmed Ss parameters associated with a given adapter Selecting Part _Conmonents _Bes tare Number allows you to rename the adapter as described at _ the beginning of this section selecting ID Components ca
20. NET 12 21261229 NET NET J3 1 27 J1 C1 18 13 NET 2 1518 NET NET Ji CT 14 5 NET 73 6 954 J3 C1 14 J1 C1 4 NET NET J1 C1 20 Cis NET J3 C1 20 5 SWITCH NET 33461 252 CHAIN J1 C1 16 NET PROMPT J1 C1 6 CLOSED NET 23 C1 6 NET NET J3 C1 17 FL TL Cl 6254 NET J3sCloly 21 61 18 NET d3 Cl2 4 8 py NET NET 2326128 J1 C1 19 NET Jg3 Gl 3 5 21 1 9 NET NET 23 C1 9 Ji Cli4 J1 C1 20 NET d3 C1 4 JI CL 2202 g1 C1l 107 NET END NET J3 C1 5 lees Bra Riles NET NET J3 C1 6 12 NET Be e E ILIV Ty Horizon Series Tester Programmer s Manual 5 59 Advanced Programming 5 8 3 Programming Switches Temporary Membrane Switches Temporary switches are also known as Keys They are seen by the Horizon as a component 1 Conpone ttings Permanent Switches Temporary twitches BT 411251061 gt a Component Settings Permanent Switches Temporary Switches Cancel
21. 00444 00 4 10 4 5 Modifying Your Test 4 11 4 6 Automated Start 4 13 4 7 Preventing Runaway Tests Max Errors 4 13 4 8 Advanced NetList Editor Optional sss 4 14 4 9 Basic Low Voltage Testing Options Continuity and Isolation 4 15 4 9 1 4 15 4 9 2 Measured 4 16 Horizon Series Tester Programmer s Manual iii Table of Contents 4 9 3 Star or Chain SCAM sci seve eet etie ete 4 18 4 9 4 TAP paced dle di etd ahi tidied 4 18 4 9 5 Improving Accuracy with High Capcitive Loads Long Cables 4 19 4 9 6 Customize Conductor Tests by 4 19 4 10 Common Cable Faults amp Faulty End Recognition FER sese 4 20 E 4 20 4102 cts ccs ies qt died tenn a ian id ince 4 22 410 3 M 4 23 4 10 4 Shorts and Opens with a Test Fixture 2 2 112 4 25 4 11 DD Em 4 26 4 11 1 Testing for Intermittent Low Voltage 4 26 4 11 2 Testing the Cable Flex Test 4 29 4 12 Assembly Aid Tools ioc ERRARE e PR 4 29 4 1
22. 2 9 4 7 Testing Your Product SLA es eee Lotte 4 13 Text File 9 3 Adapter Identification 9 6 Continuity 9 10 Isolation et teret 9 12 Low Voltage Test Parameters 9 10 Print 2 9 20 Program ID 9 5 Text File Format Tags SOU ubt 9 16 ete 9 16 9 16 9 31 ADAPTER erase 9 6 ADAPTIVE 9 15 FABDU 9 20 2 eerte 9 20 AUTODIAGNOSE 9 22 BITMAB 9 25 tales 9 15 a 9 5 CHAIN 22222 9 12 9 7 9 10 GUSTOM iere 9 32 9 15 9 31 DIODES 9 32 DWEEL 9 15 9 16 ELECTROLYTIC 9 32 cit teen ndn ete 9 20 9 20 ELEX de tede 9 13 FOOTER 9 23 9 20 FORWARD 9 32 GENERIC 9 32 GERMANIUM 9 32 iiber 9 31 9 31 HORES 9 30 9 31 HEADER
23. Er 5 30 5 5 1 Programming Capacitors Auto learn seeee 5 30 5 5 2 Programming Capacitors 5 35 5 5 3 Programming Capacitors Advanced Options 5 37 5 5 3 1 Programming Capacitors Advanced Options HIPOT 5 38 5 5 3 2 Programming Capacitors Advanced Options Electrolytic 5 38 5 5 3 3 Programming Capacitors Advanced Options Test Stimulus 5 38 554 Testing a Cable with Capacitors sse 5 38 5 5 5 Error Reporting for 5 39 56 DOMES orcas tar c cS MU m su M MM EA 5 40 5 6 1 Programming Diodes Auto learn seen 5 40 5 6 2 Programming Diodes Auto learn Special Case Phantom Diodes 5 45 5 6 3 Programming Diodes Manual 5 46 5 64 Programming Diodes Advanced Options sss 5 48 5 64 1 Programming Diodes Advanced Options LEDS 5 48 5 6 4 2 Programming Diodes Advanced Options Diodes in Parallel 5 49 5 6 4 3 Programming Diodes Advanced Options Bl colour LED s 5 49 5 6 5 Testing Cables with Diodes sse 5 50 5 6 6 Testing LEDs and BLEEDS icc
24. You must contact the factory to get the Override Key The Registration Key was provided at the time of purchase to active the TCL Package You must provide the unit s serial number as well as Uninstall Verification Key Enter the Override Key which is provided by the factory If there is an error when entering the Override Key this message will appear Select Ok and try again If it persists call the Horizon Technical Support Enter the Registration Key If there is an error when entering the Registration Key this message will appear Select Ok and try again If it persists call the Horizon Technical Support 3 4 1 3 Uninstall Advanced NetList Editor or TCL Package To uninstall the Advanced Netlist Editor or the TCL Scripting Package select Uninstall for the specific option 3 8 Horizon Series Tester Programmer s Manual System Setup are about to permanently uninstall m of the optional software 1 provided with validation Any refund where aps ene must be accompanied by the validation key 2 7 2 2 you want to permanently uninstall package Memorize Uninstall Keu F5802F79 JL2 5 Ls 7 4 4 Uninstall Netlist Editor Uninstall TCL Package
25. A Z peace crear Enter was pressed beforet Add it to the key list a Set Test Parameters Name Prompt Adapters Low Voltage Components High Uoltage More Options Net List Print Test Now Cancel Insert the product into the adapters Select Ok to continue The net list is learned Press and hold the momentary switch Once the measured resistance is displayed release the switch Enter a label name and select Enter to accept Press and hold to measure the next momentary switch With no more switches to press select Done If the same switch key has been pressed twice then the Key was pressed before screen will appear Selecting Yes will accept the switch and selecting No will continue without accepting the switch From this point on the process is identical to that for any other cable You do not have to do anything else to finish programming and to test this cable with embedded switches Select Ok to save the test procedure in the internal database 5 8 4 Manual Entering Temporary Switches Keys Horizon Series Tester Programmer s Manual 5 61 Advanced P rogramming Pronpt Adapters Low Voltage High Voltage Components Net List More Options Print Test Now Cancel EM Ed
26. Label Enter a part number for the flying lead product From here you can modify any of your test parameters or define additional tests such as DC or AC HiPot tests Consult the appropriate sections of this manual for details When you are through Select Net List to verify the learned product The Edit Net dialog reveals the correctly learned product Select Open for more details for each net Pin list for net 1 Select Ok to return to the Edit Net Ok again to return to Set Test Parameters and Ok a third time to save the learned product 5 8 Horizon Series Tester Programmer s Manual Advanced Programming Test Program as CBL File 5 datab cables main flyingle cbl CABLE FLYING LEADS 1 QUICKCONTINUITY QUICKISOLATION STAR THRESHOLD 61 ADAPTER HA 116 POSITION J1 NET FREE END 1 GREEN NET J1 C1 25 NET FREE END 3 BLACK NET J1 C1 4 NET FREE END 5 WHITE Ji Cl 554 NET J1 C1 6 NET NET J1 C1 8 NET J1 C1 9 NET 21 61210 NET NET 16112 For greater detail see section 9 JliC1 13 4 Ji Cl l4 J1 C1 15 J1 C1 16 J1 C1 17 912612490 J1 C1 20 TIL 32245 J1 C1 24 J1 C1 25 Horizon Series Tester Programmer s Manual 5 9 Advanced Programming 5 2 2 Testing A Cable With Free Ends As with all testing o
27. 8 4 5 lel 2 8 2 EB LJ O LJ Es 5 CIE LJ nter is Hanra Bar lear Set Test Parameters Mame Pronpt Adapters Low Voltage High Voltage Components Net List More Options Print Test Now Cancel 1 3 41 62 35 J1 62 4 gt 1 5 J1 62 55 1 1 6 J1 62 65 1 7 Ji 62 75 Erit Leaver Biol E 4 v e On the Component Settings menu select Ok to start learning the product Placed the appropriate adapter for the terminated end of your product Select Ok to continue Insert the product into the adapters and select Ok to begin the learning process As the product is learned a status screen keeps the user informed about the progress Enter an appropriate part number for the product learned and select Enter On this menu the user can set different test parameters test the product add or view components or view the NetList On the Set Test Parameters menu select NetList Select Twisted 5 12 Horizon Series Tester Programmer s Manual Advanced Programming Capacitors Diodes Black Boxes
28. 9 s The Horizon increments to the next Pin however our 1 Probe fluins lead product has the 5 pin as the third lead Select Next to Press OK when done lt lt Prev Done Next gt gt advance qms Probe the third lead 31 Probe flying lead 5 f Press OK when done lt lt Prev Done Next gt gt Se Enter the label for the third lead E a Lr v Iv L1 2 2 ls n I Dr HHAH Space Bar s Enter With no more leads to probe select Done 3 Probe flying lead 6 Press when done lt lt Prev Next gt gt Horizon Series Tester Programmer s Manual 5 7 Advanced Programming Enter Part Number FLYING LEADS 0 0 9 2 2 6 4 2 8 2 Space Bar E1e2x Pronpt Adapters Low Voltage Components High Voltage Net List More Options Print Test Now Cancel OK 2 Edit Net Em FLYING LEADS one eNet BLACK J1 C1 35 Ji C1 4 Net UHITE Ji1 c1 55 Net 1 1 6 JL C1 7 gt Eait Label gt Open Twisted 2 Label Pin Em FLYING LEADS Y Be an
29. Print Test Now Cancel Save Cable Record Refresh OK Cancel Select Label to assign a label to the component Enter a label and select Enter to accept All of the needed changes have been entered so select Cancel to return to Set Test Parameters Add is used to add capacitors to a cable without learning them and to take care of certain special cases If you are through specifying the tests for your product select Ok to save the test procedure in the internal database Cancel will take you back to Program Cable and discard all of the learned parameters Select Yes to save your cable record The Save To Directory dialog appears No returns you to the Main Menu Move the cursor until the directory in which you want to save the cable is highlighted then select Ok The cable record is saved and you are returned to the Programming Cable menu If you want to store your cable in a new directory select New and you will be prompted to enter the new name Select Enter when through You can use any combination of up to 30 characters Horizon Series Tester Programmer s Manual 5 33 Advanced Programming Test Program as CBL File datab cables main capacitor cbl For greater detail see section 9 CABLE CAPACITOR 1 NET STAR 21 1 13 THRESHOLD 61 23 019 116 NET POSITION J1 J1 C
30. 4 48 AICS cei 4 46 AES 4 39 Bypass Dwell 4 47 DC 4 46 Hipot Duration 4 39 Hipot Nets 4 37 Eeakage 4 46 Leakage Settings 4 38 Horizon Series Tester Programmer s Manual iii INDEX Mass or Linear Scan 4 40 Password Protected 4 38 Regular Dwell 4 47 Settings nier e 4 38 SOAKING wei 2 ete 4 48 Voltage Setting 4 38 DC hipot test duration 4 39 2 8 4 9 Diagnostics Displayed Results Ribak trementes 4 9 ihe eed HEC 4 9 NONE ertt ee 4 9 sonent ERIS 4 9 PASSIEAIL 4 9 Diode TVpess 5 42 Diodes Autolearn 5 40 BI LED Labeling 5 50 BI LEDs Visual Test 5 49 Editing Thresholds 5 48 ott 5 51 eene pepe 5 43 LED amp BI LED Faults 5 52 LEDs Visual Test 5 48 Manual Programming 5 46 Parallel Components 5 49 Phantom Components 5
31. 9 23 rente 9 15 9 12 KELVIN iae etes 9 11 9 29 9 15 9 16 9 32 9 21 LINEAR 9 16 9 16 NETS Linien 9 26 itii 9 25 BASS iue 9 20 9 20 9 6 PRINTER 9 21 9 24 9 24 9 15 9 32 REGULAR serene aa 9 15 REPORTS cannes 9 20 RESISTOR ie 9 29 5 9 32 REVERSED 9 32 TSCHOTTKY eret 9 32 SERIALNUMBER 9 22 PELO 9 27 SIGNAL aiia eee 9 32 OAR iei pepe 9 15 POLAR 9 12 SWITCH 9 27 TEARE S gation deus 9 31 5 9 22 THRESHOLD 9 14 VALUE 9 29 VISUAL iit ets 9 31 9 33 9 21 Time setting 3 4 Tools See Assembly Aid Tools Touch Screen Failure 3 14 Turn on your Horizon 2 3 y ER
32. Select Twist window displays the twisted pairs that were found during the learning process In this window the user can add edit delete or label the twisted pair When Edit is selected from Select Twist the user can delete the nets label the nets or change the threshold value Select Ok to continue The Select Twist menu can also be displayed by selecting Components on the Set test Parameters menu This will open the Edit Component List menu Select Twisted Pairs to enable the Select Twist menu Horizon Series Tester Programmer s Manual 5 13 Advanced Programming Test Program as CBL File datab cables main twisted cbl For greater detail see section 9 CABLE TWISTED 1 NET THRESHOLD 61 250 25537 QUICKCONTINUITY STAR NET QUICKISOLATION J1 1 565 ADAPTER HA 116 POSITION J1 NET ADAPTER HA 115 POSITION J3 TWIST NET THRESHOLD 2e 11 NET d3 0l28 J1 C1 9 NET 43 1 9 di l l0 NET JgJ3 Cl 10 J1 C1 21 23 1 21 le Del Lys TWIST dae cl Ll THRESHOLD 2e 11 NET NET 5 J1 C1 16 dS 12y J3 C1 16 NET NET 13 J1 C1 22 2220112 J3 C1 22 TWIST J1 Cl 14 THRESHOLD 2e 11 J3 C1 14 NET NET J1 C1 24 15 23 1 24 NET NET J1 C1 25
33. a Component Settings Resistors Capacitors Diodes Switches HE Back Cancel A Insert fidapter s 112 J3 J4 i 112 112 J7 Select Cancel In the Component Setting screen you have two available options Permanent Switches Used for mechanical switches Temporary Switches Used for momentary switches such as membrane switches Select Temporary Switches Input the maximum expected resistance for the embedded switch In the example shown the highest expected value is 50Q Select Enter when through to return to Component Settings menu Notice that the Temporary Switches box is now checked and the maximum resistance value has changed Select Ok to continue Notice that the Switches box is checked indicating to the Horizon that your cable has an embedded switch es Select Ok to continue the learning process Insert the appropriate adapters Select Ok to continue 5 60 Horizon Series Tester Programmer s Manual Advanced Programming a Learn New Cable then press OK Insert the o Product continue Enter Key s Label 8 Reset s 2 2 5 7 2 5 9 EI ED TET
34. 31 Cathode Ji Ci 3 More Options Label 3 Edit Diode H Parallel min 5 6 4 1 1 Edit Diode H Zest UF i 74U More Ortions _Labe1 From the Edit Diode dialog select More Options From the More Options dialog select Test Params to manually edit the Diode s Thresholds Should you wish to alter the forward and reverse values select either Vf or Ir to enter the minimum and maximum values Programming Diodes Advanced Options LEDs The advanced option for the LED allows the user to set a visual test on the component Select More Options 5 48 Horizon Series Tester Programmer s Manual Advanced Programming Parallel Test Params 5 6 4 2 2 Edit Diode Cathode J1 C1 3 More Options Label Edit Diode E Parallel T Be bude Test Params DK xj Edit Diode Cathode Ji Cl 1 Ji ci 3 More Options Label 5 6 4 3 Parallel Test Params Select Visual Tst to enable the visual confirmation during testing Programming Diodes
35. 7 fida Cancel Ok The default password is 1234 It is highly recommended that you change this as soon as you put the Horizon into use on your production floor The Delete key will delete the highlighted password Use the arrow keys to highlight the one to be deleted Cancel returns you to System Setup with no action taken 3 20 Horizon Series Tester Programmer s Manual System Setup V Make sure that you always leave at least one password active or you will be locked out of password protected modules If you want to add a new password select Add to enter the Enter Password dialog Input a password of four numbers Make sure that you either carefully memorize it or write it down and put it in a safe place Select Enter and you will go to the Enter Password Type dialog Valid passwords 1000 9999 Horizon currently supports three levels of passwords Operator Service and Supervisor Select the type you want for this password and you will return to the Password Settings menu Repeat these steps as necessary to set up the passwords you want When you are finished select Ok to return to System Setup Delete Enable fida Cancel OK 3 8 2 Disabling Passwords By default the Horizon system prevents unauthorized operation by requiring an operator or user to enter a valid password when accessing certain of the system s f
36. ALZ Space Bar Elear SB Once you have probed all the conductors the Done is displayed At this point you can continue to probe to verify the group Select Done to continue Enter the pins for the second group and begin probing the remaining conductors Probe until done Select Done to continue Upon completion of the second group you will now have three sets of conductors Select ESC to continue Step 4 Group Verification group continuity It is highly recommended once the groups are separated to perform a group scan on each of the groups Pin Locator Group Sorting Group Scan Cancel From the Select Tool menu select Group Scan 4 34 Horizon Series Tester Programmer s Manual Basic Programming and Testing 8 5 8 EIDE 21 2 Wee zer ness Space Bar Elear Enter the pins of Group One Place the Probe and Group One into the water and select Enter to continue see step 2 for details Repeat the scan for Group Two and Group Three Once all three groups have been verified you can move to connector population Step 5 Assembling the product The three verified groups can now be populated within the connector 1 Select Tool Pin Locator Group Sorting Group Scan Cancel
37. Language OK Available languages at the time of publication Read this warning carefully Use the up and down arrows to scroll through the warning message Select Ok to continue Select Yes to permanently uninstall the Editor or the TCL Package No will abort the uninstall process and return to the General Setup menu Write down the displayed the validation key CableTest will require this key if the Editor or the TCL Package is re installed Select Enter to return to the General Setup menu Language Select the default language of the Horizon The Select Language menu will allow the user to select the language of choice The selected language will only change the operator s menus These menus are Main Menu and Test All other screen will remain in English German French English Romanian Swedish and Spanish 3 4 2 Digital Hand Held Probe Smart Probe Horizon Series Tester Programmer s Manual 3 9 System Setup The Digital Hand Held Probe DHHP is automatically detected when connected to COM 1 of the Horizon To set the probes available options select Smart Probe from the General Setup menu For more details regarding functions and features of the Digital Hand Held Probe refer to the documentation shipped with the unit Smart Probe Setup menu Enable e Enabled Activated the DHHP is enabled The
38. Netidi ci 24 J3 C1 245 res 267 3m0hm NettJi1 C1i 25 J3 C1 25 res REZISTORI 1 497MOhm End of Report arance 4 If no results are shown you may need to set the display to Pass or All see Section 4 4 2 or the diagnostics may have already reset 5 4 5 Testing a Cable with Resistors Lamps When testing a product with an embedded illuminating Visual Test m component such as a bulb the test program halts for confirmation of illumination from the operator Reported Results ALL The diagnostic test report for a passed product list the component with the measured load in resistance selected output resistance voltage or current End of Report Print 5 4 6 Error Reporting for Resistors All of the same errors are available in this mode as for general cable testing The following additional error screens cover the special circumstances associated with embedded resistors Results The resistance for resistor 1 is below the expected value 33 c1 23 gt res including the tolerance zone The actual resistance is 279 3m0hm HettJi1 Ci 24 J3 C1 24 res Paseo one measured and reported to help a technician correct the 25 res 1 9994 problem Le 7 21 2 __ __ The resistance for resistor
39. 5 51 5 6 7 Error Reporting for Diodes seen 5 51 5 6 8 Error Reporting for LEDs and _ 5 5 52 5 7 Four Wire or Kelvin Testing esses seen 5 52 5 7 1 IntroQUCtion Ine suet fete 5 52 5 7 2 Testing a Cable using 1 5 54 5 8 nU 5 55 5 8 1 IntrOQU Con eroe pP edad tee neret e ed 5 55 5 8 2 Programming Switches Permanent sene 5 56 5 8 3 Programming Switches Temporary Membrane Switches 5 60 5 84 Manual Entering Temporary Switches Keys 5 61 5 8 5 Four Wire Measurement and Switches see 5 64 5 8 5 1 Overview of the Four Wires Measurement and Switches 5 64 5 8 5 2 Using the Four Wires Measurement and Switches 5 64 Horizon Series Tester Programmer s Manual v Table of Contents 5 8 6 Testing Cables with Switches seen 5 67 5 8 7 Prompt Abort Ignore Rely aissis eene 5 69 5 8 8 Error Reporting for Switches seen 5 69 6 Adapters 6 1 6 1 Introduction iba 6 2 Learning an Adapter 6 4
40. By default all affirmative buttons Ok and Yes can be selected by pressing Enter and all Cancel or No buttons be selected by pressing Esc Main Menu A detailed tour of the Main Menu will be provided in the following section The only two selections you will need for EE this Getting Started exercise are the Test lt Alt T gt button and Backup _ Adapter the Programming Cable lt gt button Contrast shut Please note that Programming Cable lt Alt P gt is password protected as indicated by the small key symbol to the right of the button display Most companies want to restrict the ability to perform these types of operations to a selected few so a complete multilevel password protection capability is provided Sun Sep 29 2002 12 37 The factory installed Password is 1234 Horizon Series Tester Programmer s Manual 2 3 Getting Started 2 2 Learning Your Cable The easiest and most straightforward method of programming the Horizon is to use a known good sample or Golden cable for each type of cable to be tested The parametric model for this cable is then stored internally in a simple ASCII file and used as the basis for testing all cables or harnesses of the same type and configuration For that reason the first time you learn a given cable care should be taken to use a known good sample However once a cable is learn
41. Refresh 1 1 Select Yes to save your cable record The Save Directory dialog appears No returns you to the Set Test Parameters menu Move the cursor until the directory in which you want to save the cable is highlighted then select OK The cable record is saved and you are returned to the Programming Cable menu If you want to store your cable in a new directory select New and you will be prompted to enter the new name Select Enter when done You can use any combination of up to 32 characters You can continue the learning process and program as many cables as you like by simply repeating these steps When you have finished select Cancel and you will return to the Main Menu Horizon Series Tester Programmer s Manual 4 5 Basic Programming and Testing Test Program as CBL File datab cables main testcabl cbl For greater detail see section 9 CABLE TEST CABLE 1 NET QUICKCONTINUITY Ji 124 QUICKISOLATION 931 125 STAR NET THRESHOLD 61 JisCl 13 ADAPTER HA 116 93 01 13 POSITION J1 NET ADAPTER HA 116 214 61 14 POSITION 93 J3 C1 14 NET NET 411261215 255 NET NET Jd EL J1 C1 16 13 22s J3 C1 16 NET NET Jl CT 17 J3 01 3 7 J3 C l 17 NET NET J1 C1 18 J3 C1 4 J33CESL8 NET NET Jgl Cl 5 9
42. SIGNATURE 1 1000 1 1500 SIZE 1 VERSION V4 2 50 CONNECTOR DB 25 FEMALE 18 1 6 49643e 12 0 0549 0 0347 0 0371066 0 0372955 19 2 4 225 12 0 0424 0 0224 0 0383864 20 3 3 5 12 0 0521 0 0434 0 0163888 0 0415342 21 4 4 85 12 0 0472 0 0433 0 0297879 0 0443802 22 5 5 975e 12 0 0548 0 0572 0 0458907 0 0489997 23 6 4 1e 12 0 0664 0 0477 0 0287416 0 0520463 28 7 5 175e 12 0 0745 0 0683 0 0449316 0 0758962 6 8 5 09286 12 0 074 0 0639 0 0616145 0 0653432 7 9 4 875 12 0 0503 0 0543 0 0352298 0 0545201 15 10 4 25 12 0 0443 0 0388 0 0449438 14 11 3 025 12 0 0323 0 0345 0 0299088 0 0388788 13 12 4 7 12 0 0214 0 0321 0 0337148 0 0360858 12 13 3 205 12 0 0346 0 04 0 0307894 0 0340614 17 14 3 15 12 0 05 0 0437 0 0299103 0 0417339 16 15 4 75 12 0 0545 0 0425 0 015863 0 0442314 24 16 5 15e 12 0 0483 0 0627 0 0536157 0 0579428 25 17 6 525e 12 0 0651 0 0657 0 0505918 0 0734726 26 18 5 325 12 0 102 0 0734 0 0838286 0 0856556 2 19 6 925 12 0 0847 0 087 0 0837441 0 0877148 1 20 6 825 12 0 0815 0 0826 0 051058 0 0748405 0 21 7 3e 12 0 0621 0 0745 0 056447 0 0598312 8 22 6 175 12 0 0438 0 0424 0 0382992 0 0500458 9 23 4 35 12 0 0389 0 0542 0 0314001 0 0445852 10 24 5 3e 12 0 0467 0 0379 0 0763667 0 0399493 11 25 4 575e 12 0 0404 0 044 0 056884 0 0380404 In the example above the adapte
43. lt s_pinAddress_1 gt lt s_pinLabel_1 gt lt s_pinAddress_2 gt lt s_pinLabel_2 gt VALUE lt minimum in ohms gt lt maximum in ohms HCRES value where value is in amperes 9 30 Horizon Series Tester Programmer s Manual Scripting Features HC VoltageDrop RESISTOR lt s_netName_1 gt lt s_netLabel_1 gt lt s_pinAddress_1 gt lt s_pinLabel_1 gt lt s_pinAddress_2 gt lt s_pinLabel_2 gt VALUE lt minimum in ohms gt lt maximum in ohms HCDROP value where value is in amperes HC Load RESISTOR lt s_netName_1 gt lt s_netLabel_1 gt lt s_pinAddress_1 gt lt s_pinLabel_1 gt lt s_pinAddress_2 gt lt s_pinLabel_2 gt VALUE lt minimum in ohms gt lt maximum in ohms HCLOAD lt value gt where value is in volts Programming Resistors Lamps The text file format for resitive loads such as Lamps is as follows RESISTOR lt s_netName_1 gt lt s_netLabel_1 gt lt s_pinAddress_1 gt lt s_pinLabel_1 gt lt s_pinAddress_2 gt lt s_pinLabel_2 gt VALUE lt minimum in ohms gt lt maximum in ohms VISUAL HCVOLT lt value gt Where value is in volts Programming Capacitors The text file format for capacitors is as follows CAPACITOR lt s_netName_1 gt lt s_netLabel_1 gt lt s_pinAddress_1 gt lt s_pinLabel_
44. E e 5 Space Bar lear Learn Kelvin Fixture for Switches Set Fixture for the 2nd pos then press OK to learn it Cancel to end learning Ok Cancel After the Kelvin fixture is learned you are prompted to connect the product in its first switching position first test step configuration Please make sure the product is appropriately connected and then select Ok After the first switching position first test step is learned you are asked to enter up to three prompt lines Of course you will enter your own message something that reflects the step being performed The prompt lines are displayed at the test time for the operator to know how to configure the product under test When Horizon is operated in an automated mode the display message is rather informative telling which step is being performed This is an example of a second prompt line If you don t need the third prompt line just select Esc You can actually skip by selecting Esc in any of the three prompt line screens All subsequent if any prompt line screens will be skipped Now once the first switching position first test step is completely defined the system prompts you for the second switching position At this step you have to configure the Kelvin fixture for the second test step Do not forget to disconnect the product to allow for proper test fixture learning 5 66 Horizon Series Tester Program
45. Insert the anes o en press OK product continue Set Test Parameters H Name 7 Prompt Adapters Low Voltage Components High Voltage More Options Net List Print Test Now Cancel To learn a cable using a Kelvin fixture select Program Cable from the Main Menu then from the Programming Cable menu select Learn New Cable Custom From the Learn Settings menu select Kelvin A check mark will appear indicating that this cable will be learned as Kelvin After any other desired settings select Ok Add any components at this time Select Ok when through Insert the adapters needed for the cable being tested and select Ok The Horizon must first learn the Kelvin fixture During this process the system will automatically determine which test points are being used for two wire measurements and which for four wire Insert the fixture adapter cabling only and select Ok to start learning After learning the fixture the Horizon will learn the sample cable Insert the cable making sure that all connections are completely seated then select Ok to start the process To verify the product has been properly learned select Net List Horizon Series Tester Programmer s Manual 5 53 Advanced Programming 2 D 32230 OONAN HHHMH ONNU amn
46. NET NET J1 C1 9 J1 C1 24 Jd3 01497 J3 C1 24 NET NET 1161410 21 1 25 J3 C1 10 J35 1 25 NET END Horizon Series Tester Programmer s Manual 4 55 Basic Programming and Testing 4 14 4 Customize the AC HIPOT by Nets You can choose to perform HiPot testing on only a portion of your cable by performing a HiPot test on the entire cable except for certain nets In which case you select those nets you do not wish to perform a HiPot test on Name Prompt Adapters Low Voltage More Ortions Test Components Net List Print Cancel LOC n EN Edit Net s Settings IM DC Hirot Custom nc Default Fi BC Hirot Custom Conductor Res AC Default EF Default Def au lt Default Kelvin Eh The is se o be able to customi ie ipot fiobal inear Hip met z change the scan type to global AC hipot scan tupe t to Mass nt ott Zg the se ings hipot ot To program nets to be excluded from the HiPot test select Net List from the Set Test Parameters menu The Edit Nets dialog will be displayed Using the arrow keys move the cursor to highlight the net you want to exclude or include from HiPot testing S
47. Passed 1 Failed Error Statistics Diagnose Retest Cancel Test Report Results ALL 250 9m0hm Het tJ1 C1i 23 J3 C1 23 res 242 9m0hm NettJ1 Ci 24 J2 C1 24 res 253 2m0hm Net tJ1 C1 25 J3 C1 25 res 265m0h 1 0 447mU Ir 25nf wee End of Report vema Print OK 5 6 6 Testing LEDs ud 1 Visual Test LED 1 Tested i Passed 1 Failed Error Statistics Diagnose Retest Cancel LED i LED 1 visual test OK wee End of Report vema At the end of the test disconnect the product to reset the system for the next test Prior to disconnecting the product if the user selects Diagnose the results of the last test will be displayed and BI LEDS The same tests are performed for LEDs as with diodes and will include the same error results However once the standard diode test is complete and passed a visual test if selected will be preformed The operator is prompted to confirm the component is lit With BI LEDs the operator will be prompted twice once for each direction of the component The special labelling option will apply at this point At the end of the test disconnect the product to reset the system for the next test Prior to disconnecting the product if the user selects
48. Scan Star Conductor Res Scan SmA Stimulus Isolation Min Res Tare Quick Scan OK The Specify Continuity Type menu is displayed and the following options are available Quick Scan MSR Resistance 5mA HC Resistance Voltage Drop Fixed HC From Sample Maximum conductor resistance in 6 500 Elear BS Enter MSR Programmable HCS Programmable HCS Fixed HCS MSR To utilize the Programmable HCS select HC Resistance Enter the Maximum Conductor Resistance ira 3 2 3 Es vers e Esc onductor enter the Minimum Conductor Resistance and the nominal continuity current must be entered The 2 2 continuity test will be performed using the high current Ss programmable source The maximum resistance entered at 5 the step above will be used to qualify the continuity test Le ese SE Select Ok to accept the settings and return to the Set Test Parameters menu Tare OR 4 64 Horizon Series Tester Programmer s Manual Basic Programming and Testing 1 000 Enter Low Voltage Settings H
49. Test Now Batches Cancel Since the test specification calls for an AC HiPot test the Horizon automatically performs a degauss cycle before testing starts SShart Betugen eto CE 7 The Horizon will first perform all of the specified low voltage le rom H H amd tests If any of the tests fail the Fail light will turn on you will have the opportunity to select Diagnose The low voltage faults will be shown in a display similar to that Ok shown If a product fails any of the low voltage tests HiPot testing will not be performed After the product has passed all of its low voltage tests it Perforn the can now be tested with high voltage If you set up Autohipot Hipot Test during the system setup HiPot testing will proceed automatically If not the Perform AC Hipot Test dialog will Slave Test gansel appear In either case if you specified Password Protected when the cable was learned an Operator level password will have to be entered before testing will start Select the Yes button HiPot testing will start and the Performing Tests dialog appears Selecting No will return you to the Test Statistics window and the Fail light will be lit Selecting Diagnose will show a message indicating that all tests have passed what has happened is in essence a forc
50. a Batch Settings Number of Batches Cables per Batch eo m 1 Batch Settings Number of Batches Cables per Batch Enter of cables HI 1 Elear Enter Esc Humber of Batches 5 Cables per Batch 19 The Batches feature is set up from the Test Configuration menu accessed by selecting Test on the Main Menu From this menu select Batches to set up the batch parameters needed for a given product Note that the operator must set this up for each testing session where batches are needed In that way using the batch feature is straightforward and will not require any special attention by supervisory personnel Selecting Batches brings up the Batch Settings dialog Select Number Of Batches to input the desired number of batches select Cables Per Batch to enter the number of cables per batch needed The example requirement calls for five batches of ten cables each Selecting Enter enters the number of batches Select Cables per Batch Selecting Enter inputs the number of cables per batch The Batch Settings menu shows that the data has been entered correctly Select Ok to return to the Test Configuration dialog Once the values become active not shaded
51. ol ened J3 C1 25 NOTWIST NET NET 21 1 18 ly J3 C1 18 930101 NET Jl Cl1 19 J1 C1 2 480 NET NET 1 1 20 2022920 NET NET 21261003 J1 C1 4 J3 C1 4 END 5 14 Horizon Series Tester Programmer s Manual Advanced Programming 5 3 2 Testing a Cable with Twisted Pairs J1 5 4 Resistors When Test Now is selected to the Set Test Parameter menu or Test Configuration menu a progress bar will display the status of the test The Test Report menu will display all test results This menu displays all tests that passed This Test Report menu displays a failed twisted pair cable during test J3 Learn Settings 7902 N Twisted Nets Only Free Ends Kelvin onductor Max Res Use Kelvin Probe 1 Figure 5 2 PUT with embedded Resistor 5 4 1 Programming Resistors autolearn For proper resistor measurement and detection Conductor Max Res must be set to a specific value This is especially true for resistor values 300Q or less The Horizon will need to be able to differentiate between conductors and low value resistors Select Ok to continue Horizon Se
52. 4 13 6 Error Reporting Should the product fail or if the HiPot was a linear scan select Diagnose on the Statistics window to view the diagnostics A linear HiPot was performed and passed The diagnostics reports the measurements made during the test For the PUT the IR is extremely high The Horizon reports should the measurement be over range In addition to the standard Error Reports three additional ones are associated with DC HiPot tests Test Report over load Betis poa Recrlead Net25 End of epor en Reported Results FAIL leakage 19 ZBE breakage petan 335pA Lae ae Test Report Reported Results ALL arc during mass hipot arc arc Netia End of Report Lae ae The sample Test Report indicates that during the DC HiPot test a fault occurred at nets 19 and 25 DC Overload is reported when an arc or excessive current leakage occurs during the charging cycle of the DC HiPot test The message is used to differentiate between arcs during the HiPot test duration and during the time the cable is being charged to the HiPot voltage level This sample report indicates that during the DC HiPot test there was current leakage at nets 19 and 25 The Horizon measures and reports the level of leakage In this example an arc occurred durin
53. Advanced Options Diodes in Parallel The Horizon is capable of auto detecting diodes in parallel If you are manually entering diodes you will need to open the more options for the component and select Parallel to properly identify the component Select More Options from the Edit Diode dialog Select Parallel to properly define the component Select Ok to return to the Edit Diode dialog The diode is now identified as being in parallel by the duplication of its type Diodes Advanced Options Bl colour LED s The Bl color LED is both a visual component and a parallel component If you are manually entering diodes you will need to open the More Options for the component and select Parallel and Visual Tst to properly identify the component Select both under More Options from the Edit Diode dialog Horizon Series Tester Programmer s Manual 5 49 Advanced Programming a Edit Diode Anode Cathode Betect Test 1 73 Ur i 4U More Options Label OK Ji Cci 1 Ji ci 2 LED3sx LED3s a Label Diode 8 4 5 6 7 8 9 9 21029 20 00005 CIE HBL EHHE 5 Enter ALZ Space Bar lear The component settings will be properly displayed With Test selected the Vf Vr will be displayed as well the component will light in both d
54. Advanced Programming Con Dwell programmable dwell to lengthen the time the source is held on each net during the learning cycle This option may improve learning accuracy on very long products Use Kelvin Probe Option to create a probe using two test points for accurate resistance measurements of Free End products Select Ok after setting any of these desired parameters to start the Component Settings dialog ee The Horizon will help you detect and program one or all nss istarai Lig esgeeteses of the listed embedded components but it must have a etesse swstenes starting point and it must know what it is looking for While you can have any one or all of these component types in Back Cancel e your cable they will be discussed separately for ease of understanding Simply follow the procedure s for the component s you have 5 2 Free Ends or Flying Leads Many cables and harnesses have wires that are terminated Into a connector on one end only These can also be fully tested by using the supplied probe All you need to do is to tell the Horizon where these leads are and how you want them tested Ji gd 127 i Horizon Ground Probe 25e Figure 5 1 Product Under Test Flying Leads 5 2 1 Programming a Free Ends Test 5 4 Horizon Series Tester Programmer s Man
55. BUILDAID RANDOM PIN Probing during Build Aid By default the system doesn t use the Horizon Ground Probe during the build aid process In order to active the use of the Probe BUILDAID PROBE ALL The optional ALL subcommand specifies that all wires may be probed and not only the one that is currently being built When this option is used the Horizon s response when probing is deteriorated since it must scan all available points To activate the probe just for the wire that is being built BUILDAID PROBE To activate the probe just for all wires Horizon Series Tester Programmer s Manual 9 19 Scripting Features BUILDAID PROBE ALL 9 1 6 Print Options Each tested product can have its own print options set within the test program To set global print options see section 7 1 Global report options will take precedence over embedded report options Logging Test Results to File To enable the report logging use the syntax described below REPORTS FILE APPEND FORMFEED PASS FAIL PASSFAIL ALL The optional specifies that the results are to be appended at the end of the existent log file if any If APPEND is missing or the log file doesn t exist then a new log file is generated The optional FORMFEED specifies that a form feed character is to be output to the file after each tested product This is esp
56. Insert tare adapter s sequentially in all VW Hn ran Rare In order to perform the Resistance Tare users must have a special tare adapter as designed by CableTest International Inc Contact your sales representative for more details Update Horizon client software updates can be inserted using the update feature By selecting Update the user is prompted whether to perform the update Insert the first of the provided diskettes this disk will be labelled 1 of n and select OK 3 14 Horizon Series Tester Programmer s Manual System Setup Perform Update of the Software Upgrade done succesfully Press CANCEL to exitt OK Cancel Once complete select Cancel to exit the Update module If your system is operating through a network the update will only update the local Horizon You will need to update the files located on the network server manually Isolation Tests the isolation of all installed test points in your Horizon system Action Required Remove all adapters CUT or MUX cards An isolation test for all 15 of th available oints system will be performed HU Tests HUS Tests Program 19 06 00 1 0 5932 Shorted C61 59215 1 Card6 Susi5 gt Shorted C61 59514 weer End of Report se TL
57. Introduction 1 1 Welcome Thank You Congratulations and thank you for purchasing your Horizon Series Tester CableTest Systems Inc is proud of its Horizon line of testers and warranty s them for one 1 full year parts and labour please see our complete Warranty at the beginning of this manual Where to get more help Check out our web site www CableTest com Email our Support Team service CableTest com Call Toll Free in the US and Canada 800 495 1998 International 1 905 475 2607 Fax 1 905 475 2609 1 2 Abbreviations and Symbols 9004 40 EP EXP FER HCS MSR NetList PUT TCL Important Additional User Information Caution Indicates how to avoid potential damage to parts components or loss of data Warning Indicates how to avoid potential bodily harm Keyboard Shortcut Horizon Lite user navigation information Examples of Horizon Script Language Emergency Power Off Expansion Faulty End Recognition High Current Source High Potential Test High Voltage Low Voltage Measurement Board Groups of test points sorted by their connections Nets Product Under Test Tool Command Language Horizon Series Tester Programmer s Manual 1 3 Introduction 1 3 Safety Warning This product generates high potential as a test stimulus when programmed to do so To avoid the risk of shock do not attempt to service the supply beyond the described steps in the User s Manual To a
58. WPrPnX KX ECE Save the new file as Text Only using up to 8 characters and the CNV extension Horizon Series Tester Programmer s Manual 6 11 Adapters E g example CNV If you create the file using a word processor like Word or Word Perfect it is imperative you save as Text Only Adding the file to the Horizon To add the file to the Horizon database you can use one of two methods The first is to manually copy the new file to appropriate subdirectory on the Horizon s hard drive C v4 0 datab convent Or you can use the client software to assist you On a blank diskette create a subdirectory or Folder called Convent Copy the new convention file s into this directory on the diskette Main Menu H From the Main Menu of the Horizon select Backup Tue Aug 25 1998 03 13 3 Test Self Test System Setup Program Cable Backup Edit Adapter Contrast Shut Down Backup Restore Shell Backup Restore Save Log Files neresnitione 24 Cancel Toggle Test Programs and Adapter Files to the position the check mark will appear next to the Adapter Files Select Next to continue Pictures Files Cancel Select Restore 222 2 Zz Z Z Z P HIP P The file s will be copied Cor
59. lt s_pinAddress_1 gt lt s_pinLabel_1 gt lt s_pinAddress_2 gt lt s_pinLabel_2 gt lt type gt Where lt type gt is defined as per Table 1 Diode Types The text file format for diodes with custom or Auto detected thresholds is as follows DIODE lt s_netName_1 gt lt s_netLabel_1 gt lt s_pinAddress_1 gt lt s_pinLabel_1 gt lt s_pinAddress_2 gt lt s_pinLabel_2 gt 9 32 Horizon Series Tester Programmer s Manual Scripting Features lt type gt FORWARD minimum in volts gt lt maximum in volts REVERSED minimum in amps gt lt maximum in amps Programming Diodes Visual test with LEDs The text file format for a visual test using LEDs is as follows DIODE lt s_netName_1 gt lt s_netLabel_1 gt lt s_pinAddress_1 gt lt s_pinLabel_1 gt lt s_pinAddress_2 gt lt s_pinLabel_2 gt LED VISUAL Programming Diodes Parallel The text file format for diodes in parallel is as follows DIODE lt s_netName_1 gt lt s_netLabel_1 gt lt s_pinAddress_1 gt lt s_pinLabel_1 gt lt s_pinAddress_2 gt lt s_pinLabel_2 gt lt type gt FORWARD lt minimum in volts gt lt maximum in volts gt REVERSE lt minimum in volts gt lt maximum in volts gt PARALLEL Where lt type gt is defined as per Table 1 Diode Types Programming Diodes
60. 1 2 J3 C1 2 res select Diagnose at the end of the test to view the RI m 1 1 J3 C1 3 res Rer i a J3 C1 4 res measurements STETIT TL 7 The Reported Results is set to ALL See Section 4 4 for greater detail Selecting Error Statistics will show the Cumulative Fault Report In the example shown only one cable has been tested and it was good so the report shows all 0 s Miswired 2 Hipot DC Hipot 5 Selecting Ok returns you to Connect Cable To Start assuming that you have disconnected the previous test product Consult section 7 2 for details regarding Batches 44 Controlling the Diagnostics There are five options available for diagnostic display None No results are displayed Fail Only failed results are displayed Pass Only pass results are displayed Pass Fail For on screen diagnostics this behaves the same as Fail see section 7 1 for greater details on Pass Fail and reports All All results are displayed You can select the results to be displayed either before running a test or on the fly while results are being displayed 4 4 1 Altering the results displayed before testing Test Configuration To alter the results displayed before testing select Reports File Na oan the Test Configuration menu rt Number TEST Rew Tools Reports
61. EI WE Depending on how the diodes are wired the Horizon could find a phantom diode that is a combination of diodes 1 and 2 as illustrated by the dashed line This could either show up as a third diode or as a single diode In either case a careful examination of the components learned will reveal if this has happened and if so which occurred Auto learning the above configuration resulted in 3 found components Select Components to enter the Set Test Parameters menu Select Diodes to view the found components The the three expected diodes are displayed Select Edit to view the parameters of each component review section 5 6 1 for editing details In this example the phantom component is discovered to be D2 Highlight D2 and select Delete Horizon Series Tester Programmer s Manual 5 45 Advanced Programming Confirm deletion with a Yes Do you really 1 to Delete Diode Once the Diode list is correct select Ok to return to the Set Test Parameters menu Delete ax ETEA ICA Edit rape tarer 5 6 3 Programming Diodes Manual Even when you program embedded diodes manually the NetList must have already been automatically learned see Section 4 for details From Set Test Parameters select Components and the z aaarters Edit Component List dialog appears Low Voltage Components
62. Figure 4 4 Open at 30 FAIL In this example the open has occurred at 30 the distance ops e the first adapter RI End OF Report 52 Horizon Series Tester Programmer s Manual 4 21 Basic Programming and Testing J1 J3 esc 9979 Y 5 Figure 4 5 Open at 47 Test Report i i fec motui N this example the open has occurred at 47 the distance dite e from the first adapter SML I ELE TI CN 4 10 2 Miswires Miswire reports are extremely accurate as well A miswire error is reported when the Horizon tests a cable and the nets do not match the configuration of the original golden sample J1 h J3 Figure 4 6 Miswired Test Report i i i sported Heculiz Inthe example to the left the Horizon cable is miswired and 17537 CABLE to notes the current wrong configuration and the correct ire migwired configuration it expected I 1 6 43 51 65 open of Report Lec 4 22 Horizon Series Tester Programmer s Manual Basic Programming and Testing Ji gd J3 Reversing the cable and re testing the Horizon reports the 58 S same net to be faulty but points to the correct adapter at miswired to L xPi
63. Insert the product Select Ok to continue The net list is learned Horizon Series Tester Programmer s Manual 5 41 Advanced Programming Test Points 16 3 67 Found 1 Enter Part Number H CABLE WITH DIODE 2 e Tis Medel ed EY EU EET s 5 9 Space Elear Set Test Parameters Name Prompt Adapters Low Voltage Components High Voltage Options Net List Print Test Now Cancel a Edit Component List Resistors Keys Capacitors Diodes Black Boxes Twisted Pairs Select Diode DIOD 4 fad Delete S Edit Label Table 1 Diode Types The Horizon scans for diodes in your product Label the product under test If you want to review the parameters select Components This is always recommended as a sanity check especially if you have not programmed diodes or diodes of this type before Then select Diodes The Edit Diodes dialog is shown In the example cable the Horizon found one diode and detected that this diode is a Generic type The following table lists the parameter by which diodes are identified by the Horizon Select Edit to view
64. LEDS BI LEDs The text file format for a visual test of BI LEDs is as follows DIODE lt s_netName_1 gt lt s_netLabel_1 gt lt s_pinAddress_1 gt lt s_pinLabel_1 gt lt s_pinAddress_2 gt lt s_pinLabel_2 gt LED FORWARD lt minimum in volts gt lt maximum in volts gt REVERSE lt minimum in volts gt lt maximum in volts gt VISUAL PARALLEL Where type is defined as per Table 1 Diode Types Horizon Series Tester Programmer s Manual 9 33 Scripting Features 9 2 Adapter File Format The tested products are usually connected to the Horizon system through conventional adapters or adapter cables The adapters or adapter cables are described in the adapter files These files contain the connectivity tables that make correspondence between the connector s pin name and the system s test point number In this way the Horizon 1500 system is able to test the product by means of using test point numbers while providing the user with meaningful diagnostics by means of using connector pin names Format The syntax of an adapter file is as follows ADAPTER lt adapter s name gt SIGNATURE type 1 value 1 type 2 value 2 SIZE adapter size CONNECTOR name of connector 1 gt Sys Pin Pin Name Pin Label Sense CTare LVRL Tare LVRH Tare HCRL Tare HCRH Tare ADAPTER Required The name of the adapter is required and limited by 30
65. Learn Cable Insert the sample product then press OK to continue Insert the adapters that you will need to test your product select Ok when done to go to the Learn A New Cable window Mount your sample cable on the adapters as instructed then select Ok and the Horizon will learn your cable If you selected Common Ground the NetList will be learned and the user will be prompted to select from the learned list the common bus prior to learning the resistors 5 16 Horizon Series Tester Programmer s Manual Advanced Programming While the Horizon is learning your cable a number of status screens will appear including one that indicates how many 1804 resistors it is finding that meet the search criteria you set up Found 1 When it has completed learning your cable the Set Test Parameters menu is displayed From this menu you can set up additional tests modify None Pronrt tests you have already specified verify that the tests you Low Voltage Components a want to perform have the correct parameters and provide Hig 1 is Hore mue natural language labels for all nets and nodes Test Now 1 OK Labelling will help your rework station more easily identify and correct any faults found Select Components to apply these features to the resistors just learned T
66. pa tar MEN Remove all adapters and products from the Horizon Select Ok to continue The Horizon learns the number of available test points The isolation resistance between points is verified at a default level of 100kQ Select Enter to continue Switchcard isolation is being verified If a fault is found the Test Report window lists the points that failed Select Ok to return to the Service menu LV Tests An in depth method of verifying the LV measurement circuitry of the Horizon 1500 The LV Tests cannot be performed without the special simplex and Kelvin Horizon Series Tester Programmer s Manual 3 15 System Setup test adapters Contact your sales representative for more details Action Required Remove any adapter test ixture alibration erification Tool or zt lugs SUstem wide isolation test ill be performed Simplex test plug Required Insert the simplex test card in Box 1 Reported Results Pass Fail Test Pro en Product 04718 2001 11 14 12 3 67 24566 too high 299 2 Ohm End of Report se kelvin test plug Remove all adapters fixtures product from the switching of the Horizon Horizon performs a standard isolation test on the switching netw
67. s Manual Basic Programming and Testing i Remove shorting plugs from all adapters 22 Press to citive tare connectors perform capa Ay Plug adapters in the final est positions 22 Insert shorting plugs in all used connecta 3 ALL lugs cally interconnected in a massive Of short z2 Press OK to perform resis tive t must be electri Low Uoltage Settings H Con Dwell s Iso Dwell us Tare 4 9 5 Remove the shorting connectors and select OK to start the capacitive tare In order to perform the tare you must short all points together that are contained on each connector Each connector must be then be shorted together connections will be tared in a single pass Select OK to start the resistive tare When the tare is complete Tare will be checked To disable the tare select Tare again to remove the checkmark Improving Accuracy with High Capcitive Loads Long Cables In order to improve measurement accuracy it may be beneficial to add a delay to continuity or isolation measurements To add a delay to your test program select More Options from the Set Test Parameters menu Low Uoltage Settings Con Dwell s Iso Dwell pz Tare Name Pronpt Adapters Low Voltage Components High Voltage Net List More
68. select Start Test to run the test Select Cancel to return to the Set Test Parameters menu If you are satisfied with the modifications select Ok Horizon Series Tester Programmer s Manual 4 11 Basic Programming and Testing Refresh Cancel 2 2 Refresh aAA Bex cancel OK a Set Test Parameters Pronpt Adapters Low Voltage High Voltage Components Net List More Options Print Test Now Cancel You are prompted to confirm that you wish to save Select Yes to continue Select a directory to save the file within or select New to create a new directory Select Ok to continue If you are saving the file into the directory that it originated you now have the option of saving the file as a next revision or overwriting the existing file If you select Yes to next revision a new record is created with the same part number and an incremented revision number If you select No you are prompted whether you wish to overwrite the existing file Select Yes to do so If you do not wish to save your modifications then simply select Cancel from Set Test Parameters Then confirm you wish to abandon the changes 4 12 Horizon Series Tester Programmer s Manual Ba
69. 1000000 gt Q 10000000 20 100 pF 1000 pF 10000 pF 78000 pF Edit the file to reflect the actual measured values of each component The units are not required within the file Once complete save the file as text only onto the calibration verification tool diskette Horizon Series Tester Programmer s Manual 17 Appendix Calibration Verification Example File 123456 12 1000 9994 1001 99987 1002400 10040200 101 1003 10107 78115 Company Name Horizon 1500 Model Serial Number Date amp Time HORIZON 1500 CALIBRATION TOOL VERIFICATION REPORT Please refer to the manual for the recommended method for measuring each component RESISTORS 21 R2 R3 R4 R5 R6 CAPACITORS C21 C33 C4 Calibration verified by 18 Horizon Series Tester Programmer s Manual Glossary of Terms CABLETEST Glossary of Terms 2 Horizon Series Tester Programmer s Manual Glossary of Terms Build Aid Calibration Verification CapTare Conventions EPO FER Flex Test Flying Leads Hipot testing Kelvin four wire testing Netlist Palm Switch Quick scan ResTare Smart Probe Standard Probe A special test parameter that allows the Horizon to aid in the building of a product Assists in avoiding miswiring during product assembly Verifying your Horizon is maintaining measurement wi
70. 45 E edit adapter 6 17 Editing Test Programs 4 11 Low Voltage Settings 4 16 Editing Your Test Program Set Test 5 4 11 1 4 1 5 Error Statistics 2 10 extraction delay 3 13 F Faults 4 22 4 61 Opens eel oes 4 20 Horizon Series Tester Programmer s Manual 4 23 Test Fixtures and Faults 4 25 Fixed High Current Source 4 61 Fixtures imu degens 6 3 Flex TeSt es 4 26 Flying 5 4 Eree Ends aa 5 4 Golden Cable 2 4 H High Current Source 4 63 HC Resistance 4 64 Voltage Drop 4 64 High Voltage 1 4 1 5 Hipot Nets 4 37 Hipot Testing Autohipot 3 23 Horizon Powering 2 3 Shutting 2 10 I 3 3 Palm 3 4 Reset 3 3 Retest o eei 3 3 Start Test oem 3 3
71. 5 NET J1 C1 20 23 02 20 J3C1 6 NET 21261221 JlISCI 7 23 1 21 dO NET NET J1 61 22 J1 C1 8 J3 C1 22 J3 C1 8 NET J1 C1 23 21761 9 43 01 223 23 C1 9 NET 808 NET JiC1 24 11 1 10 J3 C1 24 13261 10 NET NET 1 1 25 1 115 7 73 1 25 7326212 END 4 66 Horizon Series Tester Programmer s Manual Basic Programming and Testing Horizon Series Tester Programmer s Manual 4 67 5 ADVANCED PROGRAMMING AND TESTING Components Switches and Kelvin Measurement CABLETEST Advanced Programming 5 2 Horizon Series Tester Programmer s Manual Advanced Programming 5 1 Introduction In addition to testing cables and harnesses composed of wires and connectors of different types the Horizon can test cables that contain certain embedded components including diodes capacitors resistors and switches This section describes the process for learning these types of cables and harnesses Also as described in throughout this section the Horizon can handle a number of special needs you may have such as Twisted Pair Kelvin Measurement Probing and Free Ends a Programming Cable Begin by selecting Program Cable from the Main Menu L sers Existing entering your password and select Learn New Cable Learn New Cable Default Lex a NER Cak
72. 5 0 The continuity minimum and maximum thresholds must always be given in Q For example a 1KQ resistance would be entered as 1e3 or 1000 In the example below the bolded line specifies that a Kelvin 4 wire measurement is to be performed Please note that as the name suggest a 4 wire measurement requires a special interconnection to the tested product where each point in the tested product is wired to two test points on the Horizon test bed This is usually done via the adapter interface CONTINUITY 0 0 1 KELVIN The example below specifies a Kelvin 4 wire using the high current source The bolded line instructs the tester to run a High Current source RESistance measurement using a stimulus of 0 5A CONTINUITY 0 0 3 KELVIN HCRES 0 5 The high current source can also be used in a voltage drop mode as it can be seen in the example below The minimum and maximum limits specified on the CONTINUITY line are OV and 0 08V respectively As the voltage drop test requires the two limits are given Horizon Series Tester Programmer s Manual 9 11 Scripting Features in V this time The bolded line specifies a High Current voltage DROP test using a stimulus current of 1A CONTINUITY 0 0 08 KELVIN HCDROP 1 A special case is when an empty field is specified after the CONTINUITY keyword In such a case no continuity test will be performed at all This may make sense in conjunction with the flex test w
73. C1 22 NET 23 62 22 2120128 NET J3 C1 8 Jl Cl1 23 NET 23 261 23 J1 C1 9 NET TRCI TH NET J3 C1 24 ios NET 33961 10 J1 C1 25 NET J3 C1 25 J1 C1 11 RESISTOR RESISTOR1 T3 J3 C1 1 NET J3 C1 7 Jgl Cl 12 VALUE 1 46586e 06 1 7916e 06 12 py END 5 20 Horizon Series Tester Programmer s Manual Advanced Programming 5 4 2 Programming Resistors Manual Even when you program embedded resistors manually the NetList must have already been automatically learned refer to Section 2 2 for details Pronpt Adapters Low Voltage High Voltage Components Net List More Options Print Test Now Cancel Resistors Keys Capacitors Diodes Black Boxes Twisted Pairs mwe Edit Delete Label Select Resistor DR fida Delete Eel a i esistor Terminal 1 x Terminal 2 lt 1ue omit min max Test More Options Label From Set Test Parameters select Components and the Edit Component List dialog appears Select Resistors The Select Resistor dialog box is empty if no resistors were detected during the learn process or if you did no
74. D 5 1 HiPot Test Parameters The AC HiPot test can be specified for units that are equipped with an AC HiPot module By default the AC HiPot is disabled The AC HiPot parameters are usually specified for the entire product or section of product switch position but it is possible only in the linear mode to specify the AC HiPot parameters on a per net basis When the AC HiPot is to be run in the mass mode the only parameter that can be changed on a per net basis is disabling the HiPot test on that net by setting the HiPot voltage to 0 When the HiPot is to be run in the linear mode any HiPot parameter except for the HiPot type can be modified for any net The leakage can be measured either as a current an insulation resistance or ignored altogether The ACHIPOT line must appear the first All other lines can appear in any order afterwards ACHIPOT d voltage LEAKAGE IR d limit DWELL d dwell 60HZ 50HZ2 MASS LINEAR In the example below a 60Hz 1000V ac HiPot will be performed using a 2s dwell time and the mass algorithm The leakage current won t be measured only the arcs will be monitored 9 16 Horizon Series Tester Programmer s Manual Scripting Features ACHIPOT 1000 60HZ DWELL 2 MASS In this example a 50Hz 500V ac HiPot will be performed The dwell time is 1s the insulation resistance IR threshold is set to 100MQ and the li
75. Diagnose the results of the last test will be displayed 5 6 7 Error Reporting for Diodes All of the same errors are available in this mode as for general cable testing In addition a number of extra screens track diode specific faults Horizon Series Tester Programmer s Manual 5 51 Advanced Programming Test Report Reported Results ALL est Program CABLE WITH DIODE lan E3 OF zp pen 2 Ur End of Report ss Test Report Reported Results ALL CABLE WITH DI eet dod 13 09 15 rted End of Report ema Ur Program CABLE WITH DE 6773671999 13 08 55 versed UF 2 30 Uri 2458 Emu End of Report masr 35 8 Test Report est men BI LED M 07 03 RED di CREEN visual test visual tast Falk End of Repo The diode was open Horizon measures and reports the forward voltage to be greater than 2300mV this value is the maximum forward voltage at 50 for a Generic Diode see Table 1 Diode Types D1 is the designator assigned by the Horizon to the first diode detected If there are more than one you will probably want to use the Label function so that the diagnostics are more meaningful Diode D1 is shorted The Horizon measures and reports the reverse voltage across the short The diode is present but it is installed back
76. Edit Capacitor Terminal 1 Terminal 2 lt Value min max Test More Options Label From Set Test Parameters select Components and the Edit Component List dialog appears Select Capacitors Select Add to manually enter this component Add as many capacitors as you have in your product Adding capacitors increments existing capacitors by 1 Each new capacitor will be C1 and the current C1 becomes C2 the current C2 becomes C3 etc Highlight the first and select Edit to set the components properties The Edit Capacitor dialog opens with no information present Select Terminal 1 to assign it the proper net The Select Net dialog appears Using the arrow keys scroll the cursor to highlight the correct net pin location for Terminal 1 Select Open to select a pin Horizon Series Tester Programmer s Manual 5 35 Advanced Programming Cancel on gt Edit Capacitor min More Oren Net and Pick Terminal max Ne iJi iJi 1 822187221 eed gt Open Twisted 1 Edit Capacit
77. Enter pins that belong to first group 1 17 5 6 7 8 5 WWII WII Space Elear Last Probed a Finding Pins in Range 1 17 Select ESC to return to the Select Tool menu next step involves separating the loose ends of the product into groups for easy connector assembly For the DB50 connector an ideal method would be to separate the conductors into the 3 rows of the DB50 connector From the Select Tool menu select Group Sorting Enter the pins that belong to Group 1 1 17 Select Enter to continue Using the ground probe touch the conductors to isolate group 1 As you probe the conductors the pin you last probed is displayed Conductors that do not belong to the group will not respond to the probe s touch Horizon Series Tester Programmer s Manual 4 33 Basic Programming and Testing a Finding Pins in Range 1 17 Last Probed 17 a Enter pins that belong next group 18 33 J 8 5 5 6 7 8 9 Space Bar Elear 3 Finding Pins in Range 2 8 5 6 7 8 9 6 21 28 2020
78. File datab adapters kelvin adp Horizon Series Tester Programmer s Manual 6 13 Adapters ADAPTER KELVIN SIGNATURE 3 00000000 3 00000000 SIZE 1 VERSION 4 0 0 CONNECTOR 38 1 46 0 2 8 39 3 47 16 4 24 6 5 2 Special Case Shorted Pins In some rare cases an adapter may have two pins that are shorted together In order to assist the Horizon to compensate for this scenario two important steps must be followed The first important step is to create a convention as described in 0 that represents the adapter as it exists For example if pins 1 and 3 were shorted together you must give them identical labels CONVENTION Short Example 10 Hj p oU U o gt The second important step is to disable the Kelvin toggle before probing the adapter pins Kelvin Back Print 35a Selecting 12 AB you can select the new Convention for the shorted adapter 22728 4 gt Back Pr int OK 6 14 Horizon Series Tester Programmer s Manual Adapters Edit Connector s Netlist 9 Probe the adapter The system will find the two system points for the shorted adapter points and will place them in sequence s 2 Back
79. For more details refer to section 8 1 Select Cancel to return to the Main Menu The user has the option to delete log files after transferring them to a diskette Select Yes to delete and No to continue without deletion You can read the log files saved to your diskette by using any text editor on your personal computer The files are located in a subdirectory labelled logs and another subdirectory labelled after the serial number of the Horizon the files originated and all the files have extensions ALL and ERR 7 2 Batches In many shops it is often the case where the products cables or harnesses must be sorted or packaged in lots It goes without saying that each product in the lot must be a good product While this sounds trivial in the press of running a production floor keeping this straight can prove to be difficult The Horizon has a special feature designed to help you if this is your situation 7 2 1 Setting Up Testing By Batches Horizon Series Tester Programmer s Manual 7 9 Reports and Batches Thu Sep 11 1997 01 40 Test Self Test System Setup E Program cablei Backup ij Edit Adapter i 4 Contrast Shut Down Test Configuration File Name les MAIN TES TCABL CB Part Humber TEST CABLE Rev 1 Reports select Test Now Batches Cancel
80. HCDROP lt d_stimulus gt The simplest case is when the coNTINUITY line is omitted from the test program altogether In such cases the system will default the continuity test to Quick Scan This method is by far the fastest since it uses a comparator to verify if there is continuity or not It doesn t measure the actual resistance though therefore some test engineers use it only in non critical applications like testing printer cables 9 10 Horizon Series Tester Programmer s Manual Scripting Features When a continuity resistance measurement is needed then the CONTINUITY line must be specified When including the CONTINUITY line in the test program the minimum and maximum limits must be specified When the measured continuity resistance is within the range defined by the two limits the test passes When the measured continuity resistance is outside the range the test fails Most of the time the minimum limit would be set to 0 It only makes sense to specify a higher minimum limit when a 4 wire measurement is used best to be used in conjunction with the High Current Source option When a continuity resistance lower than the minimum limit is measured it is probably because of a wrong wire gauge or length Most of the time test engineers are only interested to have the measured resistance values below the maximum limit In the example below a continuity test with the 00 and 50 limits is specified CONTINUITY 0 0
81. High Uoltage Het List More options Print Test Now 1 Select Diodes Resistors Capacitors Diodes Black Boxes Twisted Pairs ER CDI The Select Diode dialog box is empty if no diodes were detected during the learn process or if you did not select the Diode option within a custom learn z 4 s Ada Delete ES EJEA ICA Edit Label 5 46 Horizon Series Tester Programmer s Manual Advanced Programming Delete Label Edit Diode GENERIC More ptionz Label More Options t Cancel a EHI 1 Edit Diode Cathode Detect Ture Label a Edit Diode m fede aera Cathode Retect More Options Label Select Add to manually enter this component Add as many Diodes as you have in your product the new diodes are automatically selected as Generic adding diodes increments existing diodes by 1 Each new resistor will be D1 and the current D1 becomes D2 the current D2 becomes D3 etc Highlight the first and select Edit The Edit Diode dia
82. Horizon is that you can apply natural language labels of up to 30 characters in length not only to each net in your cable but also to each node pin or connector This feature can be invaluable in helping the re work station troubleshoot and re work bad cables All of these will be explained in detail in the next section At this point however we simply want to show you how to use the NetList to help verify that the cable you just learned is in fact a golden cable Select Net List lt Alt N gt and the Edit Net display will appear 2 6 Horizon Series Tester Programmer s Manual Getting Started One obvious use of the NetList is to help verify that the cable you are learning is a good one also known as a sanity check Reading the NetList is simple and straightforward In the example shown the first entry states that Net 1 starts at J1 connector 1 pin 1 and goes to J3 connector 3 pin 1 Examining the rest of the NetList clearly shows that this is a one to one cable If the result is not what is expected based on the cable design criteria it would be one indication that the cable being learned was not in fact golden If a given net has more elements such as is common in a harness or there is more information available two periods will appear at the end of the net entry Selecting the Open lt Alt P gt button would show these additional elements The Edit lt Alt E gt button allows yo
83. Horizon software will automatically indent the saved test programs for better readability though indentation is not mandatory The space character or the TAB character can be used for indentation It is recommended to use spaces whenever possible since this would guarantee that the test program file is viewed in the same way no matter what text editor is used While the Horizon software can read the TAB character properly it is treated differently in different text editors thus rendering the source difficult to read in some cases Horizon software versions older than 4 2 17 will partially support the indentation They will only save left flushed files all lines start in the first column and the use of the PROMPT and SCRIPT keywords require that the text that follows is terminated when a character is encountered in the first column i e the next keyword cannot be indented A basic test program is generally sectioned into Identification Header Adapter Interface Test Parameters and Prompts List of Nets NetList Lists of Components Test Scripts TCL Except for the Identification Header and the Adapter Interface Section that must be present in all test programs the other sections are optional though a test program without a NetList will prevent any testing to occur Some elements of a Horizon test program are not only optional but they cannot be used unless optional software packages are purchased e g the
84. IEA Cea Custom to display the Learn Settings dialog Advanced Netlist Editor a Learn Settings From here you program or set up number of test Twisted Nets Only conditions Free Ends Kelvin Use Kevin Cancel returns you to the Main Menu Cancel Nets Only Confines the programmed testing process to complete multi point nets Single point nets any test points not connected and free ends flying leads are ignored Free Ends Enables the Horizon to test products with non continuous conductors Using the standard probe or the Digital Hand Held Probe the operator can test products for continuity that do not terminate to a connector Twisted Enables the Horizon to detect and test products with twisted pairs Kelvin Enables the four wire testing mode of the Horizon Programming a Kelvin test from this menu requires your fixture to be wired in Kelvin The Horizon will prompt to learn the fixture prior to learning the PUT If you are using a Kelvin Adapter that has been learned and saved in the Adapter Library do not enable Kelvin here Conductor Max Res As in normal cable testing you can override Quick Scan and specify values for Maximum Conductor Resistance This is required when looking for low ohm resistors or learning a Kelvin fixture Horizon Series Tester Programmer s Manual 5 3
85. Line WHEE ER 9 ee GUI IE 6 8 7 2 2 4 0 9 Space Har Elear J1 The prompt entered will appear to the operator during the test cycle prior to testing the switch position Select Enter to confirm the prompt If no more prompt lines are required select Esc to advance to the next switch position J3 Figure 5 7 PUT with embedded Switch CLOSED position 1 Learn Cable With Switches Switch to the 2nd position then Continue to learn it Cancel to end learning Ok Cancel 1 Enter First Prompt Line CLOSED 2 7 1 e e 2 4 So ausis Space Bar Elear Learn a New Cable JEEE BOE Switch to the Srd pos then press OK to learn it Cancel to end learning OK Cancel Place your product the second switch position Select Ok to continue The second net list is learned You are prompted to enter the prompt that will appear prior to the second switch position Select Enter to confirm the prompt If no more switch positions are required select Cancel to exit the learn cycle Horizon Series Tester Programmer s Manual 5 57 Advanced
86. REFERENCE VALUES CALIBRATION HISTORY Set Time amp Bate TIME 14 26 BATE 16 09 97 Operator I D Bi From the Main Menu screen you have the following options CALIBRATION By selecting this option you can choose the source of the reference components used in method from the ones built in the calibration board INTERNAL or the ones that you can connect to the external jacks EXTERNAL SYSTEM SETUP will let you adjust the system s clock and calendar TIME amp DATE and also to setup a set of parameters for the printed report list PRINTER SELF TEST will run again the self test code CONTRAST adjusts the brightness of the LCD screen SHUTDOWN Exits the calibration software Selecting SYSTEM SETUP produces the Calibration System Setup menu Selecting TIME amp DATE allows you to properly set the values to accurately log the calibration verification Selecting PRINTER SETUP allows the user to specify the extent of the print job i e including a header or the operator s id and the left margin Horizon Series Tester Programmer s Manual 3 Appendix D Calibration Verification YOUR CHOICE OF HEADER 7 EA 9 5 0 2 EXIBH 6 A EI amamos Space Bar Erea Joea BE Enter the company nane YOUR COMPANY NAME
87. Select Test Nou Batches Cancel Horizon Series Tester Programmer s Manual 4 9 Basic Programming and Testing Report Settings H General Test Reports Operator ID Reports Test Report Settings H Serial Number Options Test Results Fail Auto Diagnose Hone Header Footer Test Parameters OK Select Test Reports Selecting Test Results toggles between the four options Reports are discussed in greater detail in section 7 1 The option also exists to automatically display results after each test Auto Diagnose See Section 7 1 3 for details 4 4 2 Alter results On the Fly Altering the results displayed in the diagnostic dialogue during the test cycle can be done by touching the center of the display or using the Space Bar Touching the display toggles between the five options None Pass Fail Pass Fail and All Altering the Reported Results from the Test Report dialog will alter the Test Results setting on the Test Reports Settings menu Horizon Lite user may also do this by using the space bar on their keyboard 4 10 Horizon Series Tester Programmer s Manual Basic Programming and Testing 4 t3 Modifying Your Test Program Modify Existing Cable Learn New Cable Default Learn New Cable Custom Advanced N
88. Test Net Number Cycle Condition 1 1 Pass 2 ARC 2a Pass 2b Pass 2c ARC 2d Pass 2e Pass Pass Pass Scenario 5 Bad Product Leakage Failure During IR Test The following table shows an example of splitting as a result of a leakage condition Test cycles 3a through 3f correspond to the recursive group splitting that is used to detect the fault 6 Horizon Series Tester Programmer s Manual Appendix C Mass HiPot Examples Table 5 Bad Splitting due to excessive current leakage during Mass IR Test Test Net Number Cycle Condition Ae ae 5 1 Pass 2 Pass 3 Leakage 3a Pass 3b Leakage 3c Pass 3d Leakage 3e Pass 3f Leakage 4 Pass 5 Pass Linear Sequential or Single Phase Testing The linear fault detection method relies on holding one net at a time at the high potential and all other nets at ground potential That net under test is qualified in a single pass or test cycle and is tested against all other nets For groups of 4 nets or less linear sequential or single phase testing will be performed until all faults are found Table 6 Sequential or Linear Testing Test Net or Net Group Number Horizon Series Tester Programmer s Manual 7 Appendix C Mass HiPot Examp
89. Tester Programmer s Manual 3 INDEX my CABLETEST INDEX Horizon Series Tester Programmer s Manual A Abort titt s 3 5 AC Hipot AC Overload 4 60 4 60 AES ONIY 4 53 Degauss Cycle 4 59 4 52 Hipot 4 53 Hipot Nets Only 4 51 Leakage i tun 4 60 Leakage Setting 4 52 Mass or Linear Scan 4 54 Password Protected 4 51 Settings iiie e 4 51 Voltage Setting 4 52 Adapter Text File Format 9 34 Adapter Text File Format Tags s besos 9 34 9 35 9 34 etaed 9 35 VERSION iiie 9 35 Adapters ione eei 6 3 Building Custom Adapters 6 3 Capacitance Tare 6 9 Connector Pin Conventions 6 11 Connector Pin Name 6 8 Double Wide 2 5 6 4 Editing Adapters 6 16 Fixtures with Shorted Pins 6 14 HUGE 6 4 Kelvin Adapters 6 13 Learning an Adapter 6 4 Learning Fixtures
90. Too Dark Contrast Set Low Back Light Failure Increase Contrast Replace Back Light Can t Select Buttons on LCD Touch Screen Failure Replace Touch Screen Error Message Error initializing switching cards Power Supply 3 not present General Switching Card Failure Ensure all required power supplies are present Service Switching Cards Lost Password Contact Horizon Service Product always fails HiPot Arcs DC or AC HiPot Failure Service High Voltage Module s Horizon Series Tester Programmer s Manual 3 Appendix C Mass HiPot Examples gt 5 Appendix C Mass HiPot Examples 2 Horizon Series Tester Programmer s Manual Appendix C Mass HiPot Examples CableTest Systems Inc Mass HiPot Routine The following binary tables show the nets connected to high potential and to ground potential for a 16 net product during the Mass HiPot routine Similar patterns are generated for other product sizes The 16 net product is used for illustrative purposes only The routine presented in Table 1 below guarantees that each net is raised to high voltage at least once This is important to ensure that leakage i e Insulation Resistance or IR is measured on all points and to ensure that Dielectric Withstand Voltage DWV testing is performed on all nets against all external ground points Scenario 1 Good Product No need to sub divi
91. and Testing Enter the minimum resistance measurement for the Isolation test in kQ Select Enter to continue To restore the Quick Scan setting simply select Isolation Min Res again Select Conductor Res to select a measured value for the Continuity measurement Specify Continuity Select the desired Continuity Type Resistance 5mA Quick sean HC Resistance From Sample Resistance fron ies For this exercise select Resistance 5mA Cancel Resistance 5mA MSR measured scan Quick Scan As described above HC Resistance Programmable HCS measured scan Resistance reference Voltage Drop Programmable HCS measured scan Voltage reference From Sample Uses the MSR to measure the maximum resistance for the attached nets Set the Maximum Conductor Resistance accordingly Fixed HC Measured scan using the Fixed HCS Voltage or resistance reference The Fixed HC option can only be used for 4 wire measurements Enter the maximum conductor resistance measurements made higher than the value entered will be considered opens Select Enter to continue Horizon Series Tester Programmer s Manual 4 17 Basic Programming and Testing Enter the minimum conductor resistance the ideal is 00 If your test requires a minimum conductor resistance and 2 m gre
92. any of the buttons on the Menu 3 9 Adding Expansion Boxes As described in the introduction a standard Horizon has 128 test points enough to fully test a double ended cable with 64 wires The Horizon can be expanded to be able to test up to 1024 points by adding extra switching boxes in 128 point increments Delete 1 Double Cancel Single Double When you do this you must not only install the hardware but you must configure the system to detect the extra test points This is done from the System Setup by selecting Boxes The Box Settings menu will be displayed Cancel returns to System Setup with no action being taken Select Add to add a new box the Enter Box Type menu is displayed Select Single or Double depending on the type of the box being installed and you will be returned to Box Settings and the new box will be added to the list 64 test points 128 test points Edit allows you to change the box type Use the arrow keys to highlight the box of interest and then select Edit The Enter Box Type menu appears Select the correct box type and you will return to Box Settings Select Ok when you are through to go back to System Setup 3 22 Horizon Series Tester Programmer s Manual System Setup V If you are adding or removing expansion boxes from the Horizon it is imperative you comply with the systems power requirements V If
93. capacitors can be tested with the Horizon by selecting the Electrolytic option 5 5 3 3 Programming Capacitors Advanced Options Test Stimulus DC Hipot Settings Default Hipot Settings Default Electrolytic Ej Toggle Stimulus to select between the Horizon s 50 5mA sources 5 5 4 Testing a Cable with Capacitors Testing a product with embedded components is the same as testing any other cable or harness For details consult Section 4 pu ING LEADS 1 ISTOR Rev 1 CABLE 34 Reu 3 Refresh Delete Back Cancel OK act A tai ta tate 2 5 Processed Select the product you wish to test Highlight and select Ok to continue The test program is loaded 5 38 Horizon Series Tester Programmer s Manual Advanced Programming Test Configuration ee ee 1 Selected Cable File ies ma Part Number CAPACITOR Tools Reports Select Test Nou Batches Cancel Insert the Adapter s H Ja HA 116 116 CAPAC ITOR TR RJ Tested Passed Failed Error Statistics Diagnose Start Test Cancel Performing Tests Capacito
94. fferminal 1 cr Terminal 2 lt gt 1 21 4 SS Select Ok to return to the Capacitor List dialog zest OK More Options Label OK 5 5 3 Programming Capacitors Advanced Options ee From the Edit Capacitor dialog select More Options Terminal 1 Ji Cl 1 Value min 671 max zest OK More Options Label EN Edit Capacitor DC Hipot sett ings Default Hipot Settings Default Electrolytic The More Options are as follows Horizon Series Tester Programmer s Manual 5 37 Advanced Programming 5 5 3 4 Programming Capacitors Advanced Options HIPOT Edit Capacitor Hipot Settings Custom Hipot Settings Default Electrolytic The same as changing HiPot values for individual nets see Section 4 users have the option of adding changing values or eliminating HiPots performed on capacitors In order to change local HiPot variables the global setting for the High Voltage test must be set to Linear 5 5 3 2 Programming Capacitors Advanced Options Electrolytic Hipot Settings Default Hipot Settings Default Electrolytic Fi Electrolytic
95. flex test will not be performed if the FLEX line is not found in the text file The flex test can take one parameter that specifies the timeout Optional continuity and isolation flex test specs can follow right after the FLEX line The syntax is given below FLEX d timeout CONTINUITY d min c d gt lt 5 contScriptCmdAndArgs KELVIN HCRES HCDROP lt d_stimulus gt ISOLATION d min The first parameter is the timeout When not specified or entered as 0 the time out defaults to infinite In this case the flex test is performed until the operator selects the Advance button on the touch screen Otherwise the timeout value should be entered in seconds In the example below a flex test that times out after 5 5 seconds is specified Horizon Series Tester Programmer s Manual 9 13 Scripting Features PLEX 5 5 If the optional CONTINUITY and ISOLATION lines are not specified the flex test uses the Quick Scan mode for both the continuity and isolation tests The Quick Scan method offers the highest test speed for a greater chance to detect intermittent problems For applications where changes in the continuity or isolation resistance are to be monitored resistance values can still be specified by employing the CONTINUITY and ISOLATION lines It may be particularly useful for the flex test to be able to perform just one of the two tests i e run just th
96. mm dd yyyy convention format For example October 16 1997 would be entered as 10 16 1997 Select Enter to return to the Set Time amp Date menu 3 4 Horizon Series Tester Programmer s Manual System Setup 3 4 Gene These functions General Setup ral Setup Functions allow you to customize the Horizon to your preferences Select General to enter the General Setup dialog All settings seime m grosress E in this module are accessed by repeatedly pushing the button Reset Fail Fail amp Beset until the desired parameter is set Relay Test Opt Package 51 Mode 15 Min Volume Reset Fail Relay Test Sleep Mode Progress Fail Emart Probe Remote ort Sets the internal speaker volume 0 is softest 7 is loudest If a product fails an acknowledgement will have to be entered before testing can proceed with passwords enabled the acknowledgement is the supervisors password A check mark means that the feature is activated The internal relays are normally tested and cleaned as a part of self test and before every testing session You can choose to have them tested and cleaned at the start of every test A check mark means that the feature is activated If there is no activity on the Horizon for the programmed amount of time it wil
97. of the total length and the rear of the cable is located at 75 of the total length Adapter level shorts will be reported at 25 or 75 respectively from a particular adapter and a short along the cable would fall in between those two percentages 4 11 Flex Test 4 11 1 Testing for Intermittent Low Voltage Faults The Flex test is a method of testing a cable or harness for intermittent shorts or opens Since these usually occur at or near a connector the Flex test is a quick easy and economical method of locating these problems The Flex test is set up from the Set Test Parameters menu ame adarters This menu is displayed as the last programming step when Se learning a cable either under the Default path or under the More Options Print Customized path in the Programming Cable menu Test wow cancer ox Program Cable menu is accessed by selecting Program Cable from the Main Menu and then entering your password Set Test Parameters can also be reached directly for a cable already programmed into the database by selecting Modify Existing Cable 4 26 Horizon Series Tester Programmer s Manual Basic Programming and Testing Flex Dis can Star Conductor Res scan SmA Stimulus Isolation Min Res Quick Scan More Options In Set Test Parameters select Low Volta
98. set up High Voltage settings with Scan set to MASS you will be prompted with this message Select Ok to acknowledge the conflict 4 42 Horizon Series Tester Programmer s Manual Basic Programming and Testing XKefuin DC Hipot Tettings H Hipot Buell Regular Hipot Voltage u Leakage Limit 100 0 Duration 01 Edit Net s Settings H DC Hirot Custom nc Default BC Hirot Custom AC Default 1 Conductor Res Default Default Default B Shiela om so JilCl T ed3 You are now given the option to alter the global settings to Linear should you wish to continue editing the local High Voltage variable Select Yes to accept the change Selecting Hipot will remove the check mark and this net will not be HiPot tested Notice however that you can actually specify different HiPot test settings for different parts of the cable In the example cable that s exactly what we chose to do setting a different voltage and duration to be used for this net and this net only but leaving the leakage limit the same Select Ok to return to Edit Net s Settings Cancel returns with no action taken The display has now changed to
99. tare value Res Tare For increased resistance measurement accuracy the resistance of an adapter can by learned and utilized as a tare value In order to perform this function you must short all points together that are contained on each connector To tare a connector you must have a minimum of three 3 test points Select Ok to save the learned adapter Cancel prompts the operator to confirm abandoning the new adapter Horizon Series Tester Programmer s Manual 6 9 Adapters Adapter as ADP File 5 datab adapters special adp For greater detail see section 9 1 3 ADAPTER SPECIAL SIGNATURE 1 1000 1 150 This file can be edited using any text editor 0 SIZE 1 word processor however if you use a word CONNECTOR DB9 1 processor it is imperative to save the file as Text 4 Only otherwise you will not be able to utilize it Te 9 4 vee 8 5 Far 135 6 vee 14 7 FEF L5 8 PET 0 9 Ka CONNECTOR DB9 2 Ty T TEF r rrrr rrr EIEEEI 9 0 4 C 28 8 24 9 6 4 Testing a New Adapter If you create an adapter for the Horizon it is a good idea to test it before entering it into the database This feature is also useful for troubleshooting existing adapters and fixtures 1 H From the Main Menu select Edit Adapter Tue Aug 25 1998 03 13 PM 5 Test Self Test S
100. that you would like the DC high voltage be applied from 0 01 to 600 seconds Select Enter to return to DC Hipot Settings Horizon Series Tester Programmer s Manual 4 39 Basic Programming and Testing DC Hipot Settings Hipot Voltage Leakage Limit Hipot Duration Set Test Parameters H Hipot Dwell Regular 150 0 ph 9 01 Name Prompt Adapters Low Voltage Components High Voltage Net List More Options Print Test Now Cancel Scan switches between the Mass scan and the Linear scan methods Although the linear method is more traditional it is highly recommended that you leave it in Mass scan unless your test requirements specifically dictate otherwise Mass HiPot testing is much faster with no loss in accuracy Ok adds the DC HiPot tests to the cable record and returns to the Set Test Parameters dialog Refer to Appendix C for Mass HiPot examples Select Ok to save the record for this cable in the internal database 4 40 Horizon Series Tester Programmer s Manual Basic Programming and Testing Test Program as CBL File datab cables main testca l cbl For greater detail refer to section 9 CABLE TEST CABLE 5 2 NET QUICKCONTINUITY CL QUICKISOLATION 93261511 STAR NET THRESHOLD 61 Ji Cl 12 DCHIPOT 57
101. the batches feature has been enabled 7 10 Horizon Series Tester Programmer s Manual Reports and Batches Test Configuration Current l Selected Cable File Name databscahblesSMAINSTESTCABL Part Number TEST CABLE Rev 1 Reports select Test Now Batches d Gancel TEST CABLE 57 Batch Tested Passed Failed Error Statist ics Diagnose Retest Cancel o 5 to go 44 Starting Mew Batch his product belongs to a new batch Press OK to continue 1 TEST CABLE 57 Batch 2 of 5 Tested 11 to so 39 Passed 11 Failed Error Statist ics Diagnose Retest Cancel 7 2 2 Note that the box by Batches now has check mark indicating that the Horizon will keep track of each lot as the cables are tested Select Test Now to continue testing The Test Cable display has changed to reflect the data entered above In the example shown a total of six cables have been tested of which all have passed The batch portion of the display reflects this fact and indicates that an additional 44 good cables will need to be tested in order to fulfill the requirement The failed cables have not been counted towards meeting the requirement Selecting Cancel will forc
102. the Range dialog appears Select Common Ground for capacitors tied to a common Minimum l100pF point Maximum 166nF Common Grouna 27 Enter the minimum maximum expected values Cancel Do not enter 0 for the minimum The Capacitors box is now checked to show that the Horizon will look for capacitors in the range shown Verify that the settings are what you want and then select Ok so the Insert The Adapters dialog appears You will be prompted to insert the required adapters After finishing select Ok Insert the adapters that you will need to test your product select Ok when done to to the Learn New Cable window Select cancel 5 30 Horizon Series Tester 5 Manual Advanced Programming Learn New Cable Insert hi the sample Product e en press OK to continu Next insert your cable as instructed and select Ok to continue the learning process If you selected Common Ground the NetList will be learned and the user will be prompted to select from the learned list the common bus prior to learning the capacitors Learning Capacitors Test Points Bu Found 1 EH Set Test Parameters Pronpt Adapters Low Voltage High Voltage Co
103. the details of the learned component 5 42 Horizon Series Tester Programmer s Manual Advanced Programming 1 Edit Diode Ji Cci 1 Cathode Ji ci 2 Detect GENER ICs Test UPF 446mU More Options Label OK a Set Test Pronpt Adapters Low Voltage High Voltage Components Net List More Options Print Test Now Cancel The diode s Anode at 1 and its Cathode at pin 2 are of connector 1 on adapter J1 This agrees with the test spec for the example cable Select Label to label the component If you are through specifying the test for your product select Ok to save the test procedure in the internal database Cancel will take you back to Program Cable and discard all of the learned parameters Horizon Series Tester Programmer s Manual 5 43 Advanced Programming Test Program as CBL File datab cables main diode cbl For greater detail see section 9 3 3 CABLE LED 1 N r CONTINUITY 0 5 J1 C1 13 STAR J3 C1 13 THRESHOLD 61 NET ADAPTER HA 116 J1 SCL TA POSITION J1 J3 C1 14 116 NET POSITION J3 Ji Cl415 NET J3 C1 15 Jis NET J3 Cl 1 J1 C1 16 NET J3 C1 16 T1201
104. the learning process the Horizon effectively can recalibrate itself to the surface of the fixture The net effect is greater testing accuracy of your products with much less chance of erroneous results You should learn a fixture after it is built even if it is based CableTest supplied adapters Can build my own adapters If you would like to build some or all of your own adapters contact your CableTest Representative for details After they are built each will need to be learned using the following procedures Horizon Series Tester Programmer s Manual 6 3 Adapters 6 2 Learning an Adapter a Main Menu To learn an adapter select Edit Adapter from the Main Menu The Adapter Library dialog appears Thu Sep 11 1997 01 40 PM Test Self Test Sustem Setup i Program Cablet Backup i Edit Adapter Contrast Shut Down Programming Adapter iHi Selecting Learn New Adapter starts the process for _Medify Eust darter incorporating a new adapter into the library and brings up Learn New fidapter the Enter Part Number screen Test Adapter Advanced Netlist Editor Cancel er Part Number Input the desired name or part number for the adapter The name can be up to 30 characters long and can include any 5 2 29 2 valid visible ASCII character including etc When aa s E you have finished
105. typing the name select Enter to accept 5 5 Space Bar Elea the input and display the Enter Adapter s Size screen SPECIAL The top of the Horizon or an expansion box is divided into _ two sections each of which has four gray connectors An SS adapter that uses a single set of these gray connectors is S eee referred to as a Single while one that uses all four ir connectors in a section is referred to as a Double An Adapter that uses all eight connectors in a box is called a Quad A Huge adapter can actually be of any size but is normally applied to fixtures and adapters that span or use multiple boxes It is also commonly used with back wired boards of up to 1024 points The main identifying characteristic of a Huge adapter other than the number of pins is that it has no automatic self identification capability and must therefore be specifically identified when products are tested Select the size appropriate for your adapter Single max 32 points Single Double Quad or Huge have nothing to do with the number of connectors on an adapter nor with the number of points used but only with the maximum number of test points available For example a Single might have three DB9 s mounted on it for a total of 27 pins with 5 unused It also has nothing to do with the type or configuration of the cables being tested For exa
106. use the components of the calibration board to perform the verification test Select the tests you would like to perform A test will be included if a check mark is present next to the option Press Start to begin calibration verification At the beginning of the test the system will check automatically for the position where your calibration board is Horizon Series Tester Programmer s Manual 5 Appendix Calibration Verification Measuring Internal Resistors Nom Min Max Meas OK R 1 1 008 0 982 1 033 1 008 f 2 10 01 9 84 10 18 9 99 n 3 0 998 6 963 1 012 0 998KE 2 EI 2 99 6 93 8 105 8 100 0kKa 398 947 10 00 1949 1 8 99 11 01 19 00mMR Print result Cancel Ok F Capacitive Calibration The system will perform capacitive calibration emove Cal Ver Tool he press UK Capacitive Calibration The capacitive calibration is completed _ Plu the Cal Ver Tool in the same position then press easuring Internal Capacitors Nom ir Max Meas OK 163 107 101pF 16 05 9 64 10 25 10 16nF 77 46 75 390 79 01 7B OZnF M c 1 2 1 001 O 978 1 023 1 019nF aalala Print result Cancel Ok found If your calibration board was not identified a message Insert the calibration board will pop up on the screen and
107. with long interface cables The threshold is displayed Select Ok to return to the resistor list Programming Resistors Advanced Options From the Edit Resistor dialog Select More Options to set advanced measurement features The More Options are as follows More Opt from this screen allows the user to set a measurement dwell for the selected component Programmable Dwell 01s to 1000s Horizon Series Tester Programmer s Manual 5 23 Advanced Programming 5 4 3 1 Kelvin ae Resist Sense 2 lt gt gt ag Ge ie Cancel Twisted Cancel OK Edit Resistor RES 1 Kelvin ja i Sense 1 Sense 2 lt gt Visual 1 Edit Resistor RESIS Kelvin Sense 1 Sense 2 Visual EIE En Mode Resist 5 4 3 2 Edit Resistor Resist Visual Programming Resistors Advanced Options Kelvin Any component with 2 test points at each terminal can be measured using the 4 wire method Kelvin Select Kelvin to enable the Sense buttons Select Sense 1 to select the first sense test point For the example product the res
108. 01202 Tey NET NET J1 C1 23 J1 C1 8 J3 C1 8 NET NET 24 J1 C1 9 J3 C1 24 NET NET Tt CLD jy TILL STO J3 01 257 93 61 10 END 4 44 Horizon Series Tester Programmer s Manual Basic Programming and Testing 4 13 5 Cable Testing Using the DC Hipot To perform a DC HiPot test on a cable as part of the test specification simply follow the same procedures as for low voltage testing Test Configuration rare eed Selected Cable Bil B Rios Ma INS TESTCA 1 ch Part Number TEST CABLE 5 Rev 2 Tools Reports Select Test Nou Batches Cancel Test Report est Pr m TEST CABLE 5 11 1 8 5 51 00 xShort between Neti and Netz at 51 from Jil xShort between MetiZ and lHetzd at J3 C1 z24 7 End of Report Select Test on the Main Menu Select the cable to be tested if it is not the cable displayed and select Test Now You will then be instructed to insert the adapters and to connect the product for testing The Horizon will first perform all of the specified low voltage tests If any of the tests fail the Fail light will turn on and you will have the opportunity to select Diagnose The low voltage faults will be shown in a display similar to that shown If a product fails any of the low voltage tests HiPot testing will
109. 1 Tools Rerorts Test Nou Batches select Cancel The display shows the Directory location and the Part Number for the cable you just learned or the last cable tested depending which happened more recently If this is the product you want to test select Test Now otherwise press Select The Select Part Number dialog appears A list of directories is displayed Use the arrow keys to move the cursor to the desired directory Select Open to see a list of product part numbers contained in that Directory Cancel returns you to the Main Menu Use the arrow keys to move the cursor to the proper Part Number Select Ok to select the desired product to be tested Refresh re loads the directory from file Delete removes part numbers Back returns you to Open Directory while Cancel returns you to Test Configuration Fast Load To alleviate searching through long lists of files for your test program simply touch the center of the screen and type the name of the file to load it quickly You can also type in partial names to get a list of matching files 9 The new Part Number is now displayed as the Currently Selected Cable Select Test Now to start the testing process The function of Reports is described in section 7 1 while Batches is described in section 7 2 Cancel returns you to the Main Menu You can also use the Space Bar on a keyboard to use the Fast Load feature Horiz
110. 1 Enter pins that belong H First group 1 56 J 8 4 5 6 7 8 5 HOI WII SAAC Space Bar Elear STEE Scanning 1 Skir Cancel Scanning 11 Cancel perform Group Continuity place the Horizon Probe within the glass of water Ensure the probe is connected to 0 2 on the Horizon Connect the terminated end of the product to the Horizon Place the non terminated end into the glass of water From the Selector Tool menu select Group Scan Enter a range that includes all the conductors For this example we enter 1 50 Select Enter to continue The scan will begin as soon as the conductors are submerged in the grounded water If all the conductors are continuous the group scan will pass Select OK to continue If a conductor is open the scan will pause Select Skip to continue scanning or Cancel to exit the scan The end of the scan will display the conductor pin not probed This conductor is most likely open Select OK to continue 4 32 Horizon Series Tester Programmer s Manual Basic Programming and Testing 8 5 8 43 2 0 618171 Space Bar Elear Group 1 1 17 Group 2 18 33 Group 3 34 50 EH Select Tool Pin Locator Group Sorting Group Scan Cancel
111. 1 or Input 2 or Input 3 toggles the setting through the 3 options Start Test Selected in order for testing to start this control line must be externally activated usually by applying a 12VDC 24VDC stimulus Reset Fail If a product fails during a test this line must be reset before further testing can occur One possible application is to verify the test fixture setup Retest In the event of a failed test retest the product Horizon Series Tester Programmer s Manual 3 3 System Setup Unused Input disabled Palm Switch Toggles the Palm Switch function between Start Test and Start HiPot Ok returns you to System Setup V Make sure that all three inputs are set to Unused unless you actually plan to make use of them Failure to do so could cause your Horizon to hang unexpectedly because it might be waiting for one of these inputs to be actuated 3 3 Time and Date This button allows you to set the Horizon s internal clock and calendar Selecting Time and Date on the System Setup menu displays the Set Time amp Date dialog LL 14 56 pare 55705797 Select Ok to return to System Setup Select Time and the Set Time dialog appears Enter the time of day in hh mm format using the 24 hour clock convention For example 2 20 pm would be entered as 14 20 Select Enter to return to the Time and Date menu Select Date to display the Set Date dialog Dates are entered using the
112. 1 013nF OK 3 10 05 9 84 10 25 10 11nF OK 4 77 46 75 90 79 01 77 81nF OK CHECKING THE DIODE Calibration card on position 1 DIODE Detected Vf 87 mV CHECKING THE HIPOT Calibration card on position 1 AC Arcs Detected OK AC Current measurement OK DC Arcs Detected OK DC current measurement OK Calibration Verification Tool Reference Value Measurement Guide Calibration Procedure Introduction The Horizon 1500 Calibration Verification Tool is composed of several components that are utilized by the Calibration Verification Software to verify that the Horizon 1500 is within specifications Necessary Equipment Philips Screwdriver Kelvin Clips 14 Horizon Series Tester Programmer s Manual Appendix D Calibration Verification Instruments Critical Specifications Recommended Model DMM 2W AW 4 Digit DC Accuracy HP34401A LCR Bridge 4 Digit Accuracy SRS SR715 SR720 Calibration Conditions Warm up time N A Temperature 23 C 2 C 1 Remove the Protective Shell from the tool ee Remove the 4 screws holding the shell in Components are exposed place Horizon Series Tester Programmer s Manual 15 Appendix Calibration Verification 2 Measuring the Values 1 RI R2 R3 R4 R5 R6 BLUE e 102 100 10 ex m S i 1 C6 O pF c2 c3 zb ud c5 C1 100 pF 1nF 10nF T 38nF jj 3
113. 1 14 ADAPTER HA 116 POSITION J3 NET NET JisCli15 21 1 1 J3 C1 15 NET NET J1 C1 16 Jijcl 2 J3 C1 16 3961727 NET NET J1 C1 17 3 28 61217 JdJ3 Gl 3 5 NET NET J1 C1 4 18 J3 NET NET J1 C1 19 TIC J3 C1 19 J3 C1 5 NET NET 3161 20 Ul 1 205 J3 Cl 6 7 NET NET J3 1 21 5 NET NET It CL 224 JL Cl 85 5 J3 C1 22 d3 Cl8 NET NET Ji Cl 23 J1 C1 9 J3 1 235 73201 9 NET J1 C1 10 93 61 24 1057 NET NET 23 23261 11 CAPACITOR CAPACITOR1 NET J3 C1 1 J3 C1 4 VALUE 5 38652e 10 6 58352e 10 TARE 1 41919e 09 END 5 34 Horizon Series Tester Programmer s Manual Advanced Programming 5 5 2 Programming Capacitors Manual Even when you program embedded capacitors manually the NetList must have already been automatically learned see Section 4 for details Pronpt Adapters Low Voltage High Voltage Components Net List More Options Print Test Now Cancel Resistors Keus Capacitors Biodes Black Boxes Twisted Pairs Select Capacitor THECAPAC I TOR Delete Label
114. 1 gt lt s_pinAddress_2 gt lt s_pinLabel_2 gt VALUE lt minimum in Farads gt lt maximum in Farads gt TARE lt value gt Where value is the learned Modified tare in Farads Programming Capacitors HiPot The text file format for HiPot testing capacitors is as follows Horizon Series Tester Programmer s Manual 9 31 Scripting Features CAPACITOR lt s_netName_1 gt lt s_netLabel_1 gt lt s_pinAddress_1 gt lt s_pinLabel_1 gt lt s_pinAddress_2 gt lt s_pinLabel_2 gt VALUE lt minimum in Farads gt lt maximum in Farads gt TARE lt value gt DCHIPOT lt voltage in volts gt DWELL time in seconds LEAKAGE current in amps ACHIPOT voltage in volts DWELL time in seconds LEAKAGE current in amps Where lt value gt is the learned Modified tare in Farads Programming Capacitors Electrolytic The text file format for electroytic capacitors is as follows CAPACITOR lt s_netName_1 gt lt s_netLabel_1 gt lt s_pinAddress_1 gt lt s_pinLabel_1 gt lt s_pinAddress_2 gt lt s_pinLabel_2 gt VALUE minimum in Farads gt lt maximum in Farads gt TARE value ELECTROLYTIC Programming Diodes The text file format for diodes is as follows DIODE lt s_netName_1 gt lt s_netLabel_1 gt
115. 1 is above the expected value dm hm 33 c1 23 gt including the tolerance zone The actual resistance is 4 71 1 24 J3 C1 245 res 27E measured and reported to help a technician correct the NettJ1 C1 25 J3 C1 255 res 279 3m hm too nish problem Ce 5 28 Horizon Series Tester Programmer s Manual Advanced Programming Test Report Reported Results ALL 69 am hm HetoJl C1 23 J3 C1 235 res 274 om0hm NettJ1 Ci 24 J3 C1 245 res 279 9m0hm Net Ji C1i 25 J3 C1 25 res 279 AY as XRESISTORI too high infinite End of Report CSS ERI STERN NN The resistor path for resistor 1 is extremely high The actual problem could be the resistor itself or one of the connecting terminals is open Horizon Series Tester Programmer s Manual 5 29 Advanced Programming 5 5 Capacitors 5 5 1 Programming Capacitors Auto learn J1 m J3 i Figure 5 3 PUT with embedded Capacitor UA From Component Settings select Capacitors Component igiene Settings is accessed by selecting Program Cable the _pioass JO _sustenes Main Menu select Learn New Cable Customized from the Program Cable menu and finally Ok from Learn Back cance Settings The Choose
116. 2 23261 12 LEAKAGE 0 0001 NET DWELL 0 1 Ji Ci 137 REGULAR MASS NET ADAPTER 116 J1 C1 14 POSITION J1 J3 C1 14 ADAPTER HA 116 NET POSITION J3 NET J3 C1 15 TERI NET 9351 1 J1 C1 16 NET J3 C1 16 25 NET 973 61 2 NET J3 C1 17 TL NET 53 63 9261248 NET J3 C1 18 NET lods 21 1 19 NET 235 1 1 NET J3 15555 J1 T 20 NET J3 C1 20 J1 C1 6 NET TS CLEC te 214 NET J3 C1 215 TICE ng NET JISC 227 NET VE J1 C1 8 NET J32 GL 8 J1 Cl 23 NET dJ32C1 237 J1 C1 9 NET J3 C1 9 NET J3 C1 24 NET J3 C1 10 J1 C1 25 J3 CL 25 END Horizon Series Tester Programmer s Manual 4 41 Basic Programming and Testing 4 13 4 Customize DC Hipot by Nets You can choose to perform HiPot testing on only a portion of your cable by performing a HiPot test on the entire cable except for certain nets In which case you select those nets you do not wish to perform a HiPot test on Name Prompt Adapters Low Voltage More Ortions Test Components Net List Print Cancel a Edit Net s Settings IM DC Hirot Custom nc Default Fi B
117. 2 Horizon Series Tester Programmer s Manual System Setup 3 1 Introduction Each cable testing environment is unique incorporating a different set of requirements Many of these requirements are built around your testing philosophy and the way you have setup your production flow and have little to do with the actual testing process The Horizon allows you to make these decisions once for your shop although you can change them at any time the need arises and once they are set a password protects them so that they cannot be changed casually Uae E From Main Menu select System Setup to access the Sun Sep 29 2002 12 37 Test Self Test System Setup menu System Setup i Program cablei Backup 1 Edit Adapter Contrast Shut Down 3 2 Inputs The Horizon has three isolated inputs available through ports on the left side In addition the same port may be used to attach optional Palm Switch es S Select Inputs and the solated Inputs dialog is displayed Inputs Outputs Time and Date Passwords General Boxes Scan Delau Palm Switches Seruice Ok E a E gue a Using these isolated inputs the Horizon can be incorporated E im into a PLC or automatic tester Or they can be used to TES implement external control The Palm Switch is also Hirot programmed from this same menu Selecting Input
118. 255 NET 1326122 Ji CL NET JS Gb NET J3 C1 3 NET J3 C1 18 J1 C1 4 NET J3 C1 4 J1 C1 19 NET J3 C1 19 7126105 NET J3 C1 5 Ji CI 20 NET J3 C1 20 21 1 6 NET J3 C1 6 dicc 2 NET J3 1 21 NET J3 C1 7 Th 01 22 NET 33 61 28 NET J3 01387 Jl C1 235 7 NET J3 C1 23 J1 C1 9 NET J3 C1 9 21 61 24 NET J3 C1 24 J1 C1 10 NET J3 C1 10 NET 252 DIODE J3 C1 11 21 1 1 NET J1 C1 2 71 1 42 GENERIC 73201212 END 5 44 Horizon Series Tester Programmer s Manual Advanced Programming 5 6 2 Programming Diodes Auto learn Special Case Phantom Diodes gt 01 02 Figure 5 5 Phantom Diodes ni Learning Diodes Test Points Found 3 a Set Test Parameters Pronpt Adapters Low Voltage Components High Voltage Net List More Options Print Test Now Cancel Resistors Keys Capacitors Diodes Black Boxes Twisted Pairs Select Diode D IOD ANTO Y x DS xGCENERICA z Delete e EJEA ICA Edit Label Select Diode IODE WITH PHANTOM Eun um GENER LC3 Delete OK Label
119. 3 ne MIU MR 4 36 4 13 Introduction reden ote her e ae eee ae 4 36 45132 aa ee 4 37 4 13 3 Program the Horizon to Hipot the Entire Cable or 5 4 37 4 13 4 Customize DC Hipot by 444 4 4 42 4 135 Testing Using the DC 4 45 4 13 6 Eror Reporting a Pea Sars adt dte dena 4 46 4 137 Setting Various DC Hipot Cycle Times een 4 47 4 138 DC Hipot Ramp Up Ramp 4 50 4 14 AG FIP OUT SUNG 4 50 4 14 1 Introduction ae eA tet ene eden ped 4 50 4 14 2 e cadum uina dun 4 50 4 14 3 Programming the Horizon to Hipot the Entire Cable or Harness 4 50 4 144 Customize the AC HIPOT by 4 56 4 14 5 Testing Using AC HiPot eee 4 59 4246 Error Reporting aam usar du 4 60 4 147 AC HiPot More Options Ramp Up Ramp Down amp Current erect aa Baa ie ped 4 61 4 15 Fixed High GutrentSOUIce 4 61 4 16 Programmable High Current Source Capabilities esee 4 63 4 16 1 Overview of the Programmable High Current Source 4 63 4 162 Us
120. 6 3 Taing the 6 9 6 4 Testing a New Adapter 6 10 6 5 Connector Pin Conventions eiiis sitet tnn tette 6 11 6 5 1 Special Case The Kelvin 25 6 13 6 5 2 Special Case Shorted Pins uc c egt a e 6 14 6 6 Editing anxexisting Adapter e iro M br ae Nee S RR 6 16 7 Generating Reports and Batch Testing 7 1 7 1 Generating 5 setenta 7 3 7 1 1 Print Save to File or Both sss 7 3 7 1 1 1 Printer Settings pee need et ante ete 7 4 7 1 1 2 RIG ptem toe 7 4 7 1 2 or eet ectetuer det o D ve tuis 7 5 7 1 2 1 Serial orte ertt 7 5 7 1 2 2 Report 7 6 7 1 3 Autodiagnose 5 Sek etal asap 7 6 7 14 Header and Footer nandien cette PH Dee 7 6 7 1 5 Operator ID s eee ae 7 8 7 1 6 Enable itt 7 8 7 1 7 Viewing Reports Saved to 7 9 7 2 i e 7 9 7 2 1 Setting Up Testing By 7 9 7 2 2 Batch Completions iaceo cie eap ep eee 7 11 8 Backups and Restores 8 1 8 1 RE
121. 61 24 931 10 NET NET J1 C1 25 Jil J35 1525 END 4 28 Horizon Series Tester Programmer s Manual Basic Programming and Testing 4 11 2 Testing the Cable Flex Test Test Configuration File Name databwcablesMMAIN FLEXTEST CR Part Number ELEH i TEST Tools Reports Select Test Nou Batches ancel Test Report Reported Results Fail Test Program TEST CABLE 5 94 97 2909 iU 97 13 J3 1 6 open ide From J3 Ci 12358horted xHetcoll clz4 Ji C1 245shorted End of Report Lese To actually perform the Flex test on a product is easy and straightforward Select Test on the Main Menu to bring up the Test Configuration menu press Select to select the product for testing unless it is already displayed then select Test Now You will be instructed to insert the necessary adapters and then to connect the cable for testing The Flex Test display appears and the Horizon automatically enters a continuous scan loop looking for faults At this point you need to manually Flex or stress the cable typically by moving it back and forth or wiggling it at each connector Any detected faults will be logged and totalled at the top of the display with C standing for continuity and 1 for Isolation If a fault of any type is detected in a given net that net is re
122. 8 nF L4 30 31 32 gt lt T 11 5 a 5 Signatures Schematic of Calibration Verification Tool NOTE The PCB decal used to get the residual capacitance CO The Components are clearly labeled on the tool 2 1 Resistors R1 and R2 are measured at their terminals using a 4 wire Kelvin measurement The tolerance of the resistor components is 1 the nominal value R1 1000mo R2 10000mQ 2 2 Resistors R3 R4 R5 R6 are measured at their terminals using a simplex resistance measurement The tolerance of the resistor components is 1 the nominal value R3 10000 R4 1000000 16 Horizon Series Tester Programmer s Manual Appendix Calibration Verification 5 10000002 R6 100000000 2 3 The capacitors are measured at their terminals using an LCR Bridge at 100Hz The tolerance of the capacitor components is 2 the nominal value C1 100pF C2 1000pF C3 10000pF C4 C5 78000pF C6 need not be verified NOTE C4 and C5 are in parallel with a combined capacitance of 78nF Recording the Measured Values The measured values must be entered within the CAL REF file found on the accompanying diskette with the tool The file can be edited using any DOS or WINDOWS text editor E g Edit or Notepad The file has the following format 123456 12 Serial Number of Card 1000 10000 gt 1000 20 100000 20
123. C Hirot Custom Conductor Res AC Default EF Default Def au lt Default Kelvin Sh iela global DC hipot scan type is set to Mass Hirot gt he able to customize the ipot settings change the giobal DC hipot scan type to Linear Hipot To program nets to be excluded from the HiPot test select Net List from the Set Test Parameters menu The Edit Nets dialog will be displayed Using the arrow keys move the cursor to highlight the net you want to exclude or include from HiPot testing Select Edit for the Edit Net s Settings menu Note that the display shows that this net is currently set to assume the default settings for both DC and AC HiPot tests In the example cable being used DC HiPot has been learned per the settings above but no AC HiPot testing has been defined Therefore if no changes were made this net would be subjected to a DC HiPot test but not to an AC HiPot test Select DC Hipot Settings to display Edit the Net s DC Hipot Settings If the net you are selecting is a Ground or Chassis point in your product you may designate it as a Shield by selecting Shield from the Edit Net s Settings menu This net will no longer be charged during the High Voltage test though it will still remain as a common point If from the Set Test Parameters you
124. CableTest Systems Inc HORIZON SERIES TESTER H1500 PROGRAMMER S MANUAL v 4 5 9 http www quadtech com 1 800 253 1230 QuadTech Inc 5 Clock Tower Place 210 East Maynard MA USA _ CABLETEST Copyright 2004 by CableTest Systems Inc Markham Ontario Canada All rights reserved Printed in Canada Printed on 2 27 2004 Microsoft is a registered trademark of Microsoft Corporation MS DOS is a registered trademark of Microsoft Corporation Windows is a trademark of Microsoft Corporation Horizon Horizon 1500 and H1500 are trademarks of CableTest Systems Inc All other trademarks are the properties of their respective owners Warranty CABLETEST warrants that the shipped Product will be free from defects in material and workmanship in conformance with our specifications for a period of one year 1 from date of shipment by CABLETEST This is the only warranty which CABLETEST makes relating to the Product CABLETEST make no other warranty express or implied and specifically no warranty of merchantability or fitness for a particular purpose This warranty is limited to replacement or rebuilding of any Product and shall constitute the exclusive remedy for breach of warranty and CABLETEST shall not be responsible for any incidental or consequential damages Products covered by this warranty must be returned prepaid and received within the warranty period No allowances will be made for labour mate
125. ETEA iC Edit Print The Kelvin toggle is provided for the two special cases Kelvin adapters and adapters with shorted pins For standard adapters the toggle has no effect It is recommended for non Kelvin Huge adapters to disable the feature this will increase the probing speed as you learn your adapter Using the provided ground probe touch the tip to each connector pin in its standard numbering sequence The Horizon maps the connector pin to its corresponding system pin column one and displays a pin map similar to the one at the left The second column Sense is reserved for the special case Kelvin adapters The Horizon is equipped to let the user define the numbering convention needed for their adapter If your connector uses a unique numbering convention select 12 AB to open the Conventions list If the convention you wish to use is not present you can add it to the conventions listed You may also edit each individual connector pin name by highlighting the Conn Pin and selecting Edit See below for more details When finished select Print if you wish to print out the completed pin map Otherwise selecting Back will cycle you to the menu for the next connector on the adapter Horizon Series Tester Programmer s Manual 6 7 Adapters Enter Sustem Center 1024 for H C1 Test Point You can manually enter system pins o
126. ID to include the name of the operator for this test session The ID can be up to 30 characters in length Select Enter and you will be returned to the Report Settings menu Note the operator s name is present The final setting is to select the reports to be activated By selecting Reports a check mark appears in the neighbouring square 7 8 Horizon Series Tester Programmer s Manual Reports and Batches Select Ok and the Test Configuration menu returns Note File the check mark present the square next to the Reports REST CABLE sx button If you do not select Reports on the Report Settings Tools Select menu then this check mark will not be present and no rest Nou Batches cancel reports will be logged for your test session 7 1 7 Viewing Reports Saved to File To view the reports generated by a test session that have been saved to file s follow these steps Menu NN From the Main Menu select Backup Thu Sep 11 1997 01 40 Test Self Test System Setur i Program Backup i Edit Adapter Contrast Shut Down a Backup Restore Shell By selecting Save Log Files the Horizon will save the log sens files lt testname gt ALL and lt testname gt ERR to a diskette Restore t a inserted into the floppy drive More Options
127. N specifies the number of characters to be skipped at the left margin of the printout If not specified it defaults to 5 The optional WIDTH specifies the width of the page in number of characters If not specified it defaults to 80 The PASS specifies that test results are to be printed for passed cables only The FAIL specifies that test results are to be printed for failed cables only The PASSFAIL specifies that detailed test results are to be printed for failed cables only The passed cables will only print a brief Pass message The ALL specifies that detailed test results are to be printed for both passed and failed cables If none of the PASS FAIL PASSFAIL and ALL options is listed then no test results would be printed The FILE and PRINTER keywords are mutually exclusive Either one can be used but not both in the same test program If both are missing then the report printing defaults to the printer Horizon Series Tester Programmer s Manual 9 21 Scripting Features Auto diagnose Option To enable the auto diagnose options use the syntax described below REPORTS AUTODIAGNOSE PASS FAIL PASSFAIL ALL The PASS specifies that test results are to be displayed automatically for passed cables only The FAIL specifies that test results are to be displayed automatically for failed cables only The PASSFAIL specifies that detailed test results are to be displa
128. OR Terminal 1 x JS3 C1 1 Terminal 2 lt J3 C1 4 Value 538pF min Test More Options Label OK 658 max a Edit Capacitor CAPACITOR Terminal 1 J3 C1 1 Terminal 2 lt J3 C1 4 Value 538 min 658pF max Test More Options Label OK Select Detect Mode ir Change Tare Value Change Thresholds 5n fiutodetect Thresholds cancel 1439 nF Hi Select Detect Mode Change Tare Value Change Thresholds Autodetect Thresholds ancel ud In the example shown Terminal 1 of the first capacitor Cap1 is connected to pin 1 of the first connector on the adapter located at J1 Select Terminal 1 to view more details of this net The Select Net menu appears This display indicates which net the capacitor is wired to If this agrees with other documentation it is another indication that the cable has been learned properly Select Open to label this pin By selecting Value you can alter the capacitance thresholds tolerance as well as alter the value of capacitance tare Select Change Tare Value if you wish to alter the tare value The value is a measurement of cap
129. Options Print Test Now Cancel Edit Het H 5 4 32322 g a Monae Label Twisted Select Con Dwell to add a delay to the continuity measurement Select Iso Dwell measurement to add a delay to the isolation From the Set Test Parameters menu select Net List Select the Net you wish to customize and select Edit Horizon Series Tester Programmer s Manual 4 19 Basic Programming and Testing a Edit Net s Settings Select Conductor Res to set a custom setting for the DC Hirot Custom Dc Default Fi selected net AC Hirot Custom AC Default E Conductor Rez Default Default Default Kelvin Shield OK 1 Specifu Continuity Tupe Resistance 5mfA 105 Sos Resistance From Sample Voltage Drop Fixed HC Cancel Specify the continuity type and set the preferences as described above If the net you have selected is a Ground or Chassis and you have other nets that are ground as well you may want to designate each net as Shield by selecting Shield from the Edit Net s Settings menu If two nets each designated as Shield are shorted together during a test they will not
130. Parity Options are None Even Odd Zero and One Select OK to return to RS232 Remote Options Bar Code Reader Options Separator String 1 Header Code STH nsa Separator String Select your part number separator Bar Code Reader Options Header Code Select barcode reader programmed prefix Reader Port Only Keyboard emulators are supported at this time 3 5 Scan Delay These functions control the Horizon s automatic start of test COE In order to optimize production flow the Horizon is designed to begin testing as soon as it detects that most of the SY available pins on the cable or harness are inserted in the adapter or fixture It can t wait for 100 since there may be one or more opens in the product When inserting larger connectors the operator sometimes uses a rocking motion to more easily mount the product As a result it can happen that the Horizon will be falsely triggered and start the test cycle early The Scan Delay feature is designed to deal with this situation Select Scan Delay to enter the Scan Delay Settings menu Insert Delay Allows you to program a delay between the automatic start of test trigger event and the actual start of test to allow for the cable to be fully inserted in the adapter or fixture The allowable range is 0 1 seconds to 60 0 seconds Select Enter to accept the input and return to
131. Programming a Enter Part Number SWITCHES 5 2 2 5 BU 2 4 En eee 9 9 Space Bar Elear Set Test Parameters H Name Prompt Adapters Low Voltage Components High Uoltage More options Net List Print Cancel Test Now Select Suit ch Position You are prompted to enter the part number Select Enter to confirm the part number From this point on the process is identical to that for any other cable You do not have to do anything else to finish programming and to test this cable with embedded switches Select Ok to save the test procedure in the internal database If you select Net List you will be prompted to select the Switch Position you wish to review 5 58 Horizon Series Tester Programmer s Manual Advanced Programming Test Program as CBL File datab cables main switch cbl For greater detail see section 9 CABLE SWITCHES 1 NET NET STAR Ji Cl 18 Ji Cl 8 THRESHOLD 61 J3 Cl 13 ADAPTER 116 NET NET POSITION J1 J1 C1 9 ADAPTER 116 J3 CT 14 OERE POSITION J3 NET NET SWITCH J1 C1 15 J1 C1 10 CHAIN J3 C1 15 J3 CLEO PROMPT NET NET OPEN J1 C1 16 Ji OT 11 NET J3 C1 16 J3 Cb NET NET
132. REUR tes 3 5 Horizon Series Tester Programmer s Manual v
133. S38 ca at J1 61 24 Z5mthm d of Report 1 m Jl1 C1 12 4 RS m E i In the next example the same cable has failed as a result of a short not at either end of the cable but 8196 of the distance from the first adapter In this manner one can easily locate the fault to be dealt with at the re working station Use the down arrow button to see the remainder of the error message J3 F S B Figure 4 10 Short at 5596 4 24 Horizon Series Tester Programmer s Manual Basic Programming and Testing In this example the short has occurred at 55 the distance from the first adapter icit Za at 61 12 29mOhm Use the down arrow button to see the remainder of the error message adis Gls Sa at 29m0hm n Hi 291 CR PM 61 12 98 122 at om 11 61 Z9mthm Wd of Heport 3 J1 J3 7 4 2 x J Figure 4 11 Multiple Shorts It is not unusual to find a cable or harness that has more than one fault The Horizon will report all faults found The only exceptions are those cases where one type of fault is masking another type of fault when an open circuit is sitting behind a short on the same wire The only other exc
134. SITION J1 J3 C1 15 ADAPTER HA 116 NET POSITION J3 NET 23 C1 16 Jill NET J3 151 NET 93961 NET J35 142y Jl 01 18 NET J3 C1 18 JI OL 35 NET J336153 Jig 19 NET 23 C1 19 J1 C1 4 NET J3 C1 4 21261 20 NET g3 Cl 20 Syy NET J3 C1 5 NET J1 C1 6 NET d3 Cl 6 7 Dh Cle 22 7 NET J3 C1 22 Jil NET NET 43 1 23 Jl CLl 8 NET 23 C1 8 NET g32 1 245 J1 C1 9 NET J3 C1 9 J1 C1 25 NET 33561525 TO END 73 61 10 NET 21260 1 23 C1 11 Horizon Series Tester Programmer s Manual 4 49 Basic Programming and Testing 4 13 8 DC Hipot Ramp Up Ramp Down The slope of the charge and discharge of a PUT can be controlled by selecting Ramp from the DC Hipot Settings menu Select either Ramp Up or Ramp Down to enter the desired value Programmable range 01V to 10kV per second for both Ramp Up and Ramp Down 4 14 AC HiPot Testing 4 14 1 Introduction The Horizon can be set up to perform an AC HiPot test on any cable or harness provided that a high voltage AC source is installed HiPot testing can be done on the entire cable or only on selected nets within the cable If your product has embedded resistors or diodes and these components are learned when the cable is learned the Horizon will automatic
135. Select General for General Report Settings general Stes meret gt lt Reports n eit 7 1 1 Print Save to File or Both Select Print To to select the target for reports Printer Writes reports to the parallel port of the Horizon File Writes reports to a log file Select both options sets the setting to Multiple Reports will be printed and written to the log file Horizon Series Tester Programmer s Manual 7 3 Reports and Batches 7 1 1 1 Printer Settings General Report Settings H ia i Enter Left Margin Print Filets In the example to the left the report will be printed via the parallel port with a 5 space left margin and each line consisting of 80 characters To set the width of the left margin select Left Margin The Enter Left Margin dialog appears Enter a width from 0 32 To set the width of the page select Width The Enter Report Width dialog appears Enter a width from 20 1000 Othe default settings should suit most printers Select Form Feed if you would like each test to be ona separate printed sheet this must be selected if you plan to have a header or footer on your printed report When the Print T
136. Select Part Number ACITOR Reu 1 TEST Reu 1 ING LEADS Reu 1 d TOR Row Refresh Delete w Back Cancel OK Test Configuration File Name datab cahbles MAIN SWITCHES Part Number SWITCHES Rev 1 Tools Reports Select Test Batches Cancel Highlight the product you wish to test Select Ok to continue Select Test Now to begin testing the listed product Horizon Series Tester Programmer s Manual 5 67 Advanced Programming TE RI HA 116 SWITCHES Tested Passed Failed Error Statistics Diagnose Start Test Cancel Testing Embedded Switches OK 1 may use a Palm positions Performing Tests 5 Isolation 109 Action Required OK 1 Isolation 5 68 Horizon Series Tester Insert the required adapters Connect the product you are testing to begin the test cycle If the test doesn t automatically begin select Start Test The first instructional prompt you programmed will be displayed Flashing at the top is the message Action Required After the instructions are carried out push Ok and the Horizon
137. T 500 NET LEAKAGE 0 001 3 DWELL 0 4 LINEAR NET 60HZ ADAPTER 116 J3 C1 14 POSITION J1 NET ADAPTER 116 Ji 2CL 15 POSITION J3 NET NET 0 J1 C1 16 J3 C1 16 Jg3 T xi NET NET 2140152 J3 CT 17 J3CT22 5 NET NET J1 C1 18 Ji2C1135 J3 C1 18 023 1 3 NET NET 21 1 19 Ji Cl 4 93 61 19 NET NET J1 C1 20 0 J3 C1 20 412012552 NET J3 C1 5 21201 2 NET JiCl46 4 NET 22 NET 2227 21 61 7 NET 492017 JicOl928 NET JijCl 8j NET 935128 NET 23 61 24 J1 C1 9 NET J3 C1 9 JIS ET S255 x NET J3 C1 25 END J3 Cl 10 NET Jis Eb 4 58 Horizon Series Tester Programmer s Manual Basic Programming and Testing 4 14 5 Cable Testing Using AC HiPot To perform an AC HiPot test on a cable as part of the test specification simply follow the same procedures as for low voltage testing erent Canin Select Test on the Main Menu Select the cable to be tested fitis not the cable displayed and select Test Now You Part Humber REST CABLE 2 will then be instructed to insert the adapters and to connect Tools Rererts Select the product for testing
138. Test Sustem Seturi Program Cablel Backup E Edit Adapter i Contrast Shut Down Test Configuration File idatabscables MAIN ASSEMBLY ch Part Number ASSEMBLY AID Rev 1 Tools Reports Select Test Now Batches Cancel Insert the Adapter s IM i124 mE E 1 Select Tool Pin Locator Group Sorting Group Scan Cancel Step 2 Group Scan Before you begin it is recommended to verify the continuity of all conductors that are terminated within the connector Confirm with Yes Select the directory you wish to save the file within or create a new one by selecting New Select OK to save Select Cancel to return to the Main Menu From the Main Menu select Test to enter the Test Configuration menu The last loaded product in this case the product we just learned is displayed If it is not the correct product choose Select to load the correct one Select Tools to begin the Assembly Aid process The system prompts for the adapter needed Place the adapter to continue The Select Tool menu appears Horizon Series Tester Programmer s Manual 4 31 Basic Programming and Testing a Select Tool H Pin Locator Group Sorting Group Scan Cancel
139. Test Scripts section can only be used in conjunction with the optional TCL Interpreter package Some other elements of the test program can only be used if the Horizon hardware supports them e g DC HiPot commands can only be executed if the machine is equipped with a DC HiPot Unit Horizon Series Tester Programmer s Manual 9 3 Scripting Features Below is a sample test program with its individual sections identified CABLE AWP 1001GT 1 ID Header ADAPTER AATEST Adapter Interface POSITION J5 STAR Test Parameters and Prompts THRESHOLD 61 DCHIPOT 50 IR 5e 07 DWEL ix 2 REGULAR LINEAR NE E NetList 9 4 Horizon Series Tester Programmer s Manual Scripting Features 9 1 2 Test Program ID Header The test program ID Header is mandatory It consists of the tested product s name and test program s revision Since most tested products are cables the terms cable and tested product will be interchangeably used in this document The ID Header consists of one line that must have the following structure CABLE lt s_cableName gt lt s_programRevision gt where CABLE is a keyword or tag lt s_cableName gt indicates a string field representing the cable s name and lt s_programRevision gt indicates a string field representing the test program s revision The user must sup
140. Tester Programmer s Manual 3 Appendix C Mass HiPot Examples one net only i e a true fault is detected An example of group splitting caused by an overload condition is shown in Table 2 Table 2 Splitting caused by current overload due to mass grouping Test Net Number Cycle Condition 1 Pass 2 Overload 2a Pass 2b Pass Pass Pass Pass Pass Scenario 3 Good Product Mass IR Tests Fail Net Groups Are Too Large The IR leakage limit is typically chosen as though one net in the PUT was being tested against all other nets For this reason it is possible to reach a good product s current leakage limit during Mass IR testing due to the net grouping that occurs Table 3 Splitting caused by excessive current leakage due to mass grouping Test Net Number Cycle Condition 1 Pass 2 Leakage 2a Pass 2b Pass 3 Leakage 3a Pass 3b Pass Leakage Pass Pass Leakage Pass Pass During the Mass IR test s binary scan multiple nets are measured simultaneously As the combined leakage of all these nets adds up the PUT s IR leakage limit may be exceeded If this occurs a FAIL condition is detected by the MPT The MPT will then determine whether this condition was caused by cumulative net grouping or by the exces
141. a the test measures lower than the threshold value the fault za ees e pese oen will be reported as Wrong Gauge o Esc Select Enter to continue The settings are updated Flex LDis Scan Star Conductor Rez Sit Max stimulus on Min Isolation Min Res Quick Scan More Options 4 9 3 Star or Chain Scan The Horizon provides two methods for continuity scanning The default method is the Star scan The star scanning method selects the first point in a net and measures continuity from that point to all other points 3 The second method is the Chain scan The chain scanning method selects the first point in a net and measures continuity to the second point in a net Next the second point is select and continuity is measured to the third etc 1 2 3 4 Toggle the Scan button from the Low Voltage Settings eee menu to change between the two scan options Conductor Res Sit stimulus on Min Isolation Min Res Quick Scan Tare OK 4 9 4 Tare The Tare values can be added directly to a test program acm without performing a full System Tare or an Adapter Tare The tare is performed from the Low Voltage Setting menu Select More Options gt Tare 4 18 Horizon Series Tester Programmer
142. acitance at the test level of the system For example if you are testing from a test fixture the tare capacitance should be altered to include the capacitance of the fixture The default tolerance set is 10 Select Change Thresholds if you wish to alter the tolerance for the component Enter a new tare value and select Enter to accept Every time this screen is accessed the default tare value calculated during the system Capacitance Tare will be displayed Selecting enter will restore the default value Select Change Thresholds to input a specific tolerance you may enter the minimum and maximum expected values Enter the minimum and maximum threshold 5 32 Horizon Series Tester Programmer s Manual Advanced Programming a Edit Capacitor Terminal 1 x JS3 C1 1 Terminal 2 lt J3 C1 4 Value m in 655pF max 2 Select APA Test amp IEpF More Opt ions Label OK CAPAC ITORL 6 2 8 5 2 7 8 9 9 2 ALS Space Bar Elear apacitor Delete Hade aAA a Set Test Parameters Cancel Pronpt Adapters Low Voltage High Voltage Components Net List More Options
143. adapter s Kelvin fixture s are properly inserted select Ok to get to this screen By selecting Ok the system starts learning the configuration of the Kelvin fixture The product that is supposed to be tested must not be connected at this time since it will affect inadvertently the learning of the Kelvin fixture s structure Since the product will be tested in several steps it is possible that the Kelvin fixture s structure NetList will be different for each one of the steps This screen asks you to make sure that the Kelvin fixture is configured for the first testing step Select Ok when the fixture is configured properly Horizon Series Tester Programmer s Manual 5 65 Advanced Programming a Learn a New Cable with Switches Switch to the 15 position then press OK to learn it Cancel to end learning Ok Cancel Enter Prompt Line 1 PRODUCT LOADED 2126907 CE CE E EE 5 21517216 tz 64 21 5 Gr 81 ME 9 9 Space Bar Elear Enter Prompt Line 2 PLUNGER DEPRESSED EXER ERES IER 5 1 5 2 L3 5 gt 2 HY 2 4 ER 51 9 21 RO 9 9 9 seace Bar grear Enter Prompt Line 3 Gs CE CR CE CE CE CE EE 5 5 9 2 8 2 92 2
144. age can be specified in single 1 volt increments Remember that you are specifying an RMS voltage Take this into consideration if the test specification calls for a peak voltage When the proper voltage has been entered select Enter and you will be returned to the AC Hipot Settings menu Select Leakage Limit and you will enter the Specify Leakage Type dialog You can specify the desired leakage limit directly as a current as a function of resistance or simply ask the 1b Horizon to look for arcs only Selecting Current brings up ares the Maximum AC HiPot leakage current in uA dialog pecify Leaka Current Enter the desired leakage current paying attention to the TE insulation specifications for the wire being used The SS allowable range is from 1 to 5mA Use the arrow keys to change between pA and mA as needed Selecting Enter when done will return you to the AC Hipot Settings menu 4 52 Horizon Series Tester Programmer s Manual Basic Programming and Testing Maximum AC hipot leakage resistance in Mi Resistance Hirot Hipot Voltage 456 Leakage Limit 1 Hipot Duration 2 00 Frequency Scan M
145. al timeout parameter is missing or is 0 then an out of sequence error is signalled as soon as it is detected If a positive timeout value is specified then the system waits that period and then if the out of sequence condition still exists it will signal an error This latter feature is used when coaxial wires are built and both contacts close almost simultaneously but there is no guarantee which one closes first It is then acceptable for the second conductor to make contact before the first provided the first makes contact within the specified timeout period To build a cable with the out of sequence option with no timeout BUILDAID OUTOFSEQUENCE To build a cable with the out of sequence option with a programmed timeout in seconds BUILDAID OUTOFSEQUENCE 0 5 Building a Cable Randomly 9 18 Horizon Series Tester Programmer s Manual Scripting Features By default the Horizon expects the cable to be build sequentially When a random building order is acceptable and desired at the operators discretion then the random mode must be explicitly selected In order build a cable randomly BUILDAID RANDOM PIN The optional PrN subcommand specifies that the build aid is to be done on a pin per pin basis Otherwise the build aid is conducted on a net per net basis To build a cable on a net per net basis BUILDAID RANDOM To build a cable on a pin per pin basis
146. alized Enables the Horizon to test the true quality of the cable s insulation despite the presence of a significant reactive capacitive current in the circuit This current approaches zero in a good cable and is an excellent reference for limit setting for a HiPot leakage test 4 15 Fixed High Current Source As of September 2002 The Fixed HC Source is available on all HV models of the Horizon 1500 For models delivered prior to this date you can verify if your system has the featured installed simply by checking whether it is enabled in the Low Voltage test parameters menu The Fixed High Current Source is only used in the 4 wire measurement mode Set Test Parameters B From the Set Test Parameters menu select Low Voltage Name Prompt Adapters Low Voltage Components High Uoltage Net List Test Now Cancel OK Horizon Series Tester Programmer s Manual 4 61 Basic Programming and Testing 3 Low Voltage Settings Flex Bis Scan Star Conductor Res Mick Scan stimulus M A Isolation Min Res Quick Scan More Options 1 Specify Continu ity Tupe 2 Resistance 5mf Quick Scan Resistance Voltage Drop From Same le Fixed HC Cancel i Do you want Voltage Drop Tes O0
147. ally exclude the nets connected to these components Nets with components connected to them are automatically grouped for isolation and HiPot testing and the group of nets is treated as a single net while these tests are running You do not have to worry about manually excluding them 4 14 2 Safety Your Horizon has the capability of numerous safety procedures Which of these you use depends on local regulations your philosophies and the training level of your personnel To use Palm Switches with your High Voltage Test see Section 3 System Setup 4 14 3 Programming the Horizon to Hipot the Entire Cable or Harness The main location for setting up HiPot testing is the Set Test Parameters menu This menu is always displayed after a cable has been learned through either the Default or the Customized path Itis also directly accessed after selecting a previously learned cable in Modify Existing Cable 4 50 Horizon Series Tester Programmer s Manual Basic Programming and Testing aa Selecting High Voltage displays the High Voltage Settings ee dialog Low Voltage Components High Voltage Net List Test Now Cancel oem Selecting Hipot Nets Only a check mark is visible means Hinet oniu i pi that the Horizon will only perform a HiPot test on complete Password Protected nets Discharge Delay 9 05 Hipot Settings AC Hipo
148. ames the connector labels can be used to reduce the size of the test program file Horizon Series Tester Programmer s Manual 9 7 Scripting Features or to simplify the default Horizon pin naming scheme in some cases it can reduce the typing load 9 8 Horizon Series Tester Programmer s Manual Scripting Features CABLE AWP 1001GT 1 ID Header ADAPTER AATEST Adapter Interface POSITION J5 CONNECTOR 1 P CONNECTOR 2 K STAR Test Parameters and Prompts THRESHOLD 61 DCHIPOT 50 TR 5e 07 DWELL 2 REGULAR LINEAR NET Netlist r 11 r ON UV ows wW O UN wN W oU or WU E40 K 4 Horizon Series Tester Programmer s Manual 9 9 Scripting Features It is worth noting that labelling an adapter s connector in a test program doesn t affect other test programs i e other test programs can label the same adapter s connectors in a different way or not label them altogether 9 1 4 Test Parameters The test parameter fields are optional If they are not encountered in the text file the default test parameters are automatically used There are two main groups of testing parameters the low voltage test parameters grou
149. ant for this purpose Although it is a good practice to name the file in such a way that it reflects what the test program contains this is not always possible because of the DOS file naming limitations The Horizon generates the file name maximum 8 characters in length by truncating the internal cable name and making sure that the file name is unique this last requirement is for the sake of DOS only The Horizon will not save a test program if the cable s name and program s revision collide with an existent one When manually creating a test program the user must ensure that such a collision doesn t occur 9 1 3 Adapter Interface Section Any tested product is connected to a test system one way or another This connection is usually called an adapter interface adapter cable test fixture or test panel The Horizon calls it simply an adapter In this light an adapter defines the connections between The Horizon s test points and the device under test typically a cable The Horizon comes with a comprehensive library of standard adapter definitions Besides being able to take advantage of the standard adapters the user can easily add new adapters to the library Whether or not it employs standard adapters custom adapters or any combination thereof each test program must specify them This is done in the Adapter Interface Section as described below CABLE AWP 1001GT 1 ADAPTER AATEST POSITION J5 The first line tells
150. ass More ort Input the AC hipot test duration in seconds Hipot Voltage Leakage Limit Hipot Duration 2 00 Linear Scan More Opt If you would prefer to specify leakage in terms of resistance selecting Resistance after selecting Leakage Limit will display the Maximum AC HiPot leakage resistance in MQ dialog Input a leakage resistance between 0 1MQ and 1000MQ and then select Enter to return to the AC Hipot Settings menu The last choice is Arcs Only The Horizon will still automatically test for arcs if leakage is specified If an arc is detected testing is immediately suspended the arc is reported and no further high voltage testing is performed on that cable This test will rapidly check for any insulation or other breakdowns Cancel returns to Set Test Parameters with no changes made Selecting Hipot Duration displays the nput the AC HiPot test duration in seconds dialog Enter the length of time that you would like the AC high voltage to be applied from 0 01 to 600 seconds Select Enter to return to AC Hipot Settings Scan switches between the Mass scan and the Linear scan methods Although the linear method is more traditional it is highly recommended that you leave it in Mass scan unless your test requirements specifically dictate otherwise As detailed in Appendix C a M
151. ass HiPot test is much faster with no loss in accuracy Ok adds the AC HiPot tests to the cable record and returns to the Set Test Parameters dialog Horizon Series Tester Programmer s Manual 4 53 Basic Programming and Testing Select Ok to save the record for this cable in the internal Prompt Adapters ata base Low Voltage Components High Voltage Net List More Options Print Test Now Cancel 4 54 Horizon Series Tester Programmer s Manual Basic Programming and Testing Test Program as CBL File datab cables main testca 4 cbl For greater detail see section 9 CABLE TEST CABLE 5 5 NET STAR 12 THRESHOLD 61 985612222 ACHIPOT 456 NET LEAKAGE 0 001 DWELL 0 4 US CI 13 7 LINEAR NET 60HZ J1 Cli14 ADAPTER HA 116 J3 C1 14 POSITION J1 NET ADAPTER HA 116 POSITION J3 9326755 NET NET TLC yy J1 C1 16 Jg3 61 17 J3 C1 16 NET NET Jg1 01 277 J1 C1 17 J3 1 2 J3 C1 17 NET NET J1 C1 3 J1 C1 18 J3 1 35 J3 C1 18 NET NET 71 1 4 J1 C1 19 J3 C1 19 NET NET IPC 9121 20 20 NET NET Jl1 Clso21 J3 C14 64 23 1 21 NET NET 21 61 7 71 61 2235 0314221 NET NET J1 C1 8 23 8 5
152. at the time of purchase to active the Advanced NetList Editor You must provide the unit s serial number as well as Uninstall Verification Key Enter the Override Key which is provided by the factory If there is an error when entering the Override Key this message will appear Select Ok and try again If it persists call the Horizon Technical Support Enter the Registration Key If there is an error when entering the Registration Key this message will appear Select Ok and try again If it persists call the Horizon Technical Support Install TCL Scripting Package To install the TCL Package select Install TCL Package Select Yes to continue to install the TCL Package The Package Installation Warning menu will appear No will return you to the previous menu Horizon Series Tester Programmer s Manual 3 7 System Setup Package Installation 0 his package was previously uning hren Erom he system Stal ation en by the tor Enter Override Keu H he override key 15 mot valid Try again 9 i JL2 IC s 6 7 BEER gt pe 3 Registration he prey ited key 15 not valid Try again General Setup i Gaii R Editor Uninstall Netlist Editor Uninstall TCL Package Language OK
153. ations gt 5 Appendix A Specifications 2 Horizon Series Tester Programmer s Manual Appendix A Specifications PHYSICAL SPECIFICATIONS Dimensions 17 432mm W x 9 229mm D x 5 127mm H Weight Less than 15lbs 6 8kg Power Supply Input Voltage 100 250 50 60Hz 1 0 0 5A Output Voltage 12VDC 3 5 ENVIRONMENTAL SPECIFICATIONS Ambient Temperature Operating 0 55 C Non Operating 0 45 C Temperature Gradient Operating Non Operating 30 C hr max without condensation Relative Humidity Operating Non Operating 8 80 non condensing Vibration Operating 2 45 m s 0 256 Non Operating 11 76 m s 1 26 Shock Operating 29 4m s 3G Non Operating 490 m s 506 Corrosion Gas No Corrosion Gas HORIZON INPUTS AND OUTPUTS Outputs Rated Load 0 5A 125VAC 1A 24VDC Contact Material Ag Au clad Carry Current 2A Max Operating Voltage 125VAC 60VDC Max Operating Current 1A Max Switching Capacity 62 5VA 30W Min Permissible Load 1mA 5VDC Inputs Trigger Voltage 12 24V Horizon Series Tester Programmer s Manual Appendix A Specifications QUICK SCAN SPECIFICATIONS Continuity Stimulus 5mA Threshold 3000 Voltage Limit 5V Isolation Stimulus 50uA Threshold 80kQ Voltage Limit 5V MEASUREMENT SPECIFICATIONS Resistance 2 Wire Measurement 0 10 to2MQ 2 5 20 0 Resolution 2MQ to 10 7 0 1KQ R
154. available options Permanent Switches switches Temporary Switches Used for momentary switches such as membrane switches Used for mechanical 5 8 2 Programming Switches Permanent Insert the Adapter s 116 JL Ja TD mJ HA HA 116 116 Select Cancel OK Learn New Cable with Switches Insert the Product then press OK to continue a Learn A Cable With Switches Switch to the ist position then Continue to learn it Cancel to end learning Ok Cancel uu 2 Space Bar lear Es Insert the appropriate adapters Select Ok to continue Insert the product into the adapters Select Ok to continue The Horizon instructs you to set your product in the first switch position After this is done select Ok The Horizon learns the first net list You will be asked to enter a prompt The purpose of this prompt is to instruct the operator what action to take to prepare the cable to be tested in its first configuration 5 56 Horizon Series Tester Programmer s Manual Advanced Programming 1 Enter First Prompt Line H OPEN EXIER HEI 4 So Bee Space Elear 5 Enter Next Prompt
155. be combined with other embedded components or used in conjunction with any other testing requirement such as HiPot testing or Kelvin testing Any product that consists of multiple states net lists that differ due to mechanical manipulation is suitable for a Switch Test J1 m J3 1 e 2e 3e 4 22 5 M 7 8e 9e 25 n As with resistors and capacitors switches are learned Neeson through the customized path From the Main Menu select Me Program Cable followed by your password then Learn Use Kelvin Probe New Cable Customized The Learn Settings menu Cancel s appears You may change the Conductor Max Res From Quick Scan to a specific resistance Horizon Series Tester Programmer s Manual 5 55 Advanced Programming a Component Settings Resistors Capacitors Diodes Switches Back Cancel Component Settings Permanent Switches Temporary twitches 1 Select Ok to go to the Component Settings screen Select Switches to indicate to the Horizon that your cable has an embedded switch es The Component Settings menu will open In the Component Setting screen you have two
156. ccordingly Some convention files are provided by CableTest however the user is responsible for creating conventions needed that are not present Horizon Series Tester Programmer s Manual 5 5 Advanced Programming E 3 Select Naming Rule 0 Pins Auto Wires Prompt te The user probes the conductors and is prompted to ales 1 2 S 9 29 2 2 uisa label for each wire 2818170100 Space Bar Elear The user probes the conductors they are numbered automatically based on the convention selected Probe flying lead 1 Press OK when done Prev Bone Next gt gt wires Frame The conductors are not labelled The user probes the Hee conductors specifying the gt 2 2 Rd e conductor label and the pin E v e 1 7 for each wire Space Bar Elear poker 31 Probe flying lead 1 f Press when done lt lt Prev Done Next gt gt 2 E JHE Ec e G1 G8 e ESI Gaeta pace Bar E122 eel Using the flying lead configuration Pins Aut
157. characters No two adapters within the library can have the same name The adapter s name is capitalized automatically SIGNATURE Optional Any adapter may have up to two ID components to be used for automatic detection Either one of the two ID components can be a Resistor a Capacitor or be unused None The signature line takes 4 parameters separated by commas the type of the first ID component the value of the first ID component the type of the second ID component and the value of the last ID component The ID component types are coded as follows 1 For resistor ID components 2 For capacitor ID components 3 For no ID components For most users that connect their product by means of custom made adapter cables as opposed to standard CableTest adapters it is impractical to assign ID components to their adapter cables since it would require that each adapter cable has ID components In such cases it is recommended that the 9 34 Horizon Series Tester Programmer s Manual Scripting Features adapter cables have no ID components both ID types are set to 3 and the ID values to 0 SIZE The adapter s size is coded as follows 1 For single size adapters up to 32 test points 2 For double size adapters up to 64 test points 4 For quadruple size adapters up to 128 test points 5 For huge size adapters up to 1024 test points For adapter cables that are connected to the system through
158. conventional Horizon adapters please devise the adapter cable s size in accordance with the conventional adapter s size i e if the conventional adapter was 180 1 the adapter cable s size would be double if the adapter was HSA 272 then the adapter cable s size would be quad CONNECTOR Required The name of the connector is optional An adapter can have more than one connector such cases the subsequent connectors are listed in sequence one after another Sys Pin The actual system pin on the Horizon Switching Cards Pin Name The pin designation as selected by user default numerical Pin Label An optional designation value for each pin has a higher priority than the Pin Name Sense Sense Test Point for Kelvin connections CTare Capacitance Tare Value LVRL Tare Low Voltage Resistance Low Test Point Tare Value LVRH Tare Low Voltage Resistance High Test Point Tare Value HCRL Tare High Current Resistance Low Test Point Tare Value HCRH Tare High Current Resistance High Test Point Tare Value The pin list is terminated either when another CONNECTOR keyword is encountered or when the file ends The last line in the adapter file must be a blank line terminate the last pin list line with a carriage return such as the end of file character doesn t follow immediately after the last connector pin name Example1 ADAPTER HA 116 Horizon Series Tester Programmer s Manual 9 35 Scripting Features
159. d_soak gt IPOT lt d_voltage gt LEAKAGE IR lt d_limit gt DWELL d dwell 50HZ 60 2 11 9 26 Horizon Series Tester Programmer s Manual Scripting Features In the example below the first net is labelled Ground and the second one Term Pwr Both nets consist of two test points Neither one of the nets has customized test parameters NET Ground NET Term Pwr Ble Ji VET 25 In the example below anonymous net containing 6 test points will be tested for continuity using the customized test parameters of min 0 0Q and 0 10 measured Kelvin The DC HiPot is disabled on this net NET 1 45 1 5 1 25 1 6 B3 J6 C3 7 26 3 8 B5 J5 C1 6 CONTINUITY 0 1 KELVIN DCHIPOT 0 NetList Special Type Shields A net that is functionally a shield within your product may not need the same stringent testing that other nets need A tag exists for these nets NET B1 J5 C1 6 SHIELD The Shield tag ties all nets designated shield together for both Isolation tests and Hipot tests The result is to prevent failures do to shield nets being shorted together and or exhibiting high leakage levels during a high voltage test NetList Advanced Option Embedded Switches A cable can be tested in a multi phase fashion This kind of testing i
160. dditional error screens are the same as for embedded resistors Horizon Series Tester Programmer s Manual 5 39 Advanced Programming The measured capacitance is too low est Program CAPACITOR 6775971985 99 42 31 too iow 355 5pF d Report Print The measured capacitance is too high rogram CAPACITOR 5 09 54 58 too hish mf of Repo 5 6 Diodes 5 6 1 Programming Diodes Auto learn The Horizon can be used to test products with the following types of embedded diodes generic signal rectifier Schottky Germanium LED s and resistor LED s The diodes are tested for both forward and reverse bias and the LED s may also be visually tested Diodes may be automatically learned by the Horizon or you can choose to program them manually It is highly recommended that you let the Horizon do the work unless you a large number of diodes or you are not satisfied with the results of the automatic learning process Ji gd J3 b Figure 5 4 PUT with embedded Diode 5 40 Horizon Series Tester Programmer s Manual Advanced Programming Twisted Free Ends Nets onlu Kelvin e Use Kelvin Probe Cancel As with r
161. de into smaller groups When the Product Under Test PUT is good i e passes IR and DWV tests and the current limit of the MPT s high voltage supply is not exceeded the iterations will be carried out as shown in Table 1 Table 1 Mass HiPot Routine Product Under Test is Good no faults exist Test Net Number The MPT will automatically divide the nets into smaller groups so that the current requirements are reduced when either of the following situations occurs a More current is required to charge the PUT than the source can deliver or b The leakage limit is exceeded due to the size of the group during IR tests These situations are illustrated in Scenarios 2 through 5 for good and bad PUT s Scenario 2 Good Product PUT s High Capacitance Overloads HV Source Overload of the high voltage HV source can be caused by high capacitance when the PUT s grouped nets are connected in parallel This scenario is most likely to occur in AC Mass HiPot testing when the AC drive current is too high for a large number of nets To avoid overloading the HV source during Mass HiPot testing group splitting will occur recursively until the combined capacitance of the nets connected to the high potential is small enough so that the system s overload condition is not triggered when high voltage is applied An overload condition will not result a FAIL condition unless it is caused by Horizon Series
162. e Horizon does not rely on the computer operating system for its directory naming conventions so you can create directory names that are meaningful to your operation Horizon Series Tester Programmer s Manual 2 7 Getting Started As before you can use any combination of up to 30 characters If you want to store your cable in a new directory select New Alt N you will be prompted to enter the new name Select Enter Enter J gt when through Then move the cursor until the directory in which you want to save the cable is highlighted and select Ok Enter gt The cable record is saved and you are returned to the Programming Cable menu Congratulations you have successfully learned your first cable Although you can continue the learning process and program as many cables as you like by simply repeating these steps it is strongly recommended that you complete this Getting Started Tutorial by testing the cable you have just learned Select Cancel Alt C or Esc and you will return to the Main Menu 2 3 Testing Your Cable Many types of operations can be performed with your new Horizon Analyzer including testing for shorts opens mis wiring and many other cable faults If any of these types of faults are detected the system will not only report their presence it will tell you exactly where they are For example Short between Net 11 and Net 22 at J1 Connector 1 pin 3 J2 Connector 1 Pi
163. e Horizon will only perform a HiPot test on complete Password Protected nets Discharge Delay 9 605 DC Hipot Settings Hipot Settings This is done for two reasons 1 To speed up the test since the system doesn t have to consider open nets or 2 to prevent the programmed high voltage from possibly being present at open leads It is important to remember that the Horizon can perform a HiPot test on flying leads in fact this is quite common in many applications testing isolation Just remember not to select this option unless it is needed Horizon Series Tester Programmer s Manual 4 37 Basic Programming and Testing Selecting Password Protected a check mark is shown means that an operator level password must be entered before high voltage testing can proceed Cancel returns to Set Test Parameters with no action taken while Ok implements the desired setup Discharge Delay affects both AC and DC HiPot testing Selecting this option allows the user to control the discharge of the PUT By default the Horizon discharges the PUT as fast as possible Programmable Discharge Delay values 1s to 1200s This option is only available after AC or DC HiPot has been programmed Selecting DC Hipot Settings brings up the DC HiPot Settings menu AC HiPot testing is discussed section 4 14 For safety reasons DC high voltage testing cannot even be setup until the HiPot butt
164. e a return to Test Configuration The Horizon will indicate when each batch is filled with good cables The user is prompted to acknowledge the completion of a batch The start of a new batch Batch Completion The Horizon automatically recognizes when a batch or set of batches has been Tested Bi to go Passed 50 Failed i Error Statist ics Diagnose Retest Cancel his is the last product of the last batch Press OK to acknowledge After you have successfully completed a batch or set of batches the screen looks like this just before you disconnect the final passed cable As soon as you disconnect the last successfully tested cable the Horizon prompts the user to acknowledge the last batch completed Select Ok to return to the Test Configuration menu Horizon Series Tester Programmer s Manual 7 11 Reports and Batches Test Configuration SSISGted CANIS From here you can set up another batch or set of batches File Name turn off batch mode and continue testing select another REST CABLE cable and continue testing or return to the Main Menu Select n Batches Cancel 7 12 Horizon Series Tester Programmer s Manual 8 BACKUPS AND RESTORES e CABLETEST Backups and Restores 8 2 Horizon Series Te
165. e cannot perform a 2 wire measurement 4 16 Programmable High Current Source Capabilities If you do not have this feature installed and are interested in it contact your local CableTest Representative 4 16 1 Overview of the Programmable High Current Source The standard Horizon system uses a fixed 5mA current source to perform the continuity tests However some applications require that the continuity test to be performed at a higher current The continuity test current can be programmed up to 1A and either the conductor s resistance or the voltage drop can be used as qualifying parameters 4 16 2 Using the Programmable High Current Source When a cable is learned the continuity test is set by default to Quick Scan However the user has the ability to change the type of continuity that will be performed at test time Horizon Series Tester Programmer s Manual 4 63 Basic Programming and Testing Set Test Parameters H Name Prompt Adapters Low Voltage Components High Voltage Net List More Options Print Test Now 1 OK After learning a cable and entering a name for that cable the Set Test Parameters menu is displayed Select the Low Voltage button to change the continuity type a Low Uoltage Settings IM The default Quick Scan is displayed To change the setting select Conductor Res Flex Dis
166. e continuity test where the geometry of the cable eliminates the chance of an intermittent short in order to speed up the test Such an example is given below where the isolation test is skipped during the flex test FLEX 10 ISOLATION Auto Insertion Threshold By default when the product to be tested is plugged in the test fixture adapter the test starts automatically The test is started upon one of the following conditions whichever occurs first 10096 of the product tests OK for continuity The Start Test button on the screen is selected Less than 10096 but more than the specified threshold of the product tests OK for continuity and a specified insertion delay lapses The third option allows for defective products to automatically start the test too The default value for the insertion threshold is 6196 Depending on the product to be tested other values may be specified The user is advised to experiment with various values if the default 61 doesn t satisfy their needs The syntax for this option is given in the example below When a 100 threshold is specified the test doesn t start automatically unless all connections test good THRESHOLD 100 9 1 4 2 High Voltage Testing Parameters The high voltage testing parameters are used during the high voltage tests and affect the DC and AC HiPot tests Some of the parameters can be set globally to affect all the nets within the cable or individually on a per net basi
167. e top The two to the right make up J2 and so forth Select ea cer ox Adapters that use a single set of connectors are referred to as Single Adapters that use all four connectors are referred to as a Double The combination of four connectors on the left make up J5 while those on the right make up J6 An Adapter that uses both sections is called a Quad all eight connectors together make up J7 The example shows two Single HA116 s mounted but yours may be different Note that a given adapter covers the J designator in each section Single and Double adapters may be used in any combination and in any location except that a Double cannot span across two sections Insert your adapters in the position s of choice and select Ok lt or Enter gt Horizon Series Tester Programmer s Manual 2 5 Getting Started You are prompted to connect your cable to the adapters Make sure the connections are secure and that the cable is hooked up properly The system is about to learn exactly what constitutes a good cable of this type and configuration Learn Cable Insert the sample product then press OK to continue V Any mistakes at this stage will be treated by the system as a good cable and may affect the accuracy of later testing If everything is correct select Ok lt or Enter gt to begin the learning process Some prog
168. each test point s results are displayed HCS Service Test Failed HCS Service Test Passed The option Config is reserved for CableTest service personnel Horizon Series Tester Programmer s Manual 3 19 System Setup 3 7 Outputs The Horizon has three contact closures that are tied to specific internal events and are made available at the port on the side As with the Inputs these are designed for use in setting up external indicators or for incorporating the Horizon into an automatic system The outputs are actuated by successive pushes of the MINE Output 1 Output 2 or Output 3 buttons and are mutually UE exclusive The related functions that cause the contact closure are Unused None of the outputs are active Pass The product passed all required tests Fail The product failed one or more required tests HV On The high voltage power supply is active Test Over The testing cycle is completed Select Ok to return to System Setup 3 8 Passwords All of the modules on the Main Menu that have a small key on the button password protected Three types of passwords are provided so that you can grant access privileges to people with different skill levels 3 8 1 Setting Up Passwords Password Settings P rassuora mm Select Passwords to display the Password Settings dialog 3333 ervice 1000 Operator Leetete
169. ecially useful if the file is to be printed later The PASS specifies that test results are to be logged for passed cables only The FAIL specifies that test results are to be logged for failed cables only The PASSFAIL specifies that detailed test results are to be logged for failed cables only The passed cables will only log a brief Pass message The ALL specifies that detailed test results are to be logged for both passed and failed cables If none of the PASS FAIL PASSFAIL and ALL options is listed then no test results would be logged 9 20 Horizon Series Tester Programmer s Manual Scripting Features The FILE and PRINTER keywords are mutually exclusive Either one can be used but not both in the same test program If both are missing then the report printing defaults to the printer Printing Test Results to a Printer To enable the report printing use the syntax described below REPORTS PRINTER FORMFEED LEFTMARGIN number of characters gt WIDTH number of characters gt PASS FAIL PASSFAIL ALL The optional specifies that the results are to be appended at the end of the existent log file if any If APPEND is missing or the log file doesn t exist then a new log file is generated The optional FORMFEED specifies that a form feed character is to be output to the file after each tested product The optional LEFTMARGI
170. ed all of its parameters are retained in file until deleted so this process needs to be performed only one time for any given cable For more information regarding test programs as ASCII files see Section 9 The following procedure assumes that you are using standard CableTest adapters If you are not then you must first program or learn the adapter using the procedures defined in section 6 Adapter characteristics are also stored in a simple ASCII file TO LEARN YOUR CABLE ee On the Main Menu select Program Cable lt Alt P gt Horizon will ask for a Password The factory installed Password is 1234 Type in the Password and select Enter Enter gt The Programming Cable dialog appears As soon as you feel comfortable with the operation of the Horizon and before you put it onto the production line you should change the Password to one of your choice using the procedure outlined in Section 3 This will prevent unauthorized personnel from altering setup information or the cable and adapter databases For the following exercise it is assumed that you are using a simple end to end cable with no embedded components and no free ends or flying leads The Horizon can easily handle complex cables and harnesses with any or all of these elements but it is strongly suggested that you start with a simpler type of cable until you feel comfortable with the system s standard mode of operatio
171. ed failure of the HiPot test In all of these cases if you have installed and programmed any type of palm switch protection it will also have to be activated as programmed before HiPot testing will start Horizon Series Tester Programmer s Manual 4 59 Basic Programming and Testing The display shows the progress of AC HiPot testing Performing Tests Stati Ew Should the product fail or if the Hipot was a linear scan select Diagnose on the Statistics window to view the Failed o diagnostics Error Statistics Diagnose Retest __ 1 ALL A linear HiPot was performed and passed The diagnostics reports the measurements made during the test AC Nets z 5B8G hm AC Net 189M Uhm Ce 9 1 4 14 6 Error Reporting In addition to the standard Error Reports additional ones are associated with AC HiPot testing Raported Results FAIL The sample Test Report indicates that during the AC HiPot anc Guerioad Netze __ test a fault occurred at nets 19 and 25 AC Overload is reported when an arc or excessive current leakage occurs during the charging cycle of the AC HiPot test The message is used to differentiate between arcs during the HiPot test duration and during the time the cable is being charged to the HiPot voltage level
172. ee Section 7 for details Specific Test Cycle Headers and Footers The header and footer when entered will be added to all tested product regardless of individual test programs loaded Test Report Settings Serial Number Options est ante Diagnose Header Footer Test Parameters Fi OK 1 Enter First Header Line COMPANY X MIE 2 7 ee 1 9 2 5 2 Ts ln e e Es eid sien e 0 9 Space Bar lear Enter Mext Header Line ORDER 1234567890 X 5 Co 2 ER ER 9 2 te HEE EI sje Eh 0 9 Space Bar Elear 4 2 8 4 5 6 7 8 9 9 HAHAHAHHA eie era cel Space Bar Elear Test Report Settings Serial Number Options fest ate Diagnose R11 Header Footer Test Parameters Fi OK 1 Enter First Footer Line j OUR COMPANY 2 2 ee 1 9 2 From the Test Report Settings menu select Header The number of lines for the Header is unlimited The width of each line is limited by the maximum character width of the she
173. elect Edit for the Edit Net s Settings menu Note that the display shows that this net is currently set to assume the default settings for both DC and AC HiPot tests In the example cable being used AC HiPot has been learned per the settings above but no DC HiPot testing has been defined Therefore if no changes were made this net would be subjected to a AC HiPot test but not to a DC HiPot test Select AC Hipot Settings to display Edit the Net s AC Hipot Settings If the net you are selecting is a Ground or Chassis point in your product you may designate it as a Shield by selecting Shield from the Edit Net s Settings menu This net will no longer be charged during the High Voltage test though it will still remain as a common point If from the Set Test Parameters you set up High Voltage settings with Scan set to MASS you will be prompted with this message Select Ok to acknowledge the conflict 4 56 Horizon Series Tester Programmer s Manual Basic Programming and Testing EM Edit Net s AC Hipot settings Hirot E U Hipot Uoltage 1506 p Leakage Limit 6 46 Hipot Duration DC Hirot Custom nc Default Fi BC Hirot Custom MH Default Conductor Res Default Default Default B Shield
174. elect The Select Part Number dialog appears The first step in the testing process is to insert the proper adapter s After the proper adapters are installed the system automatically sequences to Connect Product To Start Accept forces the Horizon to Connect Product To Start while Cancel returns to Test Configuration Insert your product in the appropriate connectors The Horizon will detect when the product is inserted and automatically start the test If your product passes the green Pass light will be lit and a positive tone will sound if it fails the red Fail light will be lit and a negative tone will sound If for some reason the test does not automatically start or you have disabled the automatic start feature selecting Start Test will force the test process to start The system performs the standard low voltage tests Continuity and Isolation then scans for the Resistors On the test is complete the display will change instructing you to disconnect the product Disconnecting the product updates the statistics database and automatically resets the system to test the next product Inserting the next cable starts the process again Horizon Series Tester Programmer s Manual 5 27 Advanced Programming Results While the screen still prompts the user to disconnect the product you may select Diagnose to view the results of the last test jars 6m0hm NettJ1 C1i 23 J3 C1 235 res 259
175. elect the Items to wish to backup by toggling the button to either A P or N ALL Partial N None In this example only partial cable files will be backed up and all of the other files will be backed up after the selection is done Select Ok to continue To select a test program to be backed up select the button to expand the directories to review saved test programs note you can collapse directories by selecting Using the arrow keys highlight the test program to be backed up and press Select A check mark will appear in the left hand column indicating that the test program is selected More than one test program can be selected for backup When you satisfied select Ok to continue If you are prompted with this screen ensure the diskette is properly inserted and it is not write protected If the diskette is not empty or the Horizon detects an older backup on the diskette the Backup Message screen appears Select Ok to continue 8 4 Horizon Series Tester Programmer s Manual Backups and Restores Erase fll Files on Target Disk DOE BO eg Backing up fidapters NADAP TERS HALOS ADP Target Disk Space Backup Progress Eject Disk and Label 976535516 1 Backup Report he backup has completed gt Press to continue File backed DA TAB ADAPTERS AMJE SP AGP File backed u
176. elvin fixture and 5 64 Horizon Series Tester Programmer s Manual Advanced Programming 2 Learning the cable s NetList This applies to the products that have embedded switches or that are to be tested in multiple steps Each different switch position or each different test step must learn both the Kelvin fixture and the cable s NetList Learn Settings H Twisted Nets Only Free Ends Kelvin Use Kelvin Probe Cancel OK a Component Settings Resistors Capacitors Diodes Switches Back Cancel Insert the Adapter s 116 JL 116 116 mir Select Cancel OK TE mJ Learning The Fixture For Kelvin Measurement lease insert the fixture without the sample and fixture unless you are prompted zo Learn Kelvin Fixture for Switches Set fixture for the ist pos then press OK to learn it Cancel to end learning Ok 1 From the Select Kelvin and then select Ok Select Switches and then select Ok Have the adapter s and the Kelvin test fixture connected to the system in their proper positions If standard Horizon adapters are used the system will auto detect them in most cases After the
177. en 2 4 High Current Source 4 63 Kelvin Measurement 5 52 EabelS e etta 2 7 Learning Your Product 2 4 4 3 Low Voltage Settings 4 15 Measured Scan 4 16 Naming Your Test Program 2 6 4 5 Nets Only eene oie 5 8 Quick Scan ned 4 16 R SiStO S ica deine eee 5 15 Saving Learned Product 2 7 4 5 Star Sean 4 18 Start att tenes 4 13 SWITCHES soi tied tente 5 55 Switches and Kelvin Measurement 5 64 Progress Bar edet 3 5 Q QUICK SCAN ese tent 4 16 R Relay 3 5 Reports oue oett 7 3 Operator 10 7 8 Printing Test Reports 7 4 Serial 5 7 5 Test 5 7 6 Test Results 7 6 Reset Fall o 3 5 Resistance 3 14 Resistors Autolearn 5 15 Edit Thresholds 5 18 FaultS vette 5 28 HC Load Components 5 25 High Current 5 24 Kelvin Measurement 5 24 5 18 Lamp 5 26 Manual Pr
178. enable them Selecting either Shut Down options places a check mark next to the item 8 6 Horizon Series Tester Programmer s Manual Backups and Restores you want te save Logs First If the Backup on Shut Down is enabled the operator is prompted at shutdown if they wish to perform a backup Select Yes or No to continue If the Save Logs on Shut Down is enabled the operator is prompted at shutdown if they wish to save log files prior to shutting down Select Yes or No to continue Horizon Series Tester Programmer s Manual 8 7 9 CREATING AND EDITING NETS FROM A TEXT EDITOR Advanced Horizon Scripting Features and Manual Test Program Writing CABLETEST Scripting Features 9 2 Horizon Series Tester Programmer s Manual Scripting Features 9 1 Horizon 1500 Test File Format 9 1 1 Introduction A Horizon test program is a Comma Delimited ASCII CDA file This makes it easy to generate test programs off line using a spreadsheet or a text editor Another advantage of using a text format is that plug in modules for popular desktop applications can be written to port legacy test programs into Horizon ones CableTest has successfully implemented such conversion plug ins for Microsoft Excel and Word Conversions from CAD programs are also possible This opens a new avenue for the Test by Design concept Starting with version 4 2 17 the
179. ented When AUTO is not specified the operator will have to enter the serial number for each product Header To insert a header into a test program use the following syntax HEADER s first header line s last header line gt keyword All text following the HEADER tag up to the next tag keyword will be printed as a header The option exists to have Header information added during the test cycle To prompt the user for Header information use the PROMPT tag following the header line that requires entry EXAMPLE HEADER CABLETEST SYSTEMS INC 400 ALDEN RD MARKHAM ON L3R 4 1 CUSTOMER PROMPT CONTRACT PO NO PROMPT PART NUMBER PROMPT Footer To insert a footer into a test program use the following syntax FOOTER s first footer line s last footer line gt lt keyword gt Horizon Series Tester Programmer s Manual 9 23 Scripting Features All text following the FOOTER tag up to the next tag lt keyword gt will be printed as a footer The option exists to have Footer information added during the test cycle To prompt the user for Footer information use the PROMPT tag following the footer line that requires entry EXAMPLE FOOTER Authorization Signature Stamp 9 1 7 Prompts In order to display instructions for the operator prior to starting the test on the product or prior to any of the switc
180. eption is a case in which the cable is removed before the e di eam Diagnostics button is selected In this case the Horizon aStharted te 1 24 J3 C1 245 at ON simply shows the cable as failed and does not retain i3shorted incite 38 at diagnostics Ob 0 gt H Use the down arrow button to see the remainder of the error message 4 10 4 Shorts and Opens with a Test Fixture If you are using a test fixture with your Horizon that is a fixture a particular distance from the adapter level of the Horizon then the cable length or 100 is will be measured from adapter to adapter unless you perform both a capacitive and resistive tare on the Horizon Series Tester Programmer s Manual 4 25 Basic Programming and Testing fixture see Section 6 3 for details If you do not wish to do this the length of cabling from the Horizon to the test fixture is part of the distance calculation Consider the following setup Test 25 wo Cables HORIZON 1500 am zx Test Cable 100 75 Figure 4 12 Example of a Test Fixture Setup The above setup demonstrates the notion of faulty end recognition when a test fixture is being used with the Horizon In the case above should a short occur on the test cable during a low voltage test then the short would be reported between 25 and 75 The front of the cable is located at 25
181. erent thresholds than listed above you must change the Low Voltage settings to the Measured method 4 9 2 Measured Scan Programming Cable H Modify Existing Cable Learn New Cable Default Learn New Cable Custom Advanced Netlist Editor At any point you wish to alter the parameters of a test you may do so by selecting Modify Existing Cable from the Programming Cable menu You can open this menu by selecting Program Cable from the Main Menu Highlight the directory containing the test program you wish to modify and select Ok Refresh Delete 1 Highlight the test program you wish to modify and select Ok Refresh Delete gt Back 1 OK a Set Test Parameters H gt From the Set Test Parameters menu select Low Voltage Mame Pronpt Adapters Low Voltage Components High Voltage Net List More Options Print Test Now Cancel The default settings of Quick Scan are displayed ted Star To select a measured value for the Isolation test select Conductor Res MET can ere Isolation Min Res Stimulus H oA Isolation Min Res Quick Scan More Options 4 16 Horizon Series Tester Programmer s Manual Basic Programming
182. es Connect probe to second position NE 1 26 1 3 NE Blg5rGLs8 124 SWITCH DCHIPOT 1000 DWELL 5 MASS IR 10e6 HIPOTNC PROMPT Disconnect probe from product Hipot Will be Performed OE c END 9 1 9 Components Programming Resistors The text file format for resistors is as follows RESISTOR lt s_netName_1 gt lt s_netLabel_1 gt lt s_pinAddress_1 gt lt s_pinLabel_1 gt lt s_pinAddress_2 gt lt s_pinLabel_2 gt VALUE lt minimum in ohms gt lt maximum in ohms Programming Resistors Kelvin The text file format for resistors wired in kelvin is as follows RESISTOR lt s_netName_1 gt lt s_netLabel_1 gt lt s_pinAddress_1 gt lt s_pinLabel_1 gt lt s_pinAddress_1 gt lt s_pinLabel_1 gt Horizon Series Tester Programmer s Manual 9 29 Scripting Features lt s_pinAddress_2 gt lt s_pinLabel_2 gt lt s_pinAddress_2 gt lt s_pinLabel_2 gt VALUE lt minimum in ohms gt lt maximum in ohms KELVIN Resistor address includes sense and source at each terminal Programming Resistors High Current Source The text file format for resistors measured using the High Current Source is as follows HC Resistance RESISTOR lt s_netName_1 gt lt s_netLabel_1 gt
183. es Hirot HC Source DC Hipot Cancel Using a voltmeter the potential across the jacks can be measured and compared to the applied voltage Once the voltmeter is across the jacks the internal resistance of the meter will be displayed as the Isolation R esistance You can also use this feature to measure known values of high resistance across the jacks to test how well the Horizon measures these values with the high voltage Press Ok to return to the Check calibration using external reference components menu Select DC Hipot to verify the DC hipot card in your machine should you have this feature installed Using a voltmeter measure the potential across the jacks to be compared to the applied voltage Once the voltmeter is across the jacks the internal resistance of the meter will be displayed as the Isolation R esistance You can also use this feature to measure known values of high resistance across the jacks to test how well the Horizon measures these values with the high voltage Example of using the high voltage to measure a resistor value The measured resistance of 4 964MQ was placed across the external jacks and the AC voltage was applied Select HC Source to verify the High Current Source of your Horizon 10 Horizon Series Tester Programmer s Manual Appendix D Calibration Verification
184. es have a failure the user will be prompted to try the same position again until the position passes or Cancel is selected Ignore Should a product with multiple states switches have a failure the failure will be logged and the user will be able to continue testing the product advancing to the next switch position Prompt During a test with multiple states switches a failure will cause the Horizon to prompt the user to select either Abort Retry or Ignore Ecl uw uum Horizon keeps track of each switch configuration 097507 1885 T4 S6 TTS separately osition Switch Position 2 End of Report 5 8 8 Error Reporting for Switches All common cable faults are reported in this mode as they are for general cable testing The switch mode differentiates by keeping track of each switch configuration separately Horizon Series Tester Programmer s Manual 5 69 Advanced Programming Test Report Results ALL est Program SWITCHES 6773071999 14 05 31 Switch Position E In this example the cable passed all tests in configuration 2 Ei but the net containing J1 C1 13 and J3 C1 13 was open in Bozition 26 7 configuration 1 5 70 Horizon Series Tester Programmer s Manual 6 ADAPTERS How to Define New Adapters and Add Them to the Library CABLETEST Adapters 6 2 Horizon Series Tester Programmer s Manual Adapters 6 1 Introduct
185. esistors and capacitors diodes are learned automatically through the customized path From the Main Menu select Program Cable followed by your password then select Learn New Cable Customized The Learn Settings menu appears You must change the Conductor Max Res from Quick Scan to a specific resistance The Quick Scan setting is intended for wire only cables 5Q is suggested the Horizon sets this value for you and works well in the vast majority of cases Failure to set Conductor Max Res to a specific value may cause the Horizon to wrongly detect the diode s as nets compromising the validity of the testing phase Select Conductor Max Res enter the desired value or accept the default 5Q select Enter and then push Ok to go to the Component Settings screen Component Settings H Resistors Capacitors Diodes Switches Back Cancel DK a Insert the Adapter s IM 116 Ja i HA 116 116 Select Cancel OK a Learn Cable Insert the aae product then press UK to continue Select Diodes to indicate to the Horizon that your cable has an embedded diode s A confirming check mark will be displayed Select Ok to continue the learning process Insert the appropriate adapters Select Ok to continue
186. esolution 10MO to 25MQ 15 10KQ Resolution 25MO to 50 30 10KQ Resolution 4 Wire Kelvin Measurement 10mQ to 4000 2 5 10mQ Resolution 4 Wire Kelvin HCS Resistance Measurement 1mQ to 4000 2 5 1mQ Resolution Capacitance 50pF to 10 0004 10 Resolution High Voltage AC 50 60Hz Optional Programmable 1mO or digits 3 digits 3 digits 3 digits 1mQ or 3 digits 1mQ or digits 3 digits Voltage 50 1000VAC 12 x1V Resolution 1V 50 1067VAC 12 1V Resolution 1V Current min 5mA typical 8mA max 10 Frequency 50Hz 60Hz 15 Measurement Leakage Current 5uA 5 mA 12 54 Resolution 14A 200MQ 12 Resolution 3 digits 1 Actual value may vary between different systems The low range 2 wire resistance measurement specifications rely on tared fixtures For resistances of more than 400Q these measurements default to 2 wires 1000VAC 4 Horizon Series Tester Programmer s Manual Appendix A Specifications Arc Detection Automatic HiPot Type Mass or Linear High Voltage DC Optional Programmable Voltage 50 1000VDC 4 0 1V Resolution 1V 50 1500VDC 4 0 1V Resolution 1V Current min 2mA typical 2 5mA max 5mA Measurement Leakage Current 5 mA 4 0 E uA Res 1pA digits IR 1 5GO 4 096 Resolution 3 digits Arc Detection Automatic HiPot Type Mass or Linear High Current Optional Pro
187. et Disk Space Restore Progress I Restore Report he restore has completed Press OK to continue File restored WCABLES MA INSBEU ILD ID CBL le restored CABLES MA IN5D IODE CEL le restored CABLES MA INSP 1 le restored CABLES MAINSTEST CBL been H 8 1 3 Auto Backups Select Restore to begin restoring backed up files from a floppy to the Horizon During restore the screen will display which directory and files are being restored The top progress bar display the available space in the diskette and the bottom progress bar display the percentage completed Once the restore is complete this screen will appear Remove the diskette from the floppy drive Once the diskette is removed the Restore Report screen will display all files restored Use the arrow keys to scroll through the list Select OK to return to the Backup Restore Shell screen Allows the user to perform a backup and or save log files each time the system is exited a Backup Restore Shell a Backup Options Backup on Shut Down Save Logs on Shut Down Backup Options Backup on Shut Doun Save Logs on Shut Down To setup the auto backup feature select More Options from the Backup Restore dialog Check either or both of the two options to
188. et to be printed on Enter the first line and select Enter to move to the next line Enter the next line and select Enter If all the lines are entered select ESC to exit Select Footer to enter Footer information Enter the first line of your footer and select Enter to continue Horizon Series Tester Programmer s Manual 7 7 Reports and Batches a Enter Next Footer Line 4 2 3 2 5 6 8 9 9 8 2 2 21 aognangEps A Z Space Bar grear General Report Settings H Print To Printer 5 Fi Com 7 1 5 Operator ID EN Report Settings General Test Reports Operator ID Reports p Dk Enter Operator s ID m Cr 1 099 2 E m o 2 aCe ROE S E1e2x Report Settings General Test Reports Reports 7 1 6 Enable Reports Report Settings General Test Reports When all lines are enter select ESC to exit For Headers and Footers to operate correctly you MUST set the reports to have a form feed after each tested product Select Operator
189. etlist Editor 2 2 Refresh elit 1 OK Refresh Delete AIP D 7 gt Back a Set Test Parameters fancel OK Pronpt Adapters Low Voltage High Voltage Components Net List More Options Print Test Now Cancel EN TEST CABLE 57 H Tested Passed Failed Error Statistics Diagnose Start Test Cancel a Set Test Parameters IM Name Prompt Adapters Low Voltage Components High Voltage More options Net List Print Test Now 1 At any point you wish to alter the parameters of a test you may do so by selecting Modify Existing Cable from the Programming Cable menu You can open this menu by selecting Program Cable from the Main Menu Highlight the directory containing the test program you wish to modify and select Ok To utilize the optional Advanced Netlist Editor refer to Section 4 8 Highlight the test program you wish to modify and select Ok The Set Test Parameters menu appears You can modify all the parameters of the test program from this menu Select Test Now to test any changes you make to the test program If the product does not automatically test
190. ew adapter Make sure you store the backup diskette in a safe place Another good use of the backup restore function is to transfer test programs or adapter library files between systems When multiple systems are used to test the same product you can learn the product on one system then use the diskette to transfer the test program to other systems Select Backup to begin Horizon Series Tester Programmer s Manual 8 3 Backups and Restores CPlartial CN Jone Cable Files Adapter Files Convention Fi les A A E mou A zzzz Pictures Files Cancel OK DEPT zi P TFE CPlartial Cable Files A Adapter Files Convention Files AIP Pictures Files A P Ei aper end Open Directory TEST E Select Nau e AID Rew 1 TEST 32 COAX CABLES Reu 2 2 1 kerren seret E erformed elonging 1 Replace target disk then ress UK to Bontinue ress the button he system erase all Message he target disk is not empty After Pressing the OK button ou can choose whether to let he erase all files Erom thi target disk or continue the backup toons files in pla continue S
191. fail 4 10 Common Cable Faults amp Faulty End Recognition FER 4 10 1 Opens Common errors or faults reported by the Horizon for a cable during a low voltage test are opens shorts and miswiring faults Should the low voltage test fail before removing the product from the adapters selecting Diagnose will report the cause of the cable failing Ziel 1 2 e a f 222 E 2 Figure 4 2 PUT with Open J3 C1 6 4 20 Horizon Series Tester Programmer s Manual Basic Programming and Testing Ezrzuricd Fail The first example is an open connection The cable is ram TEST CABLE 57 eG S open reported to fail Diagnose is selected and the screen to the Cl 6 from J3 Cl 6 OF Report m left is displayed The Horizon reports that the cause of the fail condition is an open connection and it is located at pin 6 ofthe first connector on the adapter mounted in the J3 position Note the fault is at the adapter level J3 Reported Results Fail Reversing the cable with the open connection and re testing WS oren it reveals the Horizons ability to locate the position of the Of Report Tee open net Note the same fault now appears at J1 instead of J3 Lx Ji gal J3
192. for the entire duration of the dwell cycle the test passes Otherwise it fails with a DC Leakage error Use this dwell option when the product exhibits a weak soaking characteristic or no soaking at all Bypass When using the Bypass dwell cycle the programmed leakage current or IR is measured at the end of the cycle The safety feature is bypassed This type of dwell is useful when the product exhibits a soaking characteristic The leakage current must drop below the limit by the end of the dwell cycle in order for the test to pass Use this dwell option when the product exhibits a moderate soaking characteristic and you don t want to extend the HiPot duration past the programmed value Horizon Series Tester Programmer s Manual 4 47 Basic Programming and Testing Adaptive When the Adaptive dwell cycle is enabled the programmed leakage current or IR is monitored As soon as it decreases below the limit or the IR increases over the limit the test is passed If the leakage current stays above the limit or the IR stays below the limit for the whole duration of the dwell cycle the test fails Use this dwell option when the product exhibits a moderate to high soaking characteristic and the shortest possible HiPot duration is desired This type of dwell may actually speed up the HiPot test in some cases since the test immediately terminates when the produc
193. g a MASS HiPot test 4 46 Horizon Series Tester Programmer s Manual Basic Programming and Testing Test Report SDC ape mags hipot Arc locations can only be reported during a MASS HiPot if the fault is reoccurring If the arc occurs only once the system will report it but will not give a location If you run a LINEAR HiPot the location will always be identified In this example the arc occurred during a LINEAR HiPot ALE E test DC Nets 9 31G0hm DC Net 33 6GUhm EB BE cla All failures are identified with an asterisk Print OK 4 13 7 Setting Various DC Hipot Cycle Times The Horizon has the capabilities of setting the DC HiPot dwell cycle types Access the DC Hipot Settings menu as described above Selecting the Dwell button cycles through the various dwell options as follows gt During the Regular dwell cycle the programmed leakage Hirot m peer mema current or IR is measured and as soon as it exceeds the Hipot Uoltage u ee umm limit the dwell is terminated immediately This is intended as a safety feature In the unlikely situation where an operator touches a live wire and the arc detecting circuit is not tripped the software that monitors leakage current shuts down the output voltage If the leakage current is smaller than the limit or the IR higher than the limit
194. ge to display the Low Voltage Settings menu Select Flex to toggle between the three settings Dis Disabled Perm Permanent Flex the cable until you select Ok from the touch screen A fixed time out value 1 99 9 seconds Flex the cable for the programmed duration Select Ok and you will be returned to Set Test Parameters Select Ok again and you will go through the Save Cable Record dialog Horizon Series Tester Programmer s Manual 4 27 Basic Programming and Testing Test Program as CBL File datab cables main flextest cbl For greater detail see section 9 CABLE FLEX TEST 1 NET QUICKCONTINUITY J1 C1 12 QUICKISOLATION 23261212 FLEX 10 NET STAR J1 C1 13 THRESHOLD 61 3 ADAPTER 116 NET POSITION J1 116 J3 C1 14 POSITION J3 NET NET TCL IS 2120420 J3 61 2157 NET NET J1 C1 16 Jiz6132 4 J3 C1 16 Jd3 Gl 2 NET NET 71201 3 36 177 NET NET J1 C1 18 J3 C1 18 NET NET 21 1 19 Sps J3 1 19 33901 NET NET 01 220 57 gl Cl 6 J3 1 207 J3ovClT 6 NET NET TL 261 215 Thy 932012792 NET NET py 93 61 22 NET NET 212019232 71 019 23 NET NET J1 C1 24 dica 05 J35
195. good idea to print the setup for future reference Cap Tare Update Config Isolation LU Tests HU Tests Touchscreen OK This feature tares out the capacitance of the Installed switching modules on the Horizon Should cards be changed or expansion boxes added this service must be implemented Horizon Series Tester Programmer s Manual 3 13 System Setup 1 Perform a Capacitive Tare of the System Select Ok to perform the Tare Remove all adapters from system and press to perform tare DK Cancel Make certain no Horizon adapters or interface materials are connected to the system Touch Screen Enables the user to test each of the possible touch screen positions to make sure they are working correctly Select Keys to activate this function Touch each of the displayed positions in turn As you touch it its tone will change and it will black out If you have bad position or if you wait more than 30 seconds between button pushes an error message will be displayed After a few seconds you will automatically be returned to System Setup Res Tare This feature tares out the resistance of the installed switching modules on the Horizon Should cards be changed or expansion boxes added this service must be implemented mum z xc Ok to perform the tare
196. grammable Current 1mA to 500mA 2 5 1 Resolution 1mA 1mA to 1A 2 5 1 Resolution 1mA Voltage 1 to 28VDC 2 5 01 Resolution 0 1V Measurement Voltage OV 2 5V 2 5 2mV Res 1mV 3 digits 2 5V 28V 2 5 25mV_ Res 10mV digits Current 1 2 5 1 Res 0 5mA 3 digits 0 1mA to 1A 2 5 xbmA Res 2 5mA or 3 digits Kelvin Resistance 1mQ to 4000 2 5 1mO Res 1mQO or 3 digits MilliVolt Drop 1mV 3V 5 0 1mV_ Res 1mV 3 digits 5 1500VDC From High Current Source The Horizon cannot measure external stimuli Horizon Series Tester Programmer s Manual 5 Appendix A Specifications 6 Horizon Series Tester Programmer s Manual Appendix B Troubleshooting Your Horizon CABLETEST Appendix B Troubleshooting 2 Horizon Series Tester Programmer s Manual Appendix B Troubleshooting Problem Possible Cause Possible Solution High Voltage or Noted module not detected Replace unit High Current during initialization module error during start up Adapters aren t auto detected Capacitance Signature Adapter Switch Card Failure MSR Card Failure Perform System Capacitance Tare Replace Switch Cards Replace MSR Card System Will not Boot Up BIOS settings incorrect Interface Card Not Seated Properly General Hard Drive Failure Perform HDD Auto detect Re seat Interface Card Replace Hard Drive LCD
197. h tests use one of the prompt features Horizon supports prompts on the fly defined inline in the test program prompt files and graphical bitmaps Prompts On the Fly To insert a prompt on the fly use following syntax PROMPT s first prompt line s last prompt line lt keyword gt The first line that contains a keyword starts with a character will end the prompt sequence The text enclosed between the PROMPT line and the next keyword will be displayed on the screen prior to the test In the example below the bolded text represents the prompt that will be displayed on the screen PROMPT Use following hook up cables AKS 104 0005 AKJ 100 0021 AKH 101 0001 CONTINUITY 0 1 Prompts Using Text Prompt Files Sometimes it may be desirable that multiple test programs share the same prompts To use text defined in a prompt file use the following syntax 9 24 Horizon Series Tester Programmer s Manual Scripting Features PROMPTFILE lt s_file name gt When the field s ile name contains just the name of the file without the path then the file is searched in the DATAB PROMPTS directory When the complete file path is given then the file is searched on that path The example below searches the file on an absolute path PROMPTFILE c v4 0 datab cables main prmpt1l txt The text contained in PRMPT1 TXT is loaded and displayed on the screen Using Graphical Bitmap Prompts Horizo
198. he Edit Component List dialog appears From this menu you can verify edit and label all of the re a components that have just been learned Capacitors Diodes 1 Select Resistors to begin this process Black Boxes Twisted Pairs In the example shown the Horizon has learned one resistor R1 If more resistors are learned highlight the one of interest Delete m 4 ie Edit Label vei Select Edit to show more details and bring up the Edit Hesistor menu Horizon Series Tester Programmer s Manual 5 17 Advanced Programming Terminal 2 1 min Bi J1 C1 7 1 64 More Options Label ox Change Tare Value Change Thresholds Si futodetect Thresholds Cancel e Edit Resistor Besser i cn 2 palue 3 382 min zest 1 5Hi More Options Label 1 11 1 1 1 11 1 7 1 5 max RESISTORL is 2 2 2 TET 212 2 9 00050 CL CIE Space Bar EN Select Resistor THERES IETOR aOR 1 gt 2 1 Labe
199. he product can be repaired to pass or the system will loop infinitely on a failed test Sometimes prompting the operator to choose whether to retry the test would be a better option See below the PROMPT option ONFAIL RETRY In the example below the system will continue testing with the next switching position in case the current position has failed This allows for a complete diagnostic of a defective product ONFAIL IGNORE In the example below the system will prompt the operator to choose whether to abort a failed test ignore it go to the next test or retry it ONFAIL PROMPT 9 1 8 Netlist Most test programs must contain the NetList section The NetList describes the tested product s connectivity Each net consists of a list of at least one test point and may have a name and a label Each net may also have customized test parameters Even though the customized test parameters include DC and AC HiPot ones the type of HiPot scan mass or linear cannot be specified at the net level NET lt s_netName_1 gt lt s_netLabel_1 gt lt s_pinAddress_1 gt lt s_pinLabel_1 gt lt s_pinAddress_2 gt lt s_pinLabel_2 gt lt s_pinAddress_n gt lt s_pinLabel_n gt CONTINUITY d min d max KELVIN HCRES HCDROP lt d_stimulus gt HIPOT d voltage LEAKAGE IR d limit D H ELL d dwell REGULAR BYPASS ADAPTIVE SOAK lt
200. her you wish to perform a linear or mass high voltage test See Appendix C for more details regarding Mass HiPot You are prompted whether you wish to perform the HiPot prior to High Voltage being applied to the switching If the test fails contact the Horizon Technical Support To run a service test on the programmable and or fixed High Current sources select HC HiPot Test 3 18 Horizon Series Tester Programmer s Manual System Setup TE insert the MUX Test lease Cardis First Last Relays n HC Test Resistors Fixed HCS esting MUXRLY tH 49 test poin Ris 9 117 Ohm Kelvin MUX test failed Ihe last error message 15 1 9 108 Ohm too low 4W test point 49 Kelvin MUX test passedt ance The High Current Source test cannot be performed without special test adapter Contact your sales representative for more details Insert the special test adapter and select OK First Last Relays Resistors Test This feature allows the user to select the first switchcard and the last switchcard to be tested When enabled the relays on_ the switchcards will be tested When enabled the resistors on the switchcards will be tested for the correct resistance value Start test During the test
201. hich is described below or in some cases where something else other than a cable is tested i e printed circuit board loaded with active components and the final goal is achieved by running other tests The example below specifies that the continuity test is not to be performed CONTINUITY Continuity Scan Method Horizon describes the nets by means of a test point list pin list or node list Most common nets have just two test points each the continuity test being performed on the conductor that connects the two points With nets having more than two pins in their pin list there would be more than one conductor to be checked In such cases Horizon can perform the test in two different ways Star and Chain Let s assume that we have a net with three nodes called A B and C Horizon can check the continuity among the three points in the Star mode by verifying from A to B and then from A to C or it can check the continuity in Chain mode by verifying from A to B and then from B to C To set the system for Star continuity specify the keyword STAR as in the example below STAR To set the system for Chain continuity specify the keyword CHAIN as in the example below CHAIN Isolation Test Parameters The isolation test can be performed by Quick Scan or by resistance measurement using the built in isolation test algorithm When the optional embedded TCL interpreter package is installed an isolation test procedure can be defined
202. indicate that this net is using Custom settings to define its HiPot test parameters Select Ok to go back to the Edit Net menu Cancel returns with the previous parameters intact You may wish to use the Label function to document the changes you have made to this net Repeat these steps as necessary to modify the required nets When you have finished select Ok to return to Set Test Parameters As before select Ok from this menu to save your cable record Horizon Series Tester Programmer s Manual 4 43 Basic Programming and Testing Test Program as CBL File datab cables main testca 2 cbl For greater detail see section 9 CABLE TEST CABLE 5 3 NET 3 LA QUICKCONTINUITY QUICKISOLATION J3 1 1155 STAR NET THRESHOLD 61 161 212 DCHIPOT 572 23 61 12 LEAKAGE 0 0001 NET DWELL 0 1 REGULAR J3s OT 213 5 LINEAR NET ADAPTER HA 116 Ji Clay POSITION J1 J3 CT 14 5 ADAPTER HA 116 NET POSITION J3 5155 NET J3 C1 15 DCHIPOT 0 NET 21 1 1 21 1 16 23 C1 1 J3 C1 16 NET NET 43612 NET NET Ji Cl 18 J3 C1 18 NET NET J1 1 4 J1 C1 19 73 01 75 NET NET DCHIPOT 0 JTcG12205 J1 C1 5 J3 C1 20 J3 C1 5 NET NET J1 C1 6 E o J3 Cl 6 NET NET J1 C1 22 215010072 035
203. ing the Programmable High 4 63 5 Advanced PROGRAMMING AND TESTING 5 1 5 1 nivei ER 5 2 Free Ends or Flying Leads 5 2 1 Programming a Free Ends 5 4 5 2 2 Testing A Cable With Free 5 10 5 3 Programming and Testing Twisted 5 11 5 3 1 Automatically Learning Twisted 5 11 5 3 2 Testing a Cable with Twisted 5 15 iv Horizon Series Tester Programmer s Manual Table of Contents 5 4 n 5 15 5 4 1 Programming Resistors autolearn sese 5 15 54 2 Programming Resistors Manual esee 5 21 5 4 3 Programming Resistors Advanced erersesrseee 5 23 5 4 3 1 Programming Resistors Advanced Options Kelvin 5 24 5 4 3 2 Programming Resistors Advanced Options High Current Source 5 24 5 4 3 3 Programming Resistors Advanced Options Testing Lamps 5 25 5 4 4 Testing A Cable With Resistors seen 5 27 54 5 Testing Cable with Resistors 5 28 54 6 Error Reporting for Resistors sssssssssseeeeeeeeenenenn 5 28 55
204. ion Horizon Series Tester Programmer s Manual 1 5 Introduction 1 6 Horizon Series Tester Programmer s Manual 2 GETTING STARTED How to create and test your first product CABLETEST Getting Started 2 2 Horizon Series Tester Programmer s Manual Getting Started 2 1 Overview Welcome to the Getting Started guide for the Horizon Series Testers The Horizon can be used right out of the box so as soon as you have unpacked it you can begin creating test programs No system setup is required to begin testing basic product If you wish to explore the System Setup options at this time please see Section 3 Install the Horizon as per instructions detailed in the Horizon Operator s Manual 2 1 1 Turning on the System Turn on your Horizon by toggling the power switch located on the rear panel The system will perform a complete self test and then display the Main Menu If at the end of the sequence the Main Menu is not displayed or if you see any error messages contact CableTest or an Authorized Representative immediately 2 1 2 Screen Navigation You may navigate the Menus of the Horizon LV and HV testers by selecting options on the touch screen or by using an installed keyboard to select the underlined characters using the Alt key Horizon Lite H1500 LV2 users must use an installed keyboard and can navigate using the Alt key and the underlined characters Example For select lt Alt T gt
205. ion This section is an in depth discussion of the process of Learning an adapter or fixture and adding it to the Horizon s internal database This process only needs to be done one time for a given adapter or adapter type unless that adapter is physically modified or its specifications are changed For example if an adapter for a DB25 connector with an ungrounded shield is learned then that adapter is used to the point that it must be discarded and replaced with an identical adapter the new one does not have to be relearned If however you decide to ground the shield this would represent a new adapter specification and it would have to be relearned If you purchased any of the more than 300 adapters that are in the CableTest catalogue or price list they are already part of the library and do not have to be relearned unless you are using them as part of a fixture of your own design Why should I learn a fixture Fixtures are mechanical platforms that are normally separated from the top of the Horizon and are connected to the Horizon by some sort of interface cable They are usually designed to accommodate a number of connectors or connector types and to optimize the production flow of a given shop It is beyond the scope of this manual to engage a detailed discussion of fixtures If you would like to build one and are unsure about how to proceed contact your authorized CableTest Representative for more details As part of
206. ion of Terminal 1 The first terminal is displayed Repeat the above operation for Terminal 2 With the terminals properly identified you now need to program the value of the component If your product is attached with the proper resistance in place select Test to view the measured value The Horizon engages the measurement circuitry to display the value of resistance between the selected terminals Select Value to set the tolerance 5 22 Horizon Series Tester Programmer s Manual Advanced Programming L_Chanse Thresholds Terminal 1 Ja3 Cl 1 Terminal 2 lt Value 1 3382 min 1 6 max Test OK 1 51Mn More Options Label a Edit Resistor Terminal 1 JS3 Cl 1 Terminal z J3 C1 7 1 63 max 1 min Test DE 1 518 More Options Label a Edit Resistor RESISTOR Kelvin Visual Three value options are available Autodetect Thresholds Automatically selects 10 the average value measured by the Horizon Change Thresholds Allows the user to manually set the thresholds for the component Change Tare Value This allows the user to add a resistor tare value This may be useful in scenarios that include test fixtures
207. irections A special labeling format is available for the Bl coloured LED Select Label to continue lt forward gt lt reverse gt In the example the product has been labeled GREEN RED When the user is prompted to visually confirm the component functions the appropriate label will be displayed 5 6 5 Testing Cables with Diodes The testing procedure for a product with embedded components is the same as testing any other cable or harness For details consult Section 4 a Peiete Back Cancel OK 1 Test Configuration Currently Selected Cable File datab scab les MAINSCABLEUIT CE Part Number CABLE WITH DIODE Rev 1 Tools Reports Select Cancel Test Batches Tested Passed o Failed Error Statistics Diagnose Start Test Cancel Select the proper cable and push Test Now You will be instructed to insert the proper adapters then to insert the cable to be tested Inserting the cable will automatically start the test Select Test Now to begin testing the displayed part Insert the product to begin the test After the net list is verified for continuity and isolation the system scans for the diodes 5 50 Horizon Series Tester Programmer s Manual Advanced Programming Tested i
208. is disabling the HiPot test on that net by setting the HiPot voltage to 0 When the HiPot is to be run in the linear mode any HiPot parameter except for the HiPot type can be modified for any net The leakage can be measured either as a current an insulation resistance or ignored altogether The DCHIPOT line must appear the first All other lines can appear in any order afterwards DCHIPOT d voltage LEAKAGE IR d limit DWELL d dwell REGULAR BYPASS ADAPTIVE SOAK d soak MASS LINEAR In the example below a 1000V dc HiPot will be performed using a 0 2s dwell time and the mass algorithm The leakage current won t be measured only the arcs will be monitored DCHIPOT 1000 DWELL 2 Horizon Series Tester Programmer s Manual 9 15 Scripting Features MASS In the example below a 500V dc HiPot will be performed The dwell time is 1s the insulation resistance IR threshold is set to 100MQ and the linear algorithm is used The IR is measured using the regular mode DCHIPOT 500 IR 100e6 DWELL 1 REGULAR LINEAR In the example below a 500V dc HiPot will be performed The dwell time is 1s the leakage current threshold is set to 100 and the linear algorithm is used The leakage current is measured using a soak time of up to 5s DCHIPOT 500 LEAKAGE 100e 6 WELL 1 OAK 5 INEAR
209. is specified then they are described in sequence The sequence of the listed adapters has no rules CABLE AWP 1001GT 1 AATEST POSITION J5 ADAPTER HA 116 POSITION J3 There is one more thing worth mentioning in this section By default the connectors on an adapter are named C1 through where 15 the number of connectors per adapter i e an adapter with 3 connector would have them named C1 C2 and C3 by default Although this annotation is straightforward and intuitive sometimes users want to use other names for the connectors More often than not this comes as a consequence of the fact that pre existent test fixtures are already labeled For such cases the Horizon lets the user create labels for the adapters connectors This allows for more meaningful net list annotation The user can choose to label the connectors when a new adapter is defined However it is sometimes wiser to attach the label to the connector within the test program as opposed to the adapter file The latter case is covered here Let s assume that in the test program listed above the adapter has two connectors that the user wants to label P and K The new test program looks like the one following The CONNECTOR keyword followed by the connector number and the connector label has an impact on the way the net list is generated The bolded areas show where the changes occurred Besides creating user meaningful point n
210. is that you may have a single ended cable Another is that you may have disabled the automatic start feature In these cases selecting Start Test will force the test process to start See Section 4 6 for automated start test details If you are getting inconsistent or unexpected results especially on cables that are hard to insert you can program a delay before the start of test in the system setup menu see Section 3 5 eee 6 At the completion of the test the display will change ETT instructing you to disconnect the product The act of xp E disconnecting the product updates the statistics database Error Statistiss Biaswese automatically re arms the system to test the next Retest Cancel product If you have set up reports to be printed they will be sent to the printer depending on the conditions set Inserting the next cable starts the process again Selecting Retest without removing the cable will retest the same cable This is useful in the event that a reported fault is obvious and can be easily repaired or if you are unsure of the results and want to try again 4 8 Horizon Series Tester Programmer s Manual Basic Programming and Testing icd Results If you have specified a specific conductor resistance for the Program IERI HSA continuity test i e it is not set on Quick Scan then you can
211. istor is positioned between nets each of which contain two test points Highlight the first net the component is connected to Select Open to continue When the component was defined one of the test points associated with the net was selected in this example J3 C1 1 The alternate test point must be selected for the sense test point J1 C1 1 Highlight the test point and select Ok The More Options menu contains the first sense point Repeat the above steps for the second sense point Once complete select Ok to return to the Edit Resistor dialog measurements are only viable resistances less than 4000 Programming Resistors Advanced Options High Current Source Horizons equipped with the optional High Current Source can Increase the measurement stimulus for their component by selecting MODE from the More Options dialog 5 24 Horizon Series Tester Programmer s Manual Advanced Programming The measurement modes are displayed Auto Resistance Resistance Moltage Drop HC Load Current Fixed HC vort Fixed HC Res Auto Resistance Utilizes the default Horizon source 5mA HC Resistance Voltage Drop HC Load Current Fixed HC Volt Fixed HC Res Allows the user to program a stimulus up to the limit of their programmable source e g 1A The measurement will be expressed in ohms Allows the user to program a stimulus up to the limi
212. it Component List Resistors Keus Capacitors Biodes Black Boxes Twisted Pairs Add gt gai Delete OK Label Select Key Delete gt zai Label 3 Edit Terminal 1 Terminal 2 lt 2 m Oft m in Test More Options Label From the Set Test Parameters menu select Components and the Edit Component List dialog appears Select Keys The Select Key dialog box is empty if no keys were detected during the learn process or if you did not select the Switches option within a custom learn Select Add to manually enter this component Add as many keys as you have in your product Adding resistors increments existing resistors by 1 Each new resistor will be R1 and the current R1 becomes R2 the current R2 becomes R3 etc Highlight the first and select Edit The Edit Key dialog opens with no information present Select Terminal 1 to assign it the proper net 5 62 Horizon Series Tester Programmer s Manual Advanced Programming 1 Net and Pick Terminal Cancel Twisted Pick Terminal H 21 ee aaa 2 Termi
213. izon a log is taken of the date and type of verification Internal or External To view calibration history Select SYSTEM SETUP from the Calibration Menu Select CALIBRATION HISTORY from the Calibration System Setup menu 12 Horizon Series Tester Programmer s Manual Appendix Calibration Verification Could ee Before calibration verification is done for the first time on his eate Misters file f you re the Horizon the message to the left will be reported Calibration history logs the date and type Internal or pe eae External of calibration verification done on your system The following is an example of the printed report CHOICE OF HEADER Company name Cabletest Systems Inc Operator ID Jonathan Dorfman Date Fri Oct 03 1997 01 29pm CALIBRATION AND VERIFICATION REPORT Calibration Box SN 123456 78 Horizon 1500 123456 22 Reference components PREDEFINED VALUES Measuring Internal Resistors Calibration card on position 1 R Nom Min Max Meas Ok 1 008 0 982 1 033 1 029 Ohm OK 10 01 9 84 10 18 10 02 Ohm OK 0 998 0 983 1 012 1 001KOhm OK 948 104 8 100 0Kohm 998 948 1048 997 KOHM OK 10 00 9 00 11 00 9 96 MOhm OK Measuring Internal Capacitors Calibration card on position 1 Nom Min Max Meas Ok 1 103 98 107 101pF OK Horizon Series Tester Programmer s Manual 13 Appendix Calibration Verification 2 1 001 0 978 1 023
214. izon correctly reports the absence of a diode 8 Horizon Series Tester Programmer s Manual Appendix Calibration Verification Connect the diode to the Jacks Diode UF Short Connect the diode to the jacks Diode Uf 63 mU Resistors Capacitors Diodes HC Source AC Hipot DC Hipot ii Cancel Checking the current gt miliampmeter at Jacks check the nd press OK when you are done Checking the current Connect a miliampmeter_ at he Jacks check the 50uA current press OK when you are done Check calibration using external reference components Resistors SmA DC Capacitors Diodes AC Hipot HC Source DC Hipot The Horizon correctly reports a short between the diode terminals The Horizon correctly reports the polarity and the forward voltage of the diode Press Ok to return to the Check calibration using external reference components menu The Horizon uses two fixed currents to perform it measurements Select DC to verify the value and 50 DC to verify the value Use an ammeter to measure the current through the two jacks An example measurement from a Horizon was 4 946mA Press Ok to return to the Check calibration using external reference component
215. l A 4I In the example shown Terminal 1 of the first resistor R1 is connected to pin 1 of the first connector on the adapter located at J1 Terminal 2 is connected to pin 7 of the same connector Select Terminal 1 or Terminal 2 change the location of these terminals The default tolerance for the component is set to 10 Select Value to alter the tolerance of the measured component Select Change Thresholds to set and alternate tolerance Enter the minimum and maximum threshold You can adjust the tolerance of your component based on the combined tolerance of the component and the Horizon Select Test to constantly scan the component The dynamic measured value of the component will be displayed next to Test Select Label to label the resistor Enter the label and select Enter to accept it All of the needed changes have been entered so select Ok to return to Set Test Parameters Add is used to add resistors to a cable without learning them and to take care of certain special cases 5 18 Horizon Series Tester Programmer s Manual Advanced Programming a Set Test Parameters H Name Prompt Adapters Low Voltage Components High Uoltage More options Net List Print Test Now 1 Refresh Cancel If you are through specifying the test fo
216. l go into power save mode with the touch screen turned off and the front panel lights flashing Simply touching the screen reactivates the system The up arrow increments the timer in one minute intervals while the down arrow decrements it The progress bar of the test will be displayed on the screen A check mark means that the feature is activated Toggles between four options Abort Should a product with multiple states switches have a failure the test will abort and the product will fail Retry Should a product with multiple states switches have a failure the user will be prompted to try the same position again until the position passes or Cancel is selected Horizon Series Tester Programmer s Manual 3 5 System Setup Ignore Should a product with multiple states switches have a failure the failure will be logged and the user will be able to continue testing the product Prompt During a test with multiple states switches a failure will cause the Horizon to prompt the user to select either Abort Retry or Ignore Opt Package Setup option for additional packages and language control Smart Probe Setup options for the Digital Hand Held Probe Remote Opt Setup options for Horizon Control using RS232 Select Ok to return to System Setup 3 4 1 Installing software Options Opt Package Installation of optional software packages verme rr TCL Advanced Editor or changing
217. les Summary If an error condition occurs during one of the mass high voltage test phases where multiple nets are at high potential the mass algorithm will use a recursive fault detection routine The binary mode uses a divide and strategy The group of nets connected to the high potential is divided in two new groups and testing is repeated If the new subgroups experience a new FAIL condition that requires splitting again the subgroups will be split recursively in a similar fashion until the fault is found or the FAIL condition is eliminated In this example the PUT has 16 nets and the smallest sub group that will be tested with the divide and re test strategy has 5 nets For groups of 4 nets or less linear sequential or single phase testing will be performed until all faults are found 8 Horizon Series Tester Programmer s Manual APPENDIX D CALIBRATION VERIFICATION m s CABLETEST Appendix Calibration Verification Introduction An option available to Horizon customers is a system calibration verification tool The tool is an adapter card with accompanying software The verification tool is designed to check the measurement parameters of the Horizon 1500 CableTest Systems takes great care to ensure their customers that their system conforms to the technical specifications laid out by our engineers However in order to maintain these quality standards the customers may need periodically to
218. log opens with no information present Select Anode to assign it the proper net The Select Net dialog appears Using the arrow keys scroll the cursor to highlight the correct net pin location for the Anode Select Open to select a pin Highlight a pin and select Ok to accept the location of Terminal 1 The first anode terminal is displayed Repeat the above operation for the Cathode With the anode and cathode properly identified you now need to program the type of diode embedded If your product is attached with the proper diode in place select Detect to automatically set the type and values Horizon Series Tester Programmer s Manual 5 47 Advanced Programming Select Detect Mode Autodetect Diode Tupe i f Autodetect Thresholds 1 Edit Diode Cathode Detect Test 1 74 More Options Label Ji Cl 1 Ji ci 3 LEDs You can either Autodetect Diode Type or Autodetect Thresholds The diode types preset are listed in Table 1 Diode Types If your component does not conform to one of these types select Autodetect Thresholds to learn the component attached The threshold is displayed To manually edit the thresholds of the component select More Options Select Ok to return to the resistor list 5 6 4 Programming Diodes Advanced Options xj Edit Diode Anode
219. m to start the next test If you are having trouble getting your test sequence to start or sequence properly refer to the section on Scan Delay in Section 3 5 HiPot testing was not discussed at this time since it was not set up as part of the learning process for your cable in this initial exercise If you went ahead and set up the Horizon to perform High Voltage testing when you learned your cable then for safety reasons the High Voltage tests would not have been performed unless the product first passed the low voltage testing Congratulations You have successfully tested your first cable When you are finished experimenting remove the cable and select Cancel lt Alt C or Esc gt This will return you to the Test Configuration menu You can select another cable for testing or if you are through the moment select Cancel Alt C or Esc again and you will be returned to the Main Menu To turn off the Horizon select Shut Down lt gt from the Main Menu You will be asked to confirm your decision Alt Y or Enter gt then when instructed turn off the power To cancel shut down select No lt Alt N or Esc 2 10 Horizon Series Tester Programmer s Manual Getting Started W It is very important you follow the proper shut down sequence Failure to do so may corrupt your adapter cable database Horizon Series Tester Programmer s Manual 2 11 3 SYSTEM SETUP e CABLETEST System Setup 3
220. mbers are incremented automatically after each tested product 1 Enter First Serial Number To setup an automatic serial number enter the first serial HEY al number up to 30 characters and select Enter The serial number be comprised of both numbers and letters The 9 serial number will be advanced either alphabetically or Space Bar Eve numerically depending on which is required after each subsequent test and be logged a Serial Number Setup Using the arrow keys select which character s of the serial number you wish incremented after each tested product mhal erinema Use the up arrow to increase the width of the cursor to include more characters or numbers of the serial number APH Select Ok to accept the serial number and return to the Test Horizon Series Tester Programmer s Manual 7 5 Reports and Batches Report Settings menu The reports are configured to automatically increment a serial number for both passed and failed products starting see with the number that is partially displayed SN on Fail OK Move 7 1 2 2 Report Contents The Test Results button can be toggled between 5 choices None Does not include any results in the report should the cable pass or fail Pass Re
221. mer s Manual Advanced Programming a Learn a New Cable with Switches Switch to the 2nd position then press OK to learn it Cancel to end learning Ok Cancel EH Enter Prompt Line 1 PLUNGER LIFTED 1 Gs CET 2109 9 2 ES CS 6 2 218 GT CI CE C eI een 9 9 Space Bar Elear 1 Enter Prompt Line H2 H S 51651 C GL LE c 2 zi spe 9 9 Space Bar lear Learn Kelvin Fixture Set Fixture for the 3rd pos then press OK to learn it Cancel to end learning Ok Cancel After the Kelvin fixture is learned in its second configuration you are prompted to connect the product under test in its second configuration Again after the product s second test step configuration is learned you can enter up to three prompt lines Selecting Esc will skip past the current and any subsequent prompt line screens This is an example of a blank prompt line You are now prompted for the third switching position If the cable is to be tested in two distinct switching positions only select Cancel here to go to the next step 5 8 6 Testing Cables with Switches The testing procedure for a product with embedded components is the same as testing any other cable or harness For details consult section 2
222. moved from the scan list for the duration of the test The test is terminated either by a time out specified when the product was learned or by selecting Ok Selecting Diagnose for a failed flex test will reveal the same detailed results as expected from a standard or default test of a product 4 12 Assembly Aid Tools Assembly Aid allows the operator to randomly populate one end of cable product and then use the tool to test and populate the remaining end s of the product For details on the Horizon s Build Aid capabilities please see Section 9 1 5 S 24 The following is step by step example using a cable terminated at one end with a DB50 connector and not terminated at the other Horizon Series Tester Programmer s Manual 4 29 Basic Programming and Testing The following example makes use of the standard Horizon ground probe as well as a cup of ordinary unsalted water STEP 1 Learn the open product a Main Menu Thu Sep 11 1997 01 40 Test Self Test Sustem Setup Program Cablei Backup i Eait Adapter i Contrast Shut Down EN Programming Cable IM Modify Existing Cable Learn New Cable Default Learn Mew Cable Custom Advanced Hetlist E a Insert the Adapter gt HA 124 JSL HA 124 J7 Select Cancel OK
223. mple you could fully test a cable with a DB9 connector or a harness 6 4 Horizon Series Tester Programmer s Manual Adapters with three DB9 connectors on the adapter just mentioned If you select Huge as the adapter type since Huge does not self ID the Horizon will skip the next few steps and go directly to the Enter Number Of Connectors dialog i the other three types you will enter the Enter First 10 E Type menu There are two ID positions on a standard BEEN adapter These be populated with any desired Dire combination of resistors and or capacitors Select the button indicating the type of the first ID component on your adapter If the choice is Resistor or Capacitor the Enter The Value Of First ID Component dialog appears Selecting None indicates that there is no first ID component Hardwired is a Cirrus compatible ID scheme that uses short circuits between several test points not used by the product to be tested The major disadvantage of this method is that it uses valuable test points that you might need for cables The main reason for its inclusion here is that if you already have Cirrus adapters you can use them directly ona Horizon by means of a special adapter E g HA 245 If you select None or Hardwired the next step is skipped ID COMPONENT 2 ID COMPONENT 1 Horizon Series Tester Programmer s Manual 6 5 Adapters D Comp
224. mponents Net List More Options Print Test Now Cancel Resistors Keus Capacitors Biodes Black Boxes Select Capacitor THECAPAC I TOR Twisted Pairs AIP SD Delete OK Cancel While the Horizon is learning your cable a number of status screens will appear including one that indicates how many capacitors it is finding that meet the search criteria you set up When it has completed learning your cable the Set Test Parameters menu is displayed You do not have to do anything else to test this cable with an embedded capacitor However from this menu you can set up additional tests modify tests you have already specified verify that the tests you want to perform have the correct parameters and provide plain English labels for all nets and nodes Labelling will help your rework station more easily identify and correct any faults found In addition you can review all of the parameters the Horizon has set to make sure they are what you want Select the Components button to apply these features to the capacitors just learned The Edit Component List dialog appears Then select Capacitors The Horizon found one capacitor Select Edit to show more details and bring up the Edit Capacitor menu Horizon Series Tester Programmer s Manual 5 31 Advanced Programming Edit Capacitor CAPACIT
225. n 2 4 Horizon Series Tester Programmer s Manual Getting Started CG OR OS Figure 2 1 Example Cable One to One 25 Conductors Several methods of programming cables are provided in your L Berufs Existing new Horizon These are discussed in detail in the following Learn New Cable Default Lesrm New Gable lt Sections For this exercise we going to learn a new cable Advanced Netlist Editor using the standard method Using this method the Horizon will learn all of the cable s resistance and capacitance parameters and generate a complete NetList for the cable It will then store all of the information in a database and build a test procedure to be used for testing cables of the same type in the future The Modify Existing Cable lt Alt M gt selection allows you to easily change these parameters should you desire quickly implementing ECO s to already learned cables or building up families of similar cables without always going through the learn process for each one Select Learn New Cables Default lt Alt L gt The nsert Adapter s dialog appears nE The top of the Horizon is divided into two sections each of which has four grey connectors The left most set of connectors top and bottom constitutes J1 as can be seen from the label at th
226. n 23 6 miswired 401 which the fault can be located 3 C1 17 instead of J1 C1 6 pet CIT c1 6 ris _ End of fepor __ 4 10 3 Shorts One of the unique features of the Horizon is its ability to pin point the location of shorts on a test cable With a to low voltage tests shorts can be detected and located by the Horizon During the isolation test of a cable the Horizon can diagnose shorts and the location of the fault relative to its position from the adapters If a short is detected the system will display an active icon to tell the user it is still working and diagnosing faults It is important to remember that the Horizon can only detect and will not pin point the location of a short arc that is a result of a high voltage test Ji gd J3 2 ___ Figure 4 8 Short at J1 Horizon Series Tester Programmer s Manual 4 23 Basic Programming and Testing to 4 ER 24 at J1 In the example above the cable is tested and it fails as a result of a short very close to the adapter at J1 Use the Down arrow button to see the remainder of the error message Asterisks always precede faults J3 4 24e Figure 4 9 Short at 8196 Stharted cit Bay at 25m0hm n Hi Shorted ae
227. n 6 wired to J2 C1 17 instead of J1 C 1 6 In fact if during the learning process you labelled your wires and nets the diagnostics will be in natural language For example Short between Red Wire and Blue Wire at Round Connector pin 3 For now we will simply perform a set of tests on the cable you learned in the previous section To test your cable On the Main Menu select Test lt Alt T gt The Test Configuration dialog appears Test Confisiratton The display shows the Directory and the Part Number for the Current 1 Selected Cable cable you just learned File Name datab cables MAIN TESTCABL Part Number TEST CABLE 54 Rev 1 If you do not see the correct information you will have to press er Jke set Select lt Alt S gt to select your cable The Select Part Number rest Ratones O Cancel dialog appears Select Part Nunber Select the part number for your cable using the arrow keys if necessary and select Ok Enter gt The Test Configuration dialog reappears with your cable as the Currently Selected E Refresh Beiete 9 pp y y gt s Cancel Cable 2 8 Horizon Series Tester Programmer s Manual Getting Started Only one product is available since only one product has been learned This selection process is only necessary if you want to test a cable other than that shown a
228. n engages the measurement circuitry to display Perminay a co nea the value of resistance between the selected terminals Terminal 2 1 1 21 On min test AF Select Value to set the tolerance More Options Label Select Change Threshold to manually set the threshold for the product Set the minimum and maximum threshold The threshold is displayed Fermina a ce ier ae Select Ok to return to the keys list Test More Options Label 5 8 5 Four Wire Measurement and Switches 5 8 5 1 Overview of the Four Wires Measurement and Switches For test setups using a Kelvin fixture as opposed to a Kelvin adapter this section applies If you are using a Kelvin adapter you need not read this section The Four wire Kelvin resistance measurement is possible even when the product that is tested has got embedded switches or for some other reasons is tested in multiple steps In general a four wire resistance measurement setup consists of 1 The Horizon system 2 The Kelvin test fixture and 3 The product to be tested 5 8 5 2 Using the Four Wires Measurement and Switches When programming a cable using a Kelvin test fixture the tester has to go through 2 steps 1 Learning the K
229. n supports graphical files in PCX format The PCX must be 1 bit black and white and must be exactly 240 pixels wide and 128 pixels high or they won t display properly To use such a graphical prompt BITMAP s file name When the field s ile name contains just the name of the file without the path then the file is searched in the DATAB PROMPTS directory When the complete file path is given then the file is searched on that path The example below searches the file on an absolute path BITMAP c v4 0 datab cables main switchl pcx The text contained SWITCH1 PCX is loaded and displayed on the screen Abort Retry Ignore Prompt User on Failure By default the system uses a system setting to decide whether to abort retry ignore or prompt the user on a switch test failure The system setting can be overridden in the test program by using an appropriate keyword ONFATL ABORT RETRY IGNORE PROMPT In the example below the system will abort testing any further the product The product is failed as a result of the current switching position test failure ONFAIL ABORT In the example below the current switching position will be re tested following a failure this allows for some repairing the product on the fly and re testing it without removing it Horizon Series Tester Programmer s Manual 9 25 Scripting Features from the test station If this option is used the operator must make sure that t
230. n the Horizon testing a cable with free ends is easy and straightforward Make sure that the standard probe or the optional Hand Held Digital Probe is attached before starting the testing process EN Test Configuration Current 1 Selected Cable File Name idatab cah les MA IN FLY INGLE Part Number FLYING LEADS Rev 1 Tools Select Test Nou Batches Cancel Flying Leadi Wire GREEN Start Test Cancel Select Test from the Main Menu Select the cable to be tested if not already shown in the Test Configuration display and push Test Now The Horizon will instruct you to insert the adapters needed for the test and you will start the test procedure The Horizon will instruct you to touch the first flying lead free end to be tested Notice that the prompt incorporates the label used during the learning process Using the probe touch the correct lead the Horizon will sound a positive tone and automatically sequence to the next lead If you touch the wrong lead or if the lead is open a negative tone sounds and the system does not automatically sequence If you are sure you are touching the correct lead push Skip to sequence to the next lead Touching and holding the probe to the lead will display its address as well if you quickly touch any of the leads the address will a
231. nal 1 eo Terminal 2 i Test More Options ll Label Cancel Twisted 11 01 17 Edit Keu Terminal 1 eo Terminal 2 On min Test 1 1 21 More Options Label Touch key Open habei More prtionsel The Open Net and Pick Terminal dialog appears Using the arrow keys scroll the cursor to highlight the correct net pin location for Terminal 1 Select Open to select a pin select Ok If the net only has a single pin Highlight a pin and select Ok to accept the location of Terminal 1 The first terminal is displayed Repeat the above operation for Terminal 2 When the terminals properly identified you now need to program the value of the component If your product is attached with the proper resistance in place select Test view the measured value Press and hold the key on the product Horizon Series Tester Programmer s Manual 5 63 Advanced Programming ZZ 5 Horizon will measure the resistance values of the key Touch key OK 47 482 Select Advance or release the key on the product to display the value on the Edit Key menu screen The Horizo
232. ncel ux 3 takes you through the ID components process previously discussed pushing Connector List lets you re map the adapter as described above isave Adapter Recora7 m Select Ok when finished to save and return to Adapter Library want to Selecting Cancel also returns you to Adapter Library but Abandon Changes with no action taken Horizon Series Tester Programmer s Manual 6 17 7 GENERATING REPORTS AND BATCH TESTING e CABLETEST Reports and Batches 7 2 Horizon Series Tester Programmer s Manual Reports and Batches 7 1 Generating Reports As part of your test procedure you can include reports for each cable tested These reports can either be printed or saved to file Report settings can be either Global or Test Program Specific The following section details setting up Global Test Report Settings The settings will effect all tested products If you wish to have different report settings for individual test programs see section 9 1 5 Setting up reports Reports are setup up from the Test Configuration menu From the Main Menu select Test to access the Test Configuration menu a Test Configuration Ii Canrentig Selected Cable Select Reports File databscables MAINSTESTCAEL CE Part Number TEST CABLE Rev 1 Tools Reports Select Test Now Batches Cancel
233. near algorithm is used ACHIPOT 500 IR 100e6 DWELL 1 LINEAR 50HZ 9 1 5 Build Aid Activating the Build Aid Feature To activate the build aid feature add the following syntax to the test list BUILDAID Default Settings With no further parameters build aid will behave as follows Build nets sequentially All beeps will be disabled No out of sequence test will be performed Probe is disabled Audible Feedback Enable audible feedback for a passed test BUILDAID PASS BEEP Enable audible feedback for a failed test BUILDAID FAIL BEEP Building a Cable Sequentially Horizon Series Tester Programmer s Manual 9 17 Scripting Features By default the Horizon expects the cable to be built sequentially in the order defined in the test program But may be explicitly set for clarity BUILDAID SEQUENTIAL E DEIN 1 OUTOFSEQUENCE lt timeout gt The optional P IN subcommand specifies that the build aid is to be done on a pin per pin basis Otherwise the build aid is conducted on a net per net basis To build a cable on a net per net basis BUILDAID SEQUENTIAL To build a cable on a pin per pin basis BUILDAID SEQUENTIAL PIN The optional OUTOFSEQUENCE subcommand specifies the system to consider an error when a net or pin was build out of sequence If the option
234. ng connectors After you have programmed all n connectors where is the total number of connectors declared selecting OK will open the Edit Adapter menu From the Edit Adapter menu you have the option to edit any of the adapter s properties Part Number Edit or change the name of the adapter ID Components Re enter or re detect values of id components Connector List Edit connector names and pin mapping of an adapter 6 8 Horizon Series Tester Programmer s Manual Adapters 6 3 Taring the Adapter Fixture If you are adding a fixture to the Adapter Library you may desire to Tare the fixture so the resistance and capacitance is not reflected in the Horizon s results You can Tare your fixture right from the Edit Adapter menu final test position for huge test Fixture ones 2 Remove product under TeSt and ghertins fro adap 3 Press oR tD perform capa citive tal 1 Plug adapter in proper po Ye sition most for sing double and quad adapters and final test position for huge test Fixture ones 23 Remoue product under test from adapter 32 Connect Shorting plugs to dit Mc KDE that need to 4 Press to perform resis EE IESIER ave Adapter 7 Hi a you want to 0 Abandon Changes Cap Tare For increased capacitance measurement accuracy the capacitance of the adapter may be learned and utilized as a
235. not be performed After the product has passed all of its low voltage tests it can now be tested with high voltage If you set up Autohipot during the system setup HiPot testing will proceed automatically If not the Perform DC Hipot Test dialog will appear In either case if you specified Password Protected when the cable was learned an Operator level password will have to be entered before testing will start Select Yes HiPot testing will start and the Performing Tests dialog appears Selecting No will return you to the Test Statistics window and the Fail light will be lit Selecting Diagnose will show a message indicating that all tests have passed what has happened in essence is a forced failure of the HiPot test In all of these cases if you have installed and programmed any type of Palm Switch protection it will also have to be activated as programmed before HiPot testing will start Performing Tests The display shows the progress of HiPot testing Horizon Series Tester Programmer s Manual 4 45 Basic Programming and Testing TEST CABLE HI Tested i Passed 1 Failed Error Statisties Retest __ 1 ALL DC Het3 DC 5 04G0hm DC NetS 7 23 60hm DC Net 9 96COhm DC Net amp 13G 0hm DC Nets 13 4G0hm DC Net 21 23GU0hm Cue TC 1
236. ns until Ok is selected During each of the tests you have option to Print result Verify calibration using external reference components a SELECT THE SOURCE OF THE REFERENCE VALUES INTERNAL CANCEL Check calibration using external reference components Resistors Sm DC Capacitors DC Diodes AC Hipot HC Source DC Hipot 3 ENTER THE VALUE OF THE EXTERNAL REF RESISTOR 1498 199 lear BS Enter Dje 8 He mu ex Ls Esc Connect the test resistor to the Jacks eference 1498 100 Measured R 1 4Mit Tolerance o d Choosing the EXTERNAL option in the SELECT THE SOURCE OF THE REFERENCE VALUES menu allow the user to test there own measured components To verify resistance measurement select Resistors Measure your resistor and enter the value Connect the resistor to the external jacks on the calibration board The Horizon measures the value and compares it to the value you entered as a reference value The tolerance between the two is given Press Ok to return to the Check calibration using external reference components menu Horizon Series Tester Programmer s Manual 7 Appendix Calibration Verification Resistors DC
237. o File s option is selected the system saves the test results and the errors to two files The ALL file contains any report option that has been enabled including the errors The ERR file contains only the errors The file names are created from the product name by using the first few characters Some character conversions may occur in order to render the file names valid Append enables the user to have each test appended to existing log files Y Disabled no check mark each test overwrites the existing log 7 4 Horizon Series Tester Programmer s Manual Reports and Batches Report Settings General Test Reports Selecting Ok returns you to the Report Settings menu Operator ID Reports a Ok 7 1 2 Report Settings Select Test Reports to configure the reports for your test Test Report Settings Serial Number Options Header Footer Test Parameters OK 7 1 2 1 Serial Numbers To serialize a product you are testing select Serial Number Options The Serial Number Options dialog appears Manual Auto Manual Mode The operator will be prompted for a serial number at the end of each test SN on Fail Auto serial numbers will be incremented even if a product fails as well in manual mode the operator will be prompted for a serial number on fail products Auto Serial nu
238. o Wires Prompt After the Horizon has learned the low voltage parameters for the completed nets if any in your cable the Probe Flying Lead 1 Press Ok When Done dialog appears The Product Under Test has three 3 conductors flying from a DB25 connector The Next and Prev options are to allow the user to probe the connectors and have them correspond to the connector numbering convention Using the supplied ground probe touch the exposed end of one of the leads A tone will sound and the Enter The Lead s Label Connected To menu appears Input an appropriate label for the lead just touched Since this will also be the prompt when the cable is tested it is suggested that you make the label as instructive and clear as possible You can use any character and the label can be up to 30 characters in length Select Enter and you will return to the Probe Flying Leads Press Ok When Done 5 6 Horizon Series Tester Programmer s Manual Advanced Programming dialog The dialog increments to the next lead however our 1 Frohe flying lead 2 product has the 3 pin as the second lead so we can select Press when done Next to have them correspond Probe the second lead 31 Probe flying lead 3 BY Press when done Enter the label for the second flying lead BLACK jJ 2 8 1 ee 0 9 2 EVI 4 0 1 2 Space Bar
239. ogramming 5 21 iie eee eh reped ie 8 3 Other removable media 8 3 Retest deeds 2 10 5 Safety 1 4 1 5 Horizon Series Tester Programmer s Manual iii INDEX DC Hip Ot te 4 37 Scan 3 12 Selects 2 8 Serial Numbers 7 5 Service 2 Where to get more 1 3 Service 3 13 cato cec attests tte te 4 23 Shutting Down Your Horizon 2 10 Sleep Mode 3 5 SOAKING meets 4 48 Software 5 3 14 otar Scanz cie Mates 4 18 ties edes tnt 4 13 0222 5 55 5 69 Kelvin Measurement 5 64 Retry Abort Ignore 5 69 System 3 3 Abort t 3 5 BOX65 tien testet dta 3 22 3 13 3 19 Extraction Delay 3 13 General Settings 3 5 Insertion 3 12 Isolated Inputs 3 3 Outputs honest ein 3 20 Palm S
240. on Series Tester Programmer s Manual 4 7 Basic Programming and Testing ee em first step in the testing process is to insert the proper adapter s All adapters installed when the cable was learned must also be installed when it is tested The BA m Horizon will display the part number of the first adapter required starting from left to right and will flash its outline at the required location If the wrong adapter is inserted or if it is inserted in the wrong location the Horizon will continue to indicate the correct part number and location by flashing them on the display Once the proper adapter is inserted the display will go on to the next needed adapter to the right then to any installed extra boxes After the proper adapters are all installed the system automatically sequences to Connect Product To Start Accept forces the Horizon to Connect Product To Start while Cancel returns to Test Configuration eee Insert your product in the appropriate connectors The Tested 5 Horizon will detect when the product is inserted and Eli automatically start the test If your product passes the Error Statisties green Pass light will be lit If it fails the red Fail light will be Start Test Cancel lit Special circumstances may prevent the Horizon from automatically starting One example
241. on TCL and Remote Options Reset Fail Hish Voltage Programming Guide Retest Test Over Reset unit Start Test Fail Screen Controls the ClickButton and TypeButton commands Start Test Controls the StartTestON and StartTestOff commands Reset Fail Controls the ResetFailOn and ResetFailOff commands Retest Controls the RetestOn and RetestOff commands Reset Unit Controls the ResetUnitON and ResetUnitOff commands The reset unit command family requires additional conditions to be enabled Pass Controls the PassOn and PassOff commands Fail Controls the FailOn and FailOff commands High Voltage Controls the HighVoltageOn and HighVoltageOff commands Test Over Controls the TestOverOn and TestOverOff commands Remote Data Enable or disable results returned to the Host PC at the end of a test Se Port Settings Bort COMI Bits 8 soe Por Select between COM1 and COM2 The Horizon 1500 only uses COMf1 Speed Available speeds are 1200 2400 4800 9600 19200 38400 57600 115200 Flow The only available selection is Hardware Bits Although words of 5 6 7 and 8 bits are theoretically supported only 8 bits is Horizon Series Tester Programmer s Manual 3 11 System Setup supported at this time Stop 1 or 2 stop bits are supported
242. on is selected As soon as it is selected and the check mark appears the rest of the menu becomes active and is no longer greyed out Selecting Ok incorporates the DC HiPot test that was specified into the cable s test setup 1 ipot Settir Hipot Hipot Voltage Leakage Limit Hipot Duration DC Hipot Settings Now that the Horizon has been instructed to perform HiPot ce testing the test parameters can be defined Select HiPot Voltage and the nput DC HiPot test voltage Volts 160 6 ph Hirot Duration 5 581 dialog is displayed Enter the desired DC HiPot voltage You can specify any value you want from 50V up to either 1000 or 1500 Volts depending on the high voltage source installed The voltage can be specified in single 1 volt increments When the proper voltage has been entered select Enter and you will be returned to the DC Hipot Settings menu Select Leakage Limit and you will enter the Specify Leakage Type dialog 4 38 Horizon Series Tester Programmer s Manual Basic Programming and Testing i Current i m Cancel Arcs Only Maximum DC hipot leakage resistance in Mi es Current ie f Resi
243. one The Horizon will automatically measure the value of the ee component if any are present mounted in the first ID zr location If this value is what you expected select Enter to 181 lem accept it and go to the Enter Second ID Type menu In the aa example shown it is 10000 resistor If it is not what you expected check the value of the component before going on If you have not mounted any components as yet or you plan to install new values you can override the measured value at this time but don t forget to install the proper values later Otherwise the Horizon will not correctly self ID the adapter The recommended range for ID resistors is between 100Q and 100kQ You must use metal film resistors with a 1 tolerance Capacitors can range between 100pF and 100nF Capacitors must be able to withstand the HiPot test voltages of up to 1500kV and have a tolerance of at least 2 nter Second ID Tu The second ID component does not have to be of the same __ 4 type as the first so you are asked to enter the component of 2 choice Again if the choice is Resistor or Capacitor the i Comer Enter The Value Of Second ID Component dialog appears Pl ee lt As before if you select None or Hardwired the next step is skipped The Horizon automatically measures the value of the component if any are present mounted in the firs
244. only in situations in which the adapter setup is not expected to change from cable to cable Sometimes adapter s are not automatically detected This can happen if a cable is already connected to the adapter It may also happen if a test fixture is connected to the adapter or if the adapter is a huge adapter In this case the desired adapter s may be selected directly from the Horizon s internal library using the Select button If you use the Select function the Horizon will attempt to The selected adarter on the current hoxt is impossible a warning message will be generated In the example shown a double wide was selected and cannot be used since both sections are already occupied by Single Wide adapters Selecting Ok returns you to nsert The Adapter while Cancel sends you to Programming Cable cannot be placed place the selected adapter in the first open position If this Ipseet the produet Insert your golden product cable or harness into the adapters and select Ok to begin the learning process 4 44494 1 j Figure 4 1 Product Under Test PUT 4 4 Horizon Series Tester Programmer s Manual Basic Programming and Testing Test Points 16 Found 4 Ej 2 PIE 7
245. or H Terminal 1 41 1 1 Terminal 2 lt Ji Ci 4 Value OPF min max More Options Label Edit Capacitor Value min max zest OK G0GpF More Options Label Highlight a pin and select Ok to accept the location of Terminal 1 The first terminal is displayed Repeat the above operation for Terminal 2 With the terminals properly identified you now need to program the value of the component If your product is attached with the proper capacitance in place select Test to view the measured value The Horizon engages the measurement circuitry to display the value of capacitance between the selected terminals Select Value to set the tolerance 5 36 Horizon Series Tester Programmer s Manual Advanced Programming aL Select Detect Three value options are available Change Tare Value d Change Thresholds 5 Gall Autodetect Thresholds EX ETE Autodetect Thresholds Automatically selects 10 the average value measured by the Horizon Change Thresholds Allows the user to manually set the thresholds for the component Change Tare Value This allows the user to manually alter the capacitance tare value This may be useful in scenarios that include test fixtures with long interface cables The threshold is displayed
246. or the test ee On the Menu select Program Cable The Horizon will MT ask for a Password The factory installed Password is m 1234 Enter the Password and the Programming Cable dialog appears Select Learn New Cable Default The Insert Adapter s dialog appears If this is the first time you have used the Horizon and you have not yet gone through the getting started exercise it is highly recommended that you do so at this time please see section 2 Getting Started Insert your adapters in the position s of choice The ere 5 example shows two Single Wide HA116 s mounted but yours may be different HA HA 116 116 17 Select Ok after all adapters are properly mounted Cancel returns to Programming Cable It is acceptable to have adapters that are not needed for the specific product Horizon Series Tester Programmer s Manual 4 3 Basic Programming and Testing being tested mounted the Horizon It will not interfere in way with proper testing but in the future the Horizon will need all of the same adapters mounted in exactly the same positions before testing can proceed Also the more test points the greater the length of time is required by the Horizon to perform a test Therefore it is recommended that you do this
247. ork Follow the on screen prompts Once complete you are prompted whether you have the simplex test card If you have it select Yes Otherwise select No and skip the next three screens The Horizon will prompt you to insert the card into the first Quad position of the first Box J5 Select Ok to continue Simplex LV test in progress Once complete the Horizon will prompt you to move the card to the next position Repeat until all Quad positions have been tested At the end of the Simplex LV test the report is shown Any faults will be listed If a fault is reported contact CableTests Customer Support Group Once the Simplex LV tests are done or skipped you are prompted whether you have the Kelvin test card If you have it select Yes Otherwise select No to return to the Service menu dialog 3 16 Horizon Series Tester Programmer s Manual System Setup Action Required 2 Horizon will prompt you to insert the card into the first A Quad position of the first Box J5 in Box 1 Select Ok to continue Test in progress using the standard LV source Resistors EB Test in progress using the optional High Current Source if not installed will be skipped Test in progress using the Fixed High Current Source At the end of the Kelvin LV tests the report is shown Any faul
248. p DATABSADAPTERSSAMPG 44 ADP File backed up ATAB ADAPTERS CAADEP 2 ADP ile backe ATAB ADAP TERS CAADBS 2 ADP been a Backup Restore Shell Hi T R want to erase these files from Horizon driver 8 1 2 Selecting Yes in the Erase All Files on Target Disk screen will erase the contents on the diskette Select No to append the information on the disk As files are being backed up the progress bar indicates the remaining space on the disk and the progress of the total backup Once complete the user is prompted to remove the disk and a sugested label is displayed Once the diskette is removed the Backup Report screen will display all files backed up Use the arrow keys to scroll through the list Select Ok to return to the Backup Restore Shell screen Select Save Log Files to backup the log files on the Horizon The user has the option to delete log files after transferring them to a diskette Select Yes to delete and No to continue without deletion bog files can only be copied from the Horizon s hard disk to a floppy diskette Performing Restores Horizon Series Tester Programmer s Manual 8 5 Backups and Restores Backup Restore Shell Backup Restore Save Log Files More Options Cancel Restoring Cables DAThB T3T32 1 CBL Targ
249. p and the high voltage test parameters group The syntax and the default values are given for each testing parameter below 9 141 Low Voltage Test Parameters The low voltage test parameters are used during the low voltage tests and affect the continuity isolation and flex tests Some of the parameters can be set globally to affect all the nets within the cable or individually on a per net basis Others can only be set globally Continuity Test Parameters The continuity test can be performed by Quick Scan or by resistance measurement using the built in continuity test algorithm When the optional embedded TCL interpreter package is installed a continuity test procedure can be defined using the TCL language and run instead of the internal algorithm If the CONTINUITY keyword is not found in the text file then the default Quick Scan method is used The Quick Scan method works globally When the resistance thresholds are used they can be specified globally at the cable or section of cable switch position level and or individually at the net level The CONTINUITY line may require additional test parameters in some cases Whenever additional continuity related test parameters are specified they must appear immediately after the CONTINUITY line The syntax and options related to the continuity test are described below CONTINUITY lt d_min gt lt d_max gt lt s_contScriptCmdAndArgs gt KELVIN C HCRES
250. parameters using a voltmeter The result of measuring the built in components can be printed on a customized report by means of a standard parallel printer Using the Calibration Equipment Installation Insert the disk in drive A and power up the unit In a short time you will see the Horizon s logo followed by a diagnose screen were you will see the information concerning the number and the status of each detected MUX card Each MUX card deals with 64 test points therefore for a maximum of 1024 test points maximum 16 cards can be detected 2 Horizon Series Tester Programmer s Manual Appendix Calibration Verification For example if your system has 128 test points you must detect two cards usually assigned as number 0 and 1 Therefore the screen the squares number 0 and 1 should be highlighted If a MUX card is detected but does not pass a self test its corresponding position on the screen will be displayed on a gray background which means that card is defective and the situation must be reported to the supervisor Besides the MUX boards status you will see the serial number of the software that should match the serial number of the calibration board After another few seconds you will reach the main menu The Main Menu Screen Horizon 1500 Calibration Menu Thu Oct 99 1997 91 57 PM CONTRAST SHUT DOWN Calibration System Setup TIME amp DATE PRINTER SETUP
251. ply proper information in these fields The example below indicates revision 1 of a test program for the cable AWP 1001GT CABLE AWP 1001GT 1 As it can be seen in the example above commas separate the fields String fields can be of an arbitrary length unless otherwise noted and can contain any printable character including spaces Due to the nature of the CDA rules if a field contains one comma character or more the entire string must be enclosed in double quotation marks While the Horizon system and all CDA aware applications take care of this aspect automatically when manually generating test programs using a text editor the user is responsible for this An example of field embedded comma is given below CABLE RW113 RW114 RW115 1 The program revision does not have to be a number The Horizon software can automatically increment to the next revision even if it is a letter CABLE RJ45 PATCH CORD A When the above test program is modified Horizon can save it as the next revision CABLE RJ45 PATCH CORD B By default Horizon will make the revision 1 for any newly learned test program It is important to remember that all test programs that reside in the same directory must have unique combinations of cable name and program revision The file name what is seen when the DIR command is issued at the Horizon Series Tester Programmer s Manual 9 5 Scripting Features DOS prompt is not import
252. ppear on the display Probe the Next Lead Probe the Next Lead 5 10 Horizon Series Tester Programmer s Manual Advanced Programming The standard or customized low voltage tests are performed on the PUT 5 3 Programming and Testing Twisted Pairs 3 1 Learning Twisted Pairs Twisted Nets Only Free Ends Kelvin onductor Res Quick Scan Use Kelvin Probe Cancel Enable Twisted and Nets Only Twist enables the twisted pair testing mode of the Horizon Selecting Twist will automatically prompt the user to enter the threshold value The default value is 20 pf Cancel to return to the Learn Setting menu New to change the Actual Value Ok to accept the Actual value and return to the Learn Setting menu Enter the threshold value Select Enter to continue This will return you the Threshold Capacitance Setting menu Select Ok to return to the Learn Setting menu On the Learn Settings menu select Ok Horizon Series Tester Programmer s Manual 5 11 Advanced Programming Resistors Capacitors Diodes Switches Back Cancel OK Foun Twisted Pairs 3 Enter Part Mumber twisted pair
253. probe will display Enabled when activated Otherwise the DHHP will display Disabled Left Hand Activated a left handed user can easily read the display message If the box is not checked then a right handed user can read the display Trace Cable Activated the DHHP can be used to trace a failed product 3 4 3 Remote RS232 Options Bar Code Reader Setup SS Select Remote Opt Button for the Set Remote Option Uolume 8 Progress menu Reset Fail Fail Relay Test Opt Package Press to return to the System Setup menu Emart Probe Remote opt 3 Set Remote Options Select RS232 Control to externally control the Horizon RS232 Control Bar oe Press to return to the General Setup menu Select Bar Code Options for the setting up a reader NetBIOS is currently unavailable The RS232 Remote Options menu has four 4 options Remote Control emote Data i Remote Control Select control items Enable Remote Remote Data Test results Port Settings Communications Settings Enable Remote the remote interface 3 10 Horizon Series Tester Programmer s Manual System Setup The individual options enable disable the following functions as described in the Horiz
254. r Programmer s Manual Basic Programming and Testing If your product has embedded resistors or diodes and these components are learned when the cable is learned the Horizon will automatically exclude the nets connected to these components Nets with components connected to them are automatically grouped for isolation and HiPot testing and the group of nets is treated as a single net while these tests are running You do not need to worry about manually excluding them 4 13 2 Safety Your Horizon has the capability of allowing you to set up a number of safety procedures Which of these you use depends on local regulations your philosophies and the training level of your personnel To use Palm Switches with your High Voltage Test see Section 3 System Setup 4 13 3 Program the Horizon to Hipot the Entire Cable or Harness The main location for setting up HiPot testing is the Set Test Parameters menu This menu is always displayed after a cable has been learned through either the Default or the Customized path Itis also directly accessed after selecting a previously learned cable in Modify Existing Cable a Set Test Parameters Selecting High Voltage displays the High Voltage Settings Pronpt Adarters dialog Low Voltage Components More Options Print Test Now Cancel ee Selecting Hipot Nets Only a check mark is visible means that th
255. r Programmer s Manual 4 51 Basic Programming and Testing a AC Settings Hirot Frequency Hipot Voltage For safety reasons AC high voltage testing cannot even be setup until the Hipot button is selected As soon as it is selected and the check mark appears the rest of the menu Leakage Limit hirot Duration becomes active Selecting Ok incorporates the AC HiPot Sean t More ort ex test that has been specified into the cable s test setup la MEE LEVE soon as the Horizon has been instructed to perform iieo 3 2 HiPot testing the test parameters can be defined The first parameter is Frequency Selecting Frequency toggles the Hirot Duration frequency of the applied AC voltage between 50 Hz and 60 Sean Mass More Opt Hz a AC Hipot Settings IM Next select Hipot Voltage and the nput the AC HiPot test remenes jEsT voltage Volts rms dialog is displayed Hipot Uoltage o wu Leakage Limit 1600 p Hipot Duration 0 40 Sean Mass More Opt OK Input the AC hipot test voltage in Volts rms Enter the desired AC HiPot test voltage You can specify any value you want up to 1000Vrms optional systems configurations are programmable to 1061Vrms and 1067Vrms The volt
256. r called HA 116 uses a DB 25 female connector The adapter s size is Single and it uses two resistor ID s The first ID component has 1KQ and the second has 1 5KQ This adapter has been fully tared for capacitance LV Resistance and HC Resistance Example 2 ADAPTER HSA 214 SIGNATURE 1 12100 1 1210 SIZE 2 CONNECTOR MIL ROUND M 11 0 A 1 B 276 9 36 Horizon Series Tester Programmer s Manual Scripting Features 26 M CONNECTOR MIL ROUND F 11 47 39 38 37 D 36 35 41 54 53 52 50 L 51 M In the example above it can be seen that the connector names longer numbers The user has total freedom to name the connector pins according to their documentation Creating Custom Adapter Files Off line To create a custom adapter cable file one would normally start from the adapter file that the adapter cable will be interfacing to The examples below make the assumption that the HSA 272 adapter is used to interface two different types of adapter cables ADPTCBL 1 and ADPTCBL 2 Using a text editor open the file called HSA272 ADP and save it as ADPTCBL1 ADP and then as ADPTCBL2 ADP This way you have created the templates for the two new adapter files The a portion of the original HSA272 ADP is listed below ADAPTER HSA 272 SIGNATURE 3 0 3 0 SIZE 4 VERSION 4 0 0 CONNECTOR ZIF 104 SOCKETS 8 1 9 2 10 3 11 4 Ho
257. r define a point as NC not connected by highlighting the Conn Pin and selecting Edit Enter the associated system pin number select Enter and you will return to Enter Connector 1 s Netlist Continue in this manner until all pin numbers have been mapped When finished select Print and or BACK as above Enter 1024 for N C not connected pins If the Kelvin toggle is enabled selecting Edit will prompt the user to enter values for both the Sys Pin and Sense pins if your adapter is not a Kelvin adapter the default 1024 NC should be present in the Sense column With Kelvin disabled you are prompted only for the Sys Pin value E EE 7 9 0 9 2 MIEN 8 7 2 4 Space Elear In the Edit mode the operator is also given the opportunity to give the connector pin a unique name The entered value will be used instead of the default numerals The option to name pins at this level is limited since no lower case letters are available To properly set a numbering convention it is recommended to use the Conventions feature as described in section 0 AWN s 2 2 Erit Edit Adapter Part Number Tare ID Components Res Tare Connectors Cancel Repeat above steps for any and all remaini
258. r your product select Ok to save the test procedure in the internal database Cancel will take you back to Program Cable and discard all of the learned parameters Select Yes to save your cable record The Save To Directory dialog appears No returns you to the Main Menu Move the cursor until the directory in which you want to save the cable is highlighted then select OK The cable record is saved and you are returned to the Programming Cable menu If you want to store your cable in a new directory select New and you will be prompted to enter the new name Select Enter when done You can use any combination of up to 30 characters Horizon Series Tester Programmer s Manual 5 19 Advanced Programming Test Program as CBL File datab cables main resistor cbl For greater detail see section 9 CABLE RESISTOR 1 NET CONTINUITY 0 5 TEDIS STAR THRESHOLD 61 NET ADAPTER 116 POSITION J1 J3 C1 14 ADAPTER 116 NET POSITION J3 J1 C1 15 NET J3 C1 15 Ji Cll NET 23 61 1 21 1 16 NET 9 61 16 2120122 NET 49261520 FLOP Thy NET 98261474 71200239 NET 93 C123 18 NET J3 C1 18 NET 23 1 4 NET 93 61 19 J1 C1 5 NET 5 5 TL Ch 209 J3 C1 20 5 J1 C1 6 NET 23 C1 6 JL LCL 21 NET 2 NET J3 01 7 J1
259. re of the Horizon to delay the start of test once it is triggered See Section 3 System Setup for details 4 7 Preventing Runaway Tests Max Errors The Horizon s determination to discover all faults in a cable can sometimes create long test times while the operator waits for all the faults to be diagnosed One way to prevent this is to specify the number of errors the Horizon should find before aborting the test sequence and failing the product Horizon Series Tester Programmer s Manual 4 13 Basic Programming and Testing Start Max Errors 5 To enable this feature select More Options gt Max Errors from the Set Test Parameters menu Enter the number of maximum number of errors and select Ok to continue 4 8 Advanced NetList Editor Optional An available option for the Horizon is an onboard script editor To edit script from the Horizon you will need to have a VGA monitor and an AT keyboard attached to the system Modify Existing Cable Learn Heu Cable Default Learn New Cable Custom Advanced Netlist Editor Oven Directoru ES Refresh Delete 7 Cancel Select Advanced Netlist Editor to open the text editor Open the desired directory and select the product you wish to edit 4 14 Horizon Series Tester Programmer s Manual Basic Programming and Testing
260. ress bars will appear briefly indicating that the Horizon is analyzing your cable and storing its NetList and parameters in a uniquely named product file The Enter Part Number dialog will then appear Type a unique name for your cable This may be the actual part number or any other name of your choice You can use any combination IPAE CH Cd Ed of alpha upper and lower case and numeric characters as srace Clear well as other valid ASCII symbols such as parentheses amp etc Numbers and symbols are accessed from the alpha screen by selecting the 0 9 key at the lower left hand corner from the numeric symbol screen alpha characters are accessed by selecting the A Z button in the lower left The name or part number may be up to 30 characters in length TEST CABLE 5 gamann amana After you have entered the correct part number select Enter Enter gt The Set Test Parameters dialog appears harness may have Under Set Test Parameters you customize your test by specifying or modifying your products tolerances You set ae E up DC and or AC HiPot testing if your system is equipped to EE Options perform these tests and declare any embedded components Test Now 1 resistors capacitors and or diodes that your cable Another unique feature of the
261. rial time damage or transportation claims nor will Product be replaced or rebuilt if it was damaged from improper use This warranty does not apply to loss or damage caused by accidents riot labour disputes acts of God inadequate power sources power interruptions use with hazardous or explosive chemicals and or materials unfit or inadequate environmental control including site conditions and chemicals used individually or in combination improper operation maintenance supervision training or use of safety precautions relating to the operation of the Product or other causes beyond the control of CABLETEST No allowances will be made for the cost of work done or repairs done by others THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL WARRANTIES OF EVERY KIND EXPRESS IMPLIED OR STATUTORY AND IS IN LIEU OF THE IMPLIED WARRANTIES OF MERCHANTABILITY AND OF FITNESS FORA PARTICULAR PURPOSE CABLETEST Table of ContenTs 1 Introduction 1 1 1 1 ioe s e EUR e e MCA ES ed sien 1 8 1 2 Abbreviations and Symbols 1 3 1 3 1 4 1 4 B llt In 1 5 2 Getting Started 2 1 2 1 uu 2 3 2 1 1 Tuming on the System de 2 3 2 1 2 screen Navigation iau diia ben diet ede nd 2 3 2 2 Learning Your Cable 23 Testing
262. ries Tester Programmer s Manual 5 15 Advanced Programming a Component Settings Resistors Capacitors Diodes Switches Back Cancel Choose the range H Common Ground Minimum Maximum 1 1 400 En 5 1 d 3 E1224 4 5 e BS L JLs IL IL 1 600 x 5 1 2 E1224 4 5 e BS TARASS era Select Resistors to begin the Expected Range dialog Select Common Ground if components connected to a common bus Input the minimum expected resistance for all of the embedded resistors in your cable In the example shown the lowest expected value is 1 4MQ Select Enter when done The Horizon will then ask you for the maximum expected value for all of the resistors in your cable In the example shown no resistor is expected with a value greater than 1 6MQ Select Enter when done to return to the Component Settings menu The Resistors box is now checked to show that the Horizon will look for resistors in the range shown If you are satisfied select Ok and the Insert The Adapter s dialog appears eris IH Jil J2 J4 T 116 116 Select 1
263. rizon Series Tester Programmer s Manual 9 37 Scripting Features 12 5 13 6 14 7 15 8 40 9 41 10 42 11 43 12 44 13 0 14 2 15 3 16 4 17 5 18 6 19 7 20 Example 1 Now let s assume that the first adapter cable that you want to create a file for is described in the table below ADPTCBL 1 Product Connector Name Pins connector pins mating to HSA 272 Use the text editor to open the file ADPTCBL1 ADP created above and change the adapter and connector names Also based on the observation that only the odd numbered ZF pins from 1 to 19 are used eliminate all other pin lines from the file The adapter file would now look like 9 38 Horizon Series Tester Programmer s Manual Scripting Features ADAPTER ADPTCBL 1 SIGNATURE 3 0 3 0 SIZE 4 VERSION CONNECTO 8 1 10 3 12 5 14 9 40 9 42 11 44 13 2 15 4 17 6 19 4 0 0 R MIL ROUND CONN 10 PINS C Now substitute the numbers in the right column which represent the ZIF pin numbers with the product connector s pin numbers The file ADPTCBL1 ADP would now look like ADAPTER ADPTCBL 1 SIGNATURE 3 0 3 0 SIZE 4 VERSION CONNECTO 8 A 4 0 0 R MIL ROUND CONN 10 PINS C Save the file Horizon Series Tester Programmer s Manual 9 39 Appendix A Horizon Specific
264. rn to the range entry dialog Enter the range for the next group of pins you wish to locate and select Enter to continue Continue until you have fully assembled the product Once all the pins are populated in the connector it is recommend to perform a final verification that the product is correctly assembled Enter pin or pin range to be Found 8 4 5 6 7 8 9 9 964 2 Space Bar Elear Probe Any Pin NIE T FE Probe Anu Pin Last Probed 1 After the last is probed if you select Next or if you are automatically sequencing you will return to the range entry dialog If you select Enter without entering a range you will enter the Probe any Pin mode At this point probe each pin on the assembled connector noting the connector position and the pin displayed on the screen Probing pins on the newly assembled connector will display the pins as they are populated at the original terminated end Verify that the pin and displayed pin are matching 4 13 DC HiPot Testing 4 13 1 Introduction The Horizon can be set up to perform a DC HiPot test on any cable or harness provided that it has a high voltage DC source installed HiPot testing can be done on the entire cable or only on selected nets within the cable 4 36 Horizon Series Teste
265. rs Tested i Passed 1 Failed Error Statistics Diagnose Retest Cancel Test Report TE Results ALL rogram SEC 99 42 S ITORi 8927 Ter of Repo Select Test Now to begin testing the selected cable product Insert the required adapters Insert your product in the appropriate connectors The Horizon will detect when the product is inserted and automatically start the test If your product passes the green Pass light will be lit and a positive tone will sound if it fails the red Fail light will be lit and a negative tone will sound If for some reason the test does not automatically start or you have disabled the automatic start feature selecting Start Test will force the test process to start The system performs the standard low voltage tests Continuity and Isolation then scans for the Capacitors Once the test is complete the display will change instructing you to disconnect the product Disconnecting the product updates the statistics database and automatically resets the system to test the next product Inserting the next cable starts the process again Prior to disconnecting the tested product the user can select Diagnose to view the results of the last test 5 5 5 Error Reporting for Capacitors All of the same errors are available in this mode as for general cable testing Basically the a
266. s Others can only be set globally 9 14 Horizon Series Tester Programmer s Manual Scripting Features Password Protection The password protection is a safety feature used in conjunction with a product to be tested at high voltage It prevents unauthorized personnel to perform such a test The option is off by default If the password protection is turned on a valid password must be entered before the first test can start The syntax is given below PROTECTED In this example the test program is password protected HiPot Not Connected Points By default Horizon doesn t apply high voltage to the not connected points single point nets within the tested product This is intended as a safety feature that stems from the idea that the not connected pins may be part of the unused connectors on the adapter test fixture and therefore might be exposed to operator touch during the HiPot tests To HIPOT the Not Connected points use the keyword given below HIPOTNC DC HiPot Test Parameters The DC HiPot test can be specified for units that are equipped with a DC HiPot module By default the DC HiPot is disabled The DC HiPot parameters are usually specified for the entire product or section of product switch position but it is possible only in the linear mode to specify the DC HiPot parameters on a per net basis When the DC HiPot is to be run in the mass mode the only parameter that can be changed on a per net basis
267. s menu Select 50uA Use an ammeter to measure the current through the two jacks An example measurement from a Horizon was 49 97 Press Ok to return to the Check calibration using external reference components menu Select AC Hipot to verify the AC hipot card in your machine should you have this feature installed Horizon Series Tester Programmer s Manual 9 Appendix D Calibration Verification CHECKING THE AC HIGH VOLTAGE Voltage 190 Frequency Isolation R Hz 11 Touch here to activate HU As a safety precaution the high voltage will only be present and be maintained as long as the touch screen is pressed Check calibration using external reference components Resistors DC Capacitors DC Diodes AC Hipot HC Source DC Hipot CHECKING THE DC HIGH VOLTAGE Isolation R ioo u 15 Mi Touch here to activate HU As a safety precaution the high voltage will only be present and be maintained as long as the touch screen is pressed CHECKING THE AC HIGH VOLTAGE Voltage 100 Frequency Isolation R Hz 5 Touch here to activate HU Check calibration using external reference components Resistors SmA DC Capacitors DC Diod
268. s the Currently Selected Cable and will only need to be performed in the future whenever you need to change the type of cable being tested The Horizon loads the selected product Processed A e TO start testing your cable select Test Now lt Alt T or Enter gt The Insert the Adapter s dialog appears File les MAIN TESTCABL CE Part Number TEST CABLE 54 Rev 1 Tools Reports Select Test Mou Batches Cancel 1 Insert the gt 22 Ja 04 Insert the adapters required to test your cable Make sure that you insert them in the same order and position as they were HA mounted when you learned the cable Note that the system us T ee will prompt you for any missing mis positioned or incorrect adapters by flashing an outline in the appropriate position and by flashing the part number As soon as all of the proper adapters are mounted the Connect Product to Start dialog appears TEST CABLE 5 Connect Product to Start Mount your cable the adapters As soon as the cable is Passed mounted the low voltage portion of the tests automatically starts Error Statist ies Diagnose Start Test Cancel The relays are tested and cleaned The s
269. s usually associated with embedded switches Basically each switch position can have its own customized test Horizon Series Tester Programmer s Manual 9 27 Scripting Features parameters and NetList With minor exceptions a switch position may have the same features as a simple product test program i e a switch position cannot have adapters or other switch positions For the purpose of testing the switch position holds the same capabilities as the whole product without switches does SWITCH lt s_switch_name gt lt s_switch_label gt In the example below the anonymous switch position has a net list of three single point nets and will perform a HiPot on them The low voltage and HiPot parameters are the global ones specified at the cable level but a local override will force the HiPot on the single point nets SWITCH HIPOTNC NET NE vr NET 1 21 1 3 In the example below test program with switches is depicted CABLE TEST1 1 STAR ONFAIL IGNOR THRESHOLD 61 ADAPTER HA 138 POSITION B1 J5 D BI O ADAPTER HA 138 OSITION B1 J6 ROMPT Connect probe to first position E SW U H NET B1 J5 C1 9 81 026 2123 NE 7 1 25 1 10 1 26 1 1 SWITCH PROMPT 9 28 Horizon Series Tester Programmer s Manual Scripting Featur
270. sic Programming and Testing 4 6 Automated Start Test By default the Horizon is setup to begin testing once a product is inserted in the required adapters The default setting is 61 of product insertion At the start of a test when no external controls are in use the system is scanning the test points for product insertion Once 61 of the product is detected the test begins The 61 value is an arbitrary number that is less then 100 and greater than 50 If the test were not to start until 100 of the product was inserted then damaged cables would not trigger the start of the test If the test were to start when 50 or less of the product was inserted then the test may complete and fail before the product is fully inserted you wish to adjust the Start value the option is found Hame lt Eront as on the Set Test Parameters Menu Low Voltage Components High Voltage Net List More Options Print Test Now Cancel ee Select More Options gt Start to enter a new value for eeu the percent of product insertion that triggers the start of test Max Errors OK Do not use 100 since a cable with a fault will never be completely inserted and the test will never be gin If you find that your product is hard to insert and for example requires the user to rock the connectors for proper insertion you can utilize the Scan Delay featu
271. sive leakage of a faulty net This is done by performing recursive group splitting in a 4 Horizon Series Tester Programmer s Manual Appendix C Mass HiPot Examples divide and re test fashion until all faulty nets are identified or the condition disappears e g Test Cycles 2a 2b 3a 3b etc If the FAIL condition disappears on group splitting a FAIL will not be recorded Scenario 4 Bad Product Arc Detected During Mass HiPot Test When an arc is detected during a mass HiPot test the system can either split the group recursively binary iterations or it can default directly to linear sequential or CableTest Systems Inc single phase fault detection The use of binary or linear iterations upon fault detection is a programmable option Linear fault detection may be required when it is not desirable to expose the PUT to repeated arc faults that can occur during the faster binary fault detection routine The binary and linear fault detection methods are illustrated in Tables 4a and 4b respectively Table 4a Bad PUT Arc between 2 nets during Mass HiPot Binary search for fault Test Net Number Cycle Condition 1 Pass 2 ARC 2a ARC 2b Pass Pass Horizon Series Tester Programmer s Manual 5 Appendix C Mass HiPot Examples Table 4b Bad PUT Arc between 2 nets during Mass HiPot Linear search for fault
272. stance a fue Cancel d fires Only Input the hipot test uration in seconds You can specify the desired leakage limit directly as a Current as a function of Resistance or simply enable the Horizon to detect Arcs Only Select Current to enable the Maximum DC HiPot leakage current dialog Enter the desired leakage current paying attention to the insulation specifications for the wire being used The allowable range is from 1 to 5mA Use the arrow keys to change between uA and mA if needed Select Enter to confirm your input and return to the DC Hipot Settings menu If you would prefer to specify leakage in terms of resistance select Resistance after selecting Leakage Limit the Maximum DC HiPot leakage resistance in MQ dialog will appear Input a leakage resistance between 0 1MQ and 1000MQ and then select Enter to confirm your input and return to the DC Hipot Settings menu The last choice is Arcs Only The Horizon will still automatically test for arcs if leakage is specified If an arc is detected testing is immediately suspended the arc is reported and no further high voltage testing is performed on that cable This test will rapidly check for any insulation or other breakdowns Cancel returns to Set Test Parameters with no changes made Selecting Hipot Duration displays the nput the DC HiPot test duration in seconds dialog Enter the length of time
273. ster Programmer s Manual Backups and Restores 8 1 Backups and Restores 8 1 1 Performing Backups The Horizon allows you to safeguard your test programs and adapter library by backing them up to diskette Simply follow these steps From the Main Menu select Backup and then enter a valid password and the Backup Restore Shell is displayed Med Mar 19 1997 09 53 Test _ System Setup Program 1 Backup 1 Edit Adapter i 4 Contrast Shut Down 1 Select removable drive to 0 perform backup restore with The Horizon supports multiple removable media drives REPERTUS Should for example have an external drive attached the unit the system will detect it and request the user to select the drive you wish to backup to or restore from aa Highlight the drive letter and select Ok to continue _ See The Backup Restore Shell offers the user to easily aa perform backups and restores of the test program files and Restore adapter library More Options Cancel A backup transfers the files from the internal hard disk to a floppy diskette while a restore transfers the files from a floppy diskette to the hard disk You are strongly advised to perform backups regularly This is especially important after learning a new product after performing a change in a test program or after defining a n
274. ster Programmer s Manual Basic Programming and Testing 4 1 Introduction Most cables and harnesses are composed of wires of various types originating at or terminating to any of a variety of connectors These cables also do not typically contain any embedded components such as resistors diodes and capacitors As a result the most common set of test requirements are for the test operator to determine as quickly as possible whether or not the cable or harness has any shorts or opens or if any wires are connected to the wrong pins It would also be desirable if the tester and the test equipment used could provide additional information such as the location of the fault to the rework technician The Horizon was designed with these facts in mind The default learning path and the resulting tests are fast easy to use and understand and provide the needed information for most applications 4 2 Learning the Cable CableTest refers to the process of programming the Horizon to test a cable as learning the cable The reason for this term is that this is almost literally what the operator does Starting with a known good or golden cable or harness the user is guided through a series of simple steps during which a parametric profile is made of the cable that is then stored as a simple ASCII file After that anytime an operator wants to test an identical cable or harness these parameters are loaded from the file and are used as the basis f
275. sults are included only when a product passes Fail Results are included only when a product fails Pass Fail Reports are generated for both Pass and Fail products however results are excluded from passed products and included on failed products All Results are included for both passed and failed products The Test Parameters button toggles the check mark to be present or absent in the neighbouring square Present the reports will include a list of the test parameters you have set absent they will be excluded 7 1 3 Autodiagnose Selecting Auto Diagnose toggles between 5 options The result of setting Auto Diagnose automatically opens the Test Results display at the end of each test with the display option selected here None Does not include any results in the report should the cable pass or fail Pass Results are included only when a product passes Fail Results are included only when a product fails Pass Fail Reports are generated for both Pass and Fail products however results are excluded from passed products and included on failed products All Results are included for both passed and failed products 7 1 4 Header and Footer Header and Footer information can be added to the Printed and Logged reports The Header and or Footer can exist in two manners 1 The first is on a per test cycle basis 7 6 Horizon Series Tester Programmer s Manual Reports and Batches 2 The second is on individual test cable basis S
276. t Source On Manual 1660mA 20 GU Checking the High Current Source Resist Source On Manual 1660mA 28 0 Checking the High Current Source Mode Auto Current 1660mA Source Checking the High Current Source Mode Current Auto 1660mA 999m 166m 168mii Source On Calibration History EB Horizon 1500 IH Calibration Menu Thu Oct 99 1997 91 57 PM 4 CONTRAST SHUT DOWN Calibration System Setup TIME amp DATE PRINTER SETUP REFERENCE VALUES CALIBRATION HISTORY Using the Calibration Verification Tool place a voltmeter across the jacks Select Source On Check the voltmeter reads the correct voltage and compare it to value read by the Horizon in the shaded area on the screen Select Source On to turn off the High Current Source Select Mode to return to Auto Select a low value resistor example 0 1Q and place it between the jacks of the Calibration Verification Tool Select Source On Check the measured value of the resistor shown in the shaded area to the known value of the component Once you have performed calibration verification for the first time on your Hor
277. t ID location If this value is what you expected select Enter to accept it In the example shown it is 15000 resistor Enter The Number rectors Input the number of connectors mounted on your adapter Remember there is no restriction as to the number and type of connectors that can be used on one adapter so long as the total number of test pins does not exceed the maximum for the adapter type selected 32 for a Single 64 fora Double and so on In the example shown there are a total of 2 connectors mounted on the adapter Select Enter to access the Enter Connector 1 5 Name menu 6 6 Horizon Series Tester Programmer s Manual Adapters Input a name for the first connector This name be up to 30 characters length and can consist of any character It is good practice to base this name on some easily identifiable feature of the connector such as its type color manufacturer s part number etc After you have finished select Enter to access Enter Connector 1 S Nr Of Pins Input the number of test pins associated with the first connector Select Enter to go to the Enter Connector 1 S Netlist dialog You now need to map the Horizon s internal pin switch designators to the connector pin number E2768 Kelvin
278. t Settings DK This is done for two reasons 1 To speed up the test since the system doesn t have to consider open nets or 2 to prevent the programmed high voltage from possibly being present at open leads It is important to remember however that the Horizon can perform HiPot tests on flying leads Just remember not de select this option Selecting Password Protected a check mark is shown means that an Operator level password must be entered before high voltage testing can proceed Cancel returns to Set Test Parameters with no action taken while Ok implements the desired setup Discharge Delay affects both AC and DC HiPot testing Selecting this option allows the user to control the discharge of the PUT By default the Horizon discharges the PUT as fast as possible Programmable Discharge Delay values 1s to 1200s This option is only available after an AC or DC HiPot has been programmed Selecting AC Hipot Settings brings up the AC Hipot Settings menu DC HiPot testing is discussed in section 4 36 nat Installed If you do not have a high voltage AC source installed or if it Hirot jO LEeeseeses is installed incorrectly the AC Hipot Settings menu will T indicate Not Installed Contact your authorized CableTest hirot Duration representative if you are supposed to have the AC HiPot seam 52222 testing capability and you get this message Horizon Series Teste
279. t of their programmable source e g 1A The measurement will be expressed in volts Apply a voltage limit 28V and measure the current drawn by the load Use the Fixed HC source to measure the component voltage reference Use the Fixed HC source to measure the component resistance reference 5 4 3 3 Programming Resistors Advanced Options Testing Lamps Edit Resistor H Horizon s equipped with the optional High Current Source Kelvin can be utilized to test resistive load components e g lamps bulbs From the More Options dialog select Mode Horizon Series Tester Programmer s Manual 5 25 Advanced Programming Naa EE Select HC Load Current and enter the voltage you wish mute nesiskance applied to the component HC Resistance Select Enter to continue For lamps you can also add a visual test to the program From the More Options dialog select Visual to program the components The stimulus options are as follows 12U Source HCS Uoltage HCS Current Fixed volt Fixed Res 5mA Current Utilizes the default Horizon source 5mA with a 5V limit 12V Source Utilizes the Horizon s 12V source with a maximum load of 100Q HCS Voltage Allows the user to program applied voltage
280. t passes Remember that although the exact duration of the dwell cycle is unknown it will be between 0 and the programmed duration Soak The Soak dwell cycle type is used to define a maximum soaking time before the actual dwell cycle starts To program a soaking time toggle the Dwell key until the Inout DC Hipot Soak Duration dialog appears Enter the time in seconds maximum 59999 Using a programmed Soak time guarantees that the HiPot cycle will last at least the amount of time programmed as HiPot Duration The programmed leakage current or IR is monitored during the soaking time and if it drops below the limit or the IR increases over the limit the programmed HiPot duration time is entered immediately The soaking time is a maximum limit that will only be used when the leakage current doesn t decrease fast enough Use this option for applications where the product exhibits moderate to high soaking characteristic but the dwell time must be guaranteed 4 48 Horizon Series Tester Programmer s Manual Basic Programming and Testing Test Program as CBL File datab cables main testca 3 cbl For greater detail see section 9 CABLE TEST CABLE 4 NET QUICKCONTINUITY 21561222 QUICKISOLATION 33 61242 STAR NET THRESHOLD 61 DCHIPOT 500 33 61 13 LEAKAGE 0 0001 NET DWELL 0 1 J1 C1 14 SOAK 5 J3 C1 14 MASS NET ADAPTER 116 1597 PO
281. t select the Resistor option within a custom learn Select Add to manually enter this component Add as many resistors as you have in your product Adding resistors increments existing resistors by 1 Each new resistor will be R1 and the current R1 becomes R2 the current R2 becomes R3 etc Highlight the first and select Edit The Edit Resistor dialog opens with no information present Select Terminal 1 to assign it the proper net Horizon Series Tester Programmer s Manual 5 21 Advanced Programming 2 5 ecl Cancel Edit Resistor More Options Label OK omit min max 2 Cancel Twisted Edit Resistor Terminal 1 41 1 1 Terminal 2 lt Ji Ci Omit min max E More Options Label OK 1 Edit Resistor Terminal 1 41 1 1 Terminal 2 lt lue Omit min max Test OK 1 44mi More Options Label The Select Net dialog appears Using the arrow keys scroll the cursor to highlight the correct net pin location for Terminal 1 Select Open to select a pin Highlight a pin and select Ok to accept the locat
282. tches A check mark appears and Select becomes active Use Select to indicate the type of Palm Switch you have Horizon Series Tester Programmer s Manual 3 23 System Setup One Palm Sw single switch Two Synchro Two switches that must be pushed at the same time Two Asynchro Two switches that can be pushed in any order One Temporary A switch that only needs to be pushed momentarily Two Temporary Two switches that only need to be pushed momentarily in any order and Enclosure Sw switch associated with an enclosure that covers the top of the Horizon All of the Palm Switches with the exception of the two temporary configurations must be pressed and held closed for the duration of HiPot testing or the high voltage source will turn off In addition the Horizon checks the condition of the switches at the start of the test if they are already closed such as might happen if they were taped down the high voltage tests will not start Select Ok to return to the System Setup menu B This completes the system setup procedures Don t forget that dad can return here any time to change any of the setup General parameters Scan Delay Palm Switches Service 3 24 Horizon Series Tester Manual 4 PROGRAMMING AND TESTING Wire Only Cables and Harnesses UU CABLETEST Basic Programming and Testing 4 2 Horizon Series Te
283. the Scan Delay Settings menu 3 12 Horizon Series Tester Programmer s Manual System Setup Select Ok to return to the System Setup dialog unless you also want to program an extract delay Extract Delay The Horizon computes all Pass Fail statistics and re arms itself for the next test as soon as it detects that the product has been extracted If you have a product that is difficult to extract you may want to program a delay between extraction and re arming in order to prevent erroneous results Extract Delay allows you to program this time The allowable range is 0 1 seconds to 60 0 seconds Select Enter to accept your input and return to the Scan Delay Settings menu then select Ok to return to the System Setup dialog Another case in which the extract delay is useful is if you are testing a product composed mostly of components In this case the Horizon could mistakenly think that the product has been disconnected at the conclusion of the test and automatically re arm for the next test immediately before you have time to examine the diagnostics Programming an extract delay will give you time to review any diagnostics Auto Extract Resets the Horizon for the next tested product if the Diagnose screen is showing when the current product is removed 3 6 Service The Service button allows access to the Service Settings module Print Setup 5 Once you have setup the Horizon as per your requirements Ea a it is a
284. the default ELE a language for the Horizon Remote General 5 To install the Advanced NetList Editor select Install Netlist Install Netlist Editor a Install TCL Package Editor Uninstall Netlist Editor Uninstall TCL Package Language OK Select Yes to continue to install the Advance NetList Editor Pr The Package Installation Warning menu will appear install package No will return you to the previous menu 3 6 Horizon Series Tester Programmer s Manual System Setup Package Installation his package was previously uninstalled from the system To continue the installation An override key may be obtained by contacting the actoru Enter Override Keu provided override key is mot valid Tru again 9 i JL2 Ls Js a 5 7 1 BEER Le JL Registration The provided registration key 15 not valid Try again General Setup Pushali Metida Editor Install TCL Package Uninstall Netlist Editor Uninstall TCL Package Language OK 1 you want to H install package You must contact the factory to get the Override Key The Registration Key was provided
285. the system that the adapter called AATEST is to be used The second line specifies where on the test bed the adapter is placed As a reminder the adapters used by the Horizon are classified by size in four categories Single for up to 32 test points per adapter placed at J1 J2 J3 or J4 Double for up to 64 test points per adapter placed at J5 or J6 Quad for up to 128 test points per adapter placed at J7 Huge for up to 1024 test points per adapter NA If your system contains expansion boxes adapter positions will also be defined by a box number E g B1 J3 refers to a single adapter placed at position J3 on the first 128 point box or B3 J7 refers to a quad adapter placed at the third 128 point box 9 6 Horizon Series Tester Programmer s Manual Scripting Features Except for the Huge adapters the others can be physically placed in more than one position on Horizon s test bed some limitations apply Therefore it makes sense that the position of the adapter is specified The Huge adapters are more like a snapshot of the total number of test points and their position is always implicit specifying it explicitly in a test program is considered syntax error A test program snippet using a huge adapter is shown below CABLE A FICTITIOUS CABLE 1 ADAPTER A FICTITIOUS HUGE ADAPTER Please note that the ADAPTER line is not followed by a line If more than one non huge adapter
286. thin CableTest engineering specifications Measurement of capacitance up to a specific location for increased measurement accuracy The numbering lettering of connector pins using a specific sequence Emergency Power Off Faulty End Recognition a unique feature of the Horizon that enables the operator to quickly and easily locate low voltage shorts anywhere along the length of a product A special test parameter that allows the operator to manipulate the cable while the Horizon searches for opens mis wiring and shorts In many cases faults only occur intermittently depending on the cable position Any product that is terminated at one end with accessible contacts at another location The application of high voltage either DC or AC to a product Accurate low resistance measurement of a conductor or resistor The method uses four wires instead of two simplex Groups of test points sorted by their connections An optional safety feature available for the Horizon The default setting for low voltage tests of a product The scan performs a standard isolation and continuity test on your product Measurement of resistance up to a specific location for increased measurement accuracy An optional product available for the Horizon The Smart Probe currently works in conjunction with the Build Aid feature and with the Net List Editor Included tool with the Horizon to use with the Build Aid feature of the Horizon Horizon Series
287. to the load up to the limit of 28V and 1A HC Load Current Allows the user to specify the current applied to the load up to the limit of 1A and 28V Fixed HC Volt Utilizes the Horizon s Fixed HC source 1A with a 4 2V limit Fixed HC Res Utilizes the Horizon s Fixed HC source 1A with a 4 2V limit 5 26 Horizon Series Tester Programmer s Manual Advanced Programming Stimulus Visual Fully programmed resistive load with visual test 5 4 4 Testing A Cable With Resistors Testing a product with embedded components is the same as testing any other cable or harness For details consult Testing Cables in Section 4 Test Configuration File Name les MAINSRESISTOR CE Part Number HESISTOR Tools Reports select Test Nou Batches Cancel Insert the Adapter s H JL J2 i ii Tested Passed Failed Error Statistics Diagnose Start Test Cancel Resistors 100 Tested i Passed 1 Failed Error Statistics Diagnose Start Test Cancel The display shows the Directory location and the Part Number for the last cable tested If this is the product you want to test select Test Now otherwise press S
288. ts will be listed ERIT shes USD If a fault is reported contact CableTest s Customer Support fos Tout 654 Emm Grou sns67 sus64 p HV Tests If the user suspects a faulty HiPot or High Current Source during testing they use this built in feature This option will only be enabled if a HiPot or HCS is installed in the Horizon aoa Su CREE For the High Voltage sources select AC Hipot Test or DC AC Hipot Test Hipot Test DC Hipot Test HC Hipot Test OK Horizon Series Tester Programmer s Manual 3 17 System Setup Action Required Remove all adapters CUT or MUX cards An isolation test for all the available the system will be performed Do you want to test on linear 7 1 Test Report Reported Results Pass Fail Test Program 91 01 1970 00 00 00 arc Nettc Service Settings AC Hipot Test DC Hipot Test Hipot Test OK Remove all adapters or product for the Horizon A safety isolation test is performed follow the procedure shown above If the isolation test passes you are prompted to enter the voltage you wish to test at Enter the voltage AC or DC depending on which source you are testing and select Enter to continue Select whet
289. u to specify exactly on which nets to perform certain additional tests such as a HiPot test if you do not want to perform these tests on the whole cable This will be explained in detail in the next chapter The Edit lt Alt E gt function will also be explained in detail in the following sections The single arrow keys move the cursor one line at a time while the double arrow keys move it a page at a time The Label lt Alt L gt button allows you to replace any or all the standard NetList descriptors with natural language descriptors of your choice Selecting Label lt Alt L gt the Edit Label is 4 s dialog also accessed with the Open Alt O button allows oven 12 992 you to rename the individual elements of the net such as connectors and pins while selecting Label lt Alt L gt in the Edit Net dialog allows you to rename the entire net For example you might name an element red wire or red wire with white stripe and name the entire net signal 1 You can use any alpha numeric or symbolic character so long as the name does not exceed 30 characters in length Label lt Alt L gt will also be discussed in detail in the following section When finished entering any desired labels select Ok Enter gt twice and the Save Cable Record dialog appears Select Yes Enter gt to save your cable record The Save To Directory dialog appears Th
290. ual Advanced Programming EN Programming Cable Modify Existing Cable Learn New Cable Default Learn New Cable Custom fidvanced Hetlist Editor EN Learn Settings Twisted Nets Only Free Ends Kelvin Use Kelvin Probe Cancel OK Insert the Adapter s H 116 Ji 1 HA 116 E mri 6 Select cancel OK EP Learn Cable Insert the ane product then press OK to continue y Learning Netlist Es Test Points Found 14 Mii Select Naming Rule Select Pin Naming Rule __ To begin to learn cables with free ends select Program Cable from the Main Menu enter your password then select Learn New Cable Custom and the Learn Settings dialog will be displayed Select Free ends a confirming check mark appears then follow the normal learning process The system automatically detects the appropriate adapter or select and place the adapter for your test Insert the Product Under Test PUT The complete NetList is learned The user is prompted to configure the Flying Lead test Selecting Pins prompts the user to select a naming convention from the convention files The pins of your product will be numbered a
291. unctions Menu items that are password protected display a small key Jin the upper right corner The password system is designed to prevent untrained or unauthorized people from inadvertently modifying test programs or vital system parameters If desired however you can disable password protection From the Main Menu select System Setup then select Passwords 19 1997 09 53 Test _ System Setup Program Cablel Backup 1 Edit Adapter i 4 Contrast Shut Down Horizon Series Tester Programmer s Manual 3 21 System Setup a Password Settings EE S1 nra 1234 nes 234 Serr Enable can then be selected to enable or disable password protection An associated box displays the status of password protection A checkmark indicates that password protection is enabled ESIE EA Delete Enable m Ada cancel OK isi When password protection is disabled the box beside the Enable button is empty assword 1233 234 Ses ea Delete Enable 7 Add Cancel OK EN Main Menu Hi In addition when passwords are disabled the key symbol Med Mar 19 19 97 99 55 Test Self Test Sustem Setup Program Cable Backup Edit Adapter Contrast Shut Down His no longer displayed on
292. using the TCL language and run instead of the internal algorithm 9 12 Horizon Series Tester Programmer s Manual Scripting Features If the ISOLATION keyword is not found in the text file then the default Quick Scan method is used The isolation Quick Scan and resistance measurements work globally They can be specified globally at the cable or section of cable switch position level only The syntax and options related to the isolation test are described below ISOLATION lt d_min gt In the example below the isolation threshold was set for all the nets to 1MQ Any isolation resistance measurement that is below the minimum limit fails Any measurement that is above the minimum limit passes The isolation minimum limit must be always given in Q ISOLATION 1e6 A special case is when an empty field is specified after the ISOLATION keyword In such a case no isolation test will be performed at all This may make sense in conjunction with the flex test which is described below or in some cases where something else other than a cable is tested i e printed circuit board loaded with active components and the final goal is achieved by running other tests The example below specifies that the isolation test is not to be performed ISOLATION Flex Test Parameters Sometimes it is desirable that intermittent contacts or shorts are found in a product at test time The Horizon Flex test is designed just for that The
293. values 4 Horizon Series Tester Programmer s Manual Appendix D Calibration Verification Edit Reference lues RESISTOR 1 000 1 99 9 E Raj 10 08 1 000 M 1 001 10 00 M Edit Reference Values CAPACITORS Es Ez z 161 pF 9 960 nF 1 023 nF 77 038 nF Enter the new password 1234 Elear pm se Enter nal Esc Select the resistor value you would like to alter Refer to the schematic of the calibration board to select the correct resistor Select REF CAPACITORS from the Modify the Reference Values menu to alter their reference values Select the Capacitor you would like to alter Refer to the schematic of the calibration board to select the correct capacitor Select PASSWORD from the Modify the Reference Values menu to select a new password to protect your reference values calibration using the internal reference components UNCIAS select calibration verification press CALIBRATION on the Thu Oct 09 1997 91 57 CONTRAST SHUT DOWN LE SELECT THE SOURCE OF THE REFERENCE VALUES INTERNAL EXTERNAL CANCEL Select the tests Start Cancel 44 Calibration Menu Select INTERNAL to
294. verify the systems calibration Currently calibration cannot be done in the field Should a problem appear contact Horizon Technical Support at 1 800 495 1998 X240 General Overview The calibration equipment consists of a calibration board and an accompanying disk containing the software that works with the calibration board The calibration board contains resistors and capacitors that are carefully selected to be precise and stable over time The exact value of each resistor was measured using a FLUKE 8840A and four wire mode The exact value of each capacitor was measured using an LCR meter type SR715 manufacturer Stanford Research Systems These values are stored in a file on the disk and used to compare the measured values against the tolerance limits accepted for the tester The accompanying disk must be used with its designated board and they can be confirmed by comparing the serial number displayed on the calibration board cover with the tester s display at the start up time Along with the resistors and capacitors a voltage surge protector and a diode are included on the calibration board to check the capability of the system to accurately detect active components and high voltage arcs provided the unit has the high voltage testing capability A pair of external jacks provides the user with the capability to check their own external components Also if the unit has the high voltage testing capability the user can check these
295. void the risk of shock or personal injury do not remove the product covers while the unit is operating or connected the AC mains Use only a power cord rated greater than the input current rating of the external power supplies Use only in good condition If liquid is spilled on the unit shut it off immediately and disconnect it from the AC mains Ensure the unit is properly grounded using a reliably grounded AC mains input at the external power supplies Do not touch any exposed wiring on your product under test PUT while the High Voltage lamp is illuminated For additional safety it is recommended to use an approved EPO Emergency Power Off switch during High Voltage testing 1 4 Horizon Series Tester Programmer s Manual Introduction 1 4 Built In Safety The Horizon Series Tester has built in safety systems Interlock EPO Emergency Power Off switch connected to the Horizon s I O can be used as emergency high voltage shut off Software Safety The H1500 will not perform a High Voltage test on a product that has failed either continuity or isolation By default the software pauses before running a High Voltage test The operator is prompted to continue The operator prompt before High Voltage tests can be disabled enabling it allows an immediate High Voltage test to follow a passed Low Voltage test CableTest Systems Inc does not take responsibility for injury caused by the Autohipot opt
296. wards Error Reporting for LEDs and BI LEDS same error messages apply to LEDs and BI LEDs prior to the visual test Should the component pass the initial test and fail the visual test the Diagnostics will report a failure 5 7 Four Wire or Kelvin Testing 5 7 1 Introduction There are two methods for creating Kelvin measurement test programs for the Horizon The first method is to utilize the Kelvin adapter features discussed in section 6 If you choose to learn your test fixture as a Kelvin adapter you need not read this procedure The second method would be to utilize standard Horizon adapters and learn your Kelvin fixture for a specific test program 5 52 Horizon Series Tester Programmer s Manual Advanced Programming Learn Settings Twisted Nets Only Free Ends onductor Max Res SR Use Kelvin Probe Kelvin Cancel Resistors Capacitors Diodes Switches Back Cancel x Insert The IH J J4 116 miri Cancel Ok insert without cable and the press 0 You be prompted Fixture sample after wi the Fixture has been learned remove m unless you are he fixture prompted to Learn a New Cable Using Kelvin Measurement
297. will disappear when you insert the calibration board This feature is especially useful when you want to compare specific measurement on all the MUX cards available on your system The 6 resistance values are measured by the Horizon and compared to the list of reference values The 6 value of 10 is at the end of the tolerance spectrum for the Horizon and will have a tolerance of up to 1096 from the reference value Press Ok for the next test Prior to performing the Capacitance Verification the user is prompted to remove the Calibration Verification Tool from the unit to perform a capacitance tare Remove the tool and select Ok When prompted replace the tool and select Ok to continue The second test capacitance measures the 4 capacitor values and compares them to the listed reference value Press Ok for the next test 6 Horizon Series Tester Programmer s Manual Appendix Calibration Verification Checking the diode Diode detected UF 73 mu Print result High Voltage Tests current measurement arcs detected current measurement arcs detected Print result The third test is a diode test The test notes the diode orientation a successful test and measures the forward voltage The fourth test is a high voltage test measuring the AC and DC currents and the detection of AC and DC arcs The system continuously sca
298. will completely test the first configuration Regardless of the Palm Switch settings set within the System Setup you Switch to advance the Horizon through a test with switch All programmed tests are performed If the test for the first configuration is successful the Horizon will display any required prompts for the next configuration Select Ok or use the Palm Switch to continue All programmed tests are performed Programmer s Manual Advanced Programming If the system passes the second switch position the operator is prompted to disconnect the product to reset the system Tested 1 for the next test Error Statistics Diagnose Retest cancer YOu may select Retest to test the current product again If your test included specific values for Continuity or Isolation or if you ran a Linear Hipot test you can select Diagnose to view the results 5 8 7 Prompt Abort Ignore Retry Under General in the System Setup user s of the Horizon have the option to enable and disable a feature specific to Switch Tests Retry Abort Ignore d The option is labelled FAIL Please review section 3 for greater detail on setting the option Abort Should a product with multiple states switches have a failure the test will abort and the product fails Retry Should a product with multiple states switch
299. witches 3 23 Passwords 3 20 Progress 3 5 Relay 3 5 Reset 3 5 3 14 Scan 3 12 Service Options 3 13 Sleep 3 5 Time and Date 3 4 Touch Screen Diagnositc 3 14 Update rne 3 14 Volume 3 5 Horizon Series Tester Programmer s Manual T Test 402222 2 9 Testing Your Cable 4 7 Capacitors 5 38 Connect Product Start 2 9 4 8 2 8 4 9 Diodes tees 5 50 Disconnect Product 2 9 Error Statistics 2 10 4 9 Flex Test ie renes 4 29 Kelvin Measurements 5 54 LEDs amp BI LEDS 5 51 Loading the Test Code 4 7 neat 7 3 oit i ts 5 27 2 10 4 8 Selection eae aden 2 8 4 7 Stait eie 4 8 5 67 Test Configuration 2 8 Test NOW
300. y Filets 6 12 Horizon Series Tester Manual Adapters another diskette You will be prompted whether you wish to restore from another disk If you have no other files to restore or copy to the database select No 6 5 1 Special Case The Kelvin Adapter Should you wish to define your adapter as Kelvin please see Appendix F Case Studies for an explanation of Kelvin the Kelvin feature must be enabled before probing adapter points 1 Edit Netlist 9 2 2 2 22705 mn Edit Print OK Conn Pin Sus Pin Sense 1 46 2 g iv 25 1 3 12 El 12 1 Edit Print OK Select Kelvin on the Edit Connector s Netlist dialog in order to ensure a Kelvin connection is learned A check mark will appear next to the option By defining an adapter as Kelvin you are essentially assigning two system pins to each connector adapter pin In this scenario both column one and column two will have system numbers assigned It is important to remember that the number of system points it will utilize defines the size of an adapter In the case of an 18 pin connector defined in Kelvin 36 system pins are used That makes the adapter a double as opposed to a single Adapter as ADP
301. yed automatically for failed cables only The passed cables will only display a brief Pass message The ALL specifies that detailed test results are to be displayed automatically for both passed and failed cables If none of the PASS FAIL PASSFAIL and ALL options is listed then no test results would be displayed automatically The AUTODIAGNOSE coexist with either one of the PRINTER and FILE options Test Parameters Reporting the test parameters test limits can be enabled by using the syntax described below REPORTS TESTPARAMS When included in the test program the TESTPARAMS keyword enables the printing of test parameters When omitted the test parameters will not be printed Serial Numbers The serial numbers can be enabled using the syntax described below REPORTS SERIALNUMBER FAIL AUTO 9 22 Horizon Series Tester Programmer s Manual Scripting Features When included in the test program the SERIALNUMBER keyword enables the serial number printing The optional FAIL specifies that a serial number is to be generated for failed products too If omitted from the test program the serial numbers would only be generated for the passed products The optional AUTO specifies that the serial number is to be automatically generated started from an initial value entered by the operator The operator will also specify the part of the serial number that gets increm
302. you are adding or removing expansion boxes from the Horizon it is imperative a capacitance tare is performed Normally when editing the Boxes setting in the System Setup Cap Tare and Res Tare will automatically be initiated 3 10 Palm Switches Palm switches can be of several varieties and they can have different functions If you have purchased palm switches or are implementing an enclosure switch or other safety device set up their function by selecting Palm Switches from the System Setup The Palm Switch Settings menu will be displayed Start Test TETUER Start Test links to the solated Inputs menu described above Select v 55 P in and sets the Palm Switch to Start Test Selecting Ok on that menu returns you to this menu and a check mark in the small box will show the change To disable this feature reset it in the solated Inputs menu Autohipot Enables HiPot testing to start automatically as soon as the cable has passed all of the low voltage tests A check mark in the small box indicates the feature is active To disable it select Autohipot again v Selecting Autohipot will cause HiPot testing to start automatically as soon as the cable has passed all of the low voltage tests caution should be taken to prevent shock HiPot tests will not be performed if any low voltage test fails In order to use Palm Switches activate the feature by selecting Use Palm Swi
303. ystem Setup Program Cable Backup Edit Adapter Contrast Shut Down Programming Adapter Modify Existing Adapter Learn New Adapter Test Adapter Advanced Netlist Editor From the Programming Adapter menu select Test Adapter 6 10 Horizon Series Tester Programmer s Manual Adapters Using the standard ground probe for the Horizon touch all the pins on the adapter to verify they have continuity to system pins and to verify whether any shorts exist or if Kelvin connections are all existent and correct Once complete select OK to return to the Programming Adapter menu 6 5 Connector Pin Conventions Connector pin conventions can take many forms The Horizon allows the user to create their own conventions and add them to the convention database To add conventions you need to first create the file On a computer use an available text editor MS DOS Edit Windows Notepad or Wordpad There are only 3 absolute requirements for the file 1 The string CONVENTION must start the file along with a name for the convention and the number of pins it supports 2 The file must have the extension CNV 3 The file must be stored in the CONVENT subdirectory of the Horizon database EXAMPLE CONVENTION AN EXAMPLE 25 a b g h k m n 5 t
304. ystem will indicate testing progress by displaying a horizontal bar graph that visually tracks the continuity and isolation tests as they are performed Horizon Series Tester Programmer s Manual 2 9 Getting Started If you do not see the progress bar then it may be disabled on your Horizon See section 3 System Setup for more details on enabling the progress bar Assuming that you are testing the same cable learned in the previous section you will be returned to the TEST CABLE menu after testing is completed the green PASS light will be lit and a flashing message will instruct you to Disconnect the Product Note that the display has changed to indicate that you have tested one product and that one passed At this point you Tested Passed Failed I may want to experiment with cables containing different kinds of faults to fully explore how the Diagnose lt gt button will Error Statisties pias ese track all fault locations and how the Error Statistics lt Alt S gt Lees key reports cumulative statistics on type and number of faults found The Retest Alt T or Enter gt button allows you to perform the same series of tests in the event that you discovered some problem in the test setup The act of fully connecting a cable automatically starts the test while disconnecting the cable automatically re arms the syste

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