Home

Setup - Artisan Technology Group

1. Tester 82 Configuration om Browse to the location of your files n rant hos ttam If you selected all files compressed and bundled into a single file multi select the files you want to be in the bundle and click Open i If you selected each file compressed into it s own file select the desired file and click Open Insert a thumb drive into your PC and browse to the thumb drive location If you selected all files compressed and bundled into a single file give the bundle of files a name a file name with the maximum of 8 characters and click Save If you selected each file compressed into it s own file the file name will be auto generated Click Save Transfer the thumb drive from your PC to the tester and power on the tester Import the wirelists from the thumb drive into the tester see Importing Compressed Wirelists Script Files on page 28 Tester 83 Configuration SPC Data Collection SPC stands for Statistical Process Control pertaining to a series of ways you can manage a collection of data SPC Data Collection allows you to store the following information These data elements are always stored as part of SPC Data Collection Run Number Analyzer Serial number Cable Description if defined Cable File Name Operator Name if defined Date and Time tested Signature OOUOUWUUWUOUOUD These data elements are stored as part of Summary data Total Tested Total Good
2. When you copy test programs to your PC via thumb drive you can rename your wirelists with custom file names and then copy them back to the tester How file names function a If you copy wirelists to the tester via thumb drive custom file names longer than eight characters will be truncated O The first six characters will display Tools Help followed by a right arrow and a number A m Search E Folders mE For this reason Cirris recommends keeping custom file names to eight KTilename WIR E example WIR characters or less To view custom file E custonC WIR names up to 16 characters you can compress your files with Cirris compression utility see 1100 File Compression Utility on page 82 a File names MUST be followed by dot WIR for the test program to appear in the tester a If you choose not to rename a wirelist that is copied to your PC the file name will be based on the memory location you saved it in For example a test program saved in memory location 1 will be MEMO001 WIR in memory location 2 it will be MEMO002 WIR and so on Inthe tester the name will again appear as the cable signature in the memory location that the file name indicates on the PC a Inthe tester custom file names will no longer be in a memory location They will display above the list of memory locations Using the 24 Tester Creating Folders On your PC you can organize test progra
3. Total Bad Error Types Summary Custom per group if stored in Scripting Custom per Cable if stored in Scripting D ODODO These data elements are stored if Values is turned ON OW Net or Instruction Label O Net or Instruction Measurement These data elements are stored if Error Text is turned ON O Error Number OY Error Code O Error Type Q Error Text Additional data elements may be stored using Scripting in conjunction with SPC Data Collection To use SPC Data Collection you must do the following Activate SPC Data Collection Enable SPC Data Collection store SPC Data by performing tests Retrieve and analyze SPC Data using SPC Link or SPC Made Easy eS Activating SPC Data Collection gt 1100 Utilities ersion 1 0 Activate through the Option Manager tab in the 1100 Utilities Application Teer EOS TON se EAE en eens et Tester 84 Configuration Enabling SPC Data Collection 1 From the main menu press Set Up Test Program 2 Press EDIT 3 Press Set Up SPC 4 Press SPC Data to enable SPC Data Collection When SPC Data is enabled you can select which Values and Error data you wish to be stored by turning Values and Error Text ON or OFF lt _J Li Storing SPC Data by Performing Tests Before you can collect SPC data you must first create a folder named spc_data on the root of either a thumb drive or network drive if you are using a network drive the spc_data fold
4. Withstand Test the tester continues to apply the high voltage potential for a period up to the value of a max soak setting Overview of Preferences and Settings Fourth Insulation Resistance Test During this part of the high voltage test the resistance of the cable insulation is measured to assure it is greater than the insulation resistance setting Whereas the Now let s do an accurate check to Dielectric Withstand Test checks for arcs at the high see how much water leaks from the voltage setting the Insulation Resistance Test checks hose We can carefully monitor the for the gradual flow or leak of electricity An example of water flow and determine how well an error that would cause this test to fail would be an the hose holds the water inferior grade of wire insulation and contamination between connector contacts Humid conditions often lessen the measured insulation resistance of a cable DC High Voltage Test Overview These charts give a more technical overview of what happens during a typical DC high voltage test for a good cable S High Voltage Setting Voltage Time Current must be below this level for the cable to lt pass the Insulation TR Resistance Test Current The Voltage Ramps Up As the voltage rises to its High Voltage setting Insulation Resistance Test The tester uses current and current is limited for safety Optional High Voltage Soak voltage to
5. a From the main menu press Set Up Test Program b Press Create New Test c Press LEARN 3 Verify there are no connections a Press CONTINUE LEARN 4 The test program is ready for use a Save the learned test OR Start testing Using the 19 Tester Documenting a Test Program It is important to document a test program to Know what the program is and where it is located To document a test program 1 Create a test program as described in the previous section 2 Ifa printer is connected print the results a Scroll down w to view the print option b Press Print If a printer is not connected transcribe the results a Press Verify Test b Scroll down and record the information on an 1100H Cable Documentation Form blank form in appendix Using the 20 Tester Testing a Cable 1 Make sure the test program for the cable being tested is loaded Load a different test program by a Creating atest from a sample cable OR a Retrieving a test from memory 2 To duplicate the adapter setup from the Original test do one of the following a Refer to the documentation used for the test or c Press Test for the loaded test program d Press Show Required List 3 Attach the cable to be tested and start the test a lf you have not done this already press Test for the loaded test program b Attach the first cable to be tested 1100R Cable
6. Available only when Hipot Test Advanced mN is selected 1990 unit 50V 100V 200V 300V 400V 500V 630V 800V 900V 1000V 1500V Unit 50V 100V 200V 300V 400V 500V 630V 800V 900V 1000V 1100V 1200V 1300V 1400V 1500V DWV Voltage determines the voltage that is applied to each net in the Dielectric Withstand Test where gross hipot failures such as arcs and breakdown conditions are detected This setting is often dictated by a customer or engineering specification If you do not have a specification the High Voltage guidelines for the settings page 50 are applicable to this setting DWV Max Current Selections Available only when Hipot Test Advanced ieclactad 100UA 1mA 200UA 0 2mA 500uUA 0 5mA 1mA and 1 5mA DWV Max Current determines the maximum current that is allowed to flow out of each net during the Dielectric Withstand Test If current flow exceeds this setting the tester will fail the tested assembly and display a dielectric error indicating an arc or insulation breakdown DWV Max Current Guidelines The DWV Current setting is often dictated by a customer or engineering specification If you don t have a specification here are some general guidelines a Use a lower setting to provide a more stringent test but too low of a setting may cause false failures Q Cables with higher internal capacitance may necessitate using a higher setting especially if you are testing with a V
7. You will need a computer that can provide a serial interface for your tester If you do not have a computer with a serial port you may use a USB port with a Cirris qualified Keyspan USB to serial adapter A serial cable is provided with the CTLWIN kit you received with the tester To download the upgrade file from the Cirris FTP site 1 Type the URL ftp ftp cirris com 1100 in your web browser 2 Double click on the file 1100_verx xx exe where the x xx is the current revision 3 Inthe File Download dialogue box that comes up click Run to install the 1100 Upgrade software or click Save if you will be installing the software on other stations The software installation should take a few seconds When the software Is installed an 1100 Upgrade utility icon will appear on the computer desktop To run the 1100 Upgrade Application With the tester turned ON and connected to the computer double click the 1100 Upgrade Utility icon In the Download Utility screen select a language and click Download When the download is complete the tester will reboot with the selected language and updated software Tester 79 Configuration 1100 Utilities Application The 1100 Utilities Application has two tabs The Security Manager tab allows you to lock or unlock specific tester menu selections The Option Manager tab allows you to enable additionally purchased options such as scripting AC and SPC Data Collection gt 1100 Utilities Yersi
8. 1 Each tick signifies a good low and emit a Tick Tick Tick sound _ Voltage test of the cable If the cable fails a The red LED will light up a The screen will display the type of error a You can press View Errors to see the detailed error message N Single Beeps open id Two Beeps short Q The tester will sound an error tone Three Beeps miswire based on the type of error ani Three Beeps high voltage error For more information see Cable Error Messages on page 65 4 Remove cable from the tester When the cable is removed the screen will prompt you to attach the next cable Note If the screen does not display the ATTACH CABLE prompt after removing the tested cable it means the tester still sees conections Check your adapter or adapter cables for shorts Cialemitem 95 Tester Test Summaries A test summary displays the results of a batch of tested cables Displaying a Test Summary After testing a good cable 1 Scroll down w 2 Press Get Summary Count This screen shows the test summary counts for the total number of tested cables and the number of good and bad cables tested If you have a connected printer a Press here to print the test summary The printed test summary shows the cable signature parameter signature cable serial number adapter signature s parameter settings connections and test summary counts for a batch of tested cables If des
9. 400 nF to 100 uF Capacitors 5nF to 100uF 10 20pF relative measurements to 10pF Common silicon diodes Common silicon diodes Zener diodes Learn as a standard diode as Zener diodes Test as standard diode long as zener voltage gt 4V as long as zener voltage gt 4V LEDs Note The tester does not learn or test germanium diodes Shottky diodes and diodes in series with some resistors The tester recognizes these components as opens and shorts Twisted pairs Minimum length 1 to 6 feet Same as Learn depending on electrical characteristics of twisted pair Minimum of 3 wires in cable 4 Wire Kelvin 0 0019 to 10 0Q 2 Same as Learn 0 001Q0 Component 59 Settings amp Test Links In some cases the tester may sense the electrical characteristics of a component but cannot determine if the component is a resistor diode or capacitor When this occurs the tester creates a link in the test program to ensure that no high voltage is applied across the component during the hipot test Essentially the tester applies high voltage simultaneously to linked test points thereby ensuring voltage is not dropped across the link and that the link is effectively isolated from other cable connections During the Low Voltage test the tester assures the linked points have a higher resistance than the Component Resistance setting Links may be created either automatically by the tester or by the technician setting up the test Links creat
10. Documentation J1 Adapter Signature F5B4E Adap A The last loaded test program is displayed on the main menu after learning a cable Adapters set up in original positions Note Ifthe User Preference Test Mode is set to CONTINUOUS the test will start automatically If Test Mode is set to SINGLE TEST press START TEST to begin the test For more information see Test Mode on page 39 Using the o Tester The cable is tested The tester performs a low voltage test on the cable If it passes the tester with factory default User Preferences automatically starts the hipot test If it passes the hipot test the tester with factory default User Preferences will start the intermittent test The tester performs the intermittent test by repetitively performing a low voltage test on the cable until the cable is removed or the test run is ended lf you would rather press a button to start the hipot test change the User Preference Automatic Hipot to OFF You can turn off the hipot part of the test by changing the Test Setting Hipot Test to OFF For more information see Overview of Preferences amp Settings on page 32 If the User Preference Test Mode is set to SINGLE the tester will not perform the intermittent test If the cable passes a The green LED will light up a The screen will display PASSED ALL TESTS a If the Test Mode is set to CONTINUOUS the tester will SHIN a automatically scan for intermitants i
11. High Voltage Hipot Errors cccccccseeeceeeeeeeeeeeeeseeeseeeess 69 Component EMOS nrnna iaoa a 72 Digital I O 13 Digital I O on the 1100H cc cecccceeeeceeeeeeeeeseeeeseeeeees T3 MOUIS sopena Enne REEN 14 OUMU Sain E a 75 OPU EXaMDIES rorci A 76 Setting up the Events Outputs cccceccceeeeeeeeeeeeeeeeeeaes 78 Tester Configuration 79 1100 Upgrade Application ccccccccceccsecceeeeeseeeeeeeeeeaees 79 1100 Utilities Application c cc ecccccccecceeceeeeeseeeseeeseeeaees 80 1100 File Compression Utility 2 0 0 0 eeccceeceeeeeeeeeeeeees 82 SPC Data Colection 84 Checking Version Information ccccccececseeeeseeeeeeeeeeees 86 errur ola 87 ali OA NO p EERE E EE ET E E A E AT 87 Maintaining Adapters and FIXxturing cccseeeeeeeeeeeeeeees 87 OI OS a nea ace eae mee ae 87 Conditions for Operation waic s 5 2202iot aia e aadietien 87 Appendix 84 SDS CINC AOS sranane AN 84 Waranty muscrsacerisanaseuaaauanohaesnatetagenatatamsnaetacwnaataeananainauiactinn 86 Purpose of this Manual Users Manual Quick Reference a Tester setup Guide Q Operator training as a Cable Testing a You will find the 1100H Quick Reference Guide in the front pocket of this manual Keep this near the amn tester to help operators and technicians recall basic tester functions Cirris Customer Support If you need assistance with your 1100H tester a custome
12. Labels with Custom Point Labels Test Point Labeling Using CTLWIN you can create custom point labels to reflect actual point names wire colors or other assembly instructions Custom point labels may be up to 16 characters Edit Component Values and Tolerances The 1100H can test diodes resistors and capacitors When learning these components the 1100H measures the value and automatically sets a 10 default tolerance With CTLWIN you can edit the component value and the tolerance Create Links and Component Definitions If the tester senses a component but cannot identify the component as a resistor diode or capacitor the tester creates a link in the test program to ensure no high voltage is applied across the component during the hipot test You can use CTLWIN to change a link to the appropriate component command For more information see Components Learned and Tested on page 59 and Links on page 60 Running the CTLWIN Software 1 Connect the PC interface cable between the 1100H serial port and the PC serial port or USB port with the Keyspan adapter If your PC does not have a serial port Cirris has qualified a USB Serial Adapter from Keyspan You can purchase this adapter directly from Cirris or from other commercial sources If you choose to purchase another make or model we have discovered many other USB converters do not work with our equipment This adapter has consistently performed without difficulties
13. Settings Changing Learn and Test Parameter Settings 44 Connection RESISTANCE 0 ceececeececceceereccecuecerereuceerereeeees 46 LV Insulation Resistance 20 cc ceeecececeseeeeceeeceeeeeveneeeeneeeees 47 Component Resistance ccccceececseeeeceeeeseeeeeceeeesseeesees 48 High Voltage Settings 49 FAIOOT TEST sonerien E AEN 49 AION V OMAG ririri a a aE 50 HV Insulation RESIStANCE cc cceeeceseceeeeeeeeceeeeeveveeeeneeeees 51 DU ION PRN ect erect Wc orre PL mci ate em a 52 PIDOT Orena err rte me rence en nme er coer me ere cer errr 53 High Capacitance Shield ccccccccseceseeeeseeeseeeeseeeseeeens 53 Max SOAK aiian aae A oat mtvatetentncsawestaals 54 Soak Until Good 0 2 0 0 cece ec cececcececeececeeeececeaececeeaecesesaeeesaees 55 SOA FOF acdsee sda a econ Pett eae net Peseta eed att cedar eases 55 FID OU NIOGS stances ected coethnics es tains oi aenitis tiie 55 FCOUCHICY cla causal a a a in ahsts 57 DWV VOdO Gra ai 57 DWV Max CUrrenb icitiestieialeiseititeninividlteiberbeldditediieeHeds 57 AV Insulation Voltage cesneninar a a 58 Insulation Resistance TIMEC ccccecesececeeeeeeeeeeeeeeeeeeeeeeeees 58 Component Setting amp Test 59 Learn Components ccccecccseeeeceeeeeeeeeeceeeeseeeeeseeeesseeeees 59 Components Learned and Tested cccceccseeeeeeeseeeees 59 LINKS ear A E AE 60 ANNE KENI eron a N 61 Cable Error Messages 65 LOW Voltage ESI POMS seeno a ARDARA 66
14. USB SERIAL ADAPTER 2 Click on the CTLWIN icon to begin the program Using CTLWIN Editing Test Programs The following examples illustrate how to edit test programs using CTLWIN Example 1 Changing Default Cable Description and or Point Labels Edited Test Program DT SONAR MODULE 984123 2J8NM Original Test Program Cable description changed from the Cable Signature to a custom description the cable signature will be 00000 if the voltage is greater than 1000 V 984123 2J8NM J1 D507F1 CONNECTION RESIS 10 0 ohm LV INSULATION RESIS 100k ohm HIPOT VOLTAGE 50 V INSULATION RESIS 5 00M ohm HIPOT DURATION 1 SEC J1 D507F1 CONNECTION RESIS 10 0 ohm LV INSULATION RESIS 100k ohm HIPOT VOLTAGE 50 V INSULATION RESIS 5 00M ohm HIPOT DURATION 1 SEC APPLY HIPOT TO ALL ADAPTER PINS HIPOT SOAK TIME 0 SEC 1 J1 001 J1 002 2 J1 003 J1 004 APPLY HIPOT TO ALL ADAPTER PINS HIPOT SOAK TIME 0 SEC 1 J1 001 J1 002 2 J1 003 J1 004 LABELS J1 001 HEADER_PIN1 J1 002 HEADER_PIN2 J1 003 RED_WIRE Default point labels assigned custom point labels J1 004 BLUE _WIRE Example 2 Modifying Component Test Values and Links Original Test Program 477BDD MULTI 477BDD MULT J1 ACEFA1 NE AC0 1 J1 001 J2 001 2 J1 004 J2 002 3 J2 007 J2 008 CHECK COMPONENTS 1 RESIS J1 002 J2 00742 3 ohm 10 2 RESIS J1 008 J2 0098 6 64 K ohm 10 3 CAP J4 006 J1 002 420 nF t0 4 LINK J1
15. cables The tester applies high voltage Until the cable is removed for opens shorts and to the cable as required to test the tester repeatedly runs miswires Components the cable s insulation low voltage tests to check if present are also tested for intermittent errors Some preferences and settings affect the low voltage test Other preferences and settings affect the high voltage or hipot test Still others only affect the intermittent test Because of its complexity the high voltage test is explained in more detail below Note The high voltage test will not occur if the test setting Hipot Voltage is OFF or if the cable fails the low voltage test The intermittent test will not occur if the User Preference Test Mode is set to SINGLE Overview of Preferences and Settings The High Voltage or Hipot Test To correctly adjust the preferences and settings that affect the high voltage test you need to understand what happens as a high voltage test progresses Below are descriptions of each part of the high voltage test To the right of the descriptions we have added an analogy to help convey the basic idea First Voltage Ramp Up The Water Hose Analogy When the tester applies high voltage to a net on the cable the tester senses the current flow in the net Initially there is an in rush of current flow as the tester attempts to bring the net to its high voltage potential At the same time other test points are kept at a
16. error a To see the detailed cable error message Press View Errors and scroll down w to see the whole page or Press Print Errors if a printer is connected The detailed error message shows the Error Signature and the specific error or errors found in this case a short to Net 1 Error Tones When the tester finds a cable error it makes error tones based on the type of error Opens single beeps Shorts double beeps a Miswires triple beeps High voltage errors triple beeps lt lt Error tones give the operator instant feedback if there is a problem For instructions on changing speaker volume see Changing the Speaker Volume on page 10 and Changing Volume and Display Controls on page 86 Cable Error Messages 69 Low Voltage Errors Low voltage errors identify errors in the cable wire pattern Shorts The tester displays SHORT if it senses an interconnection that should not exist in the cable There are two kinds of short errors 1 Shorts that occur between nets that exist in the net list For example this kind of short would be detailed like this NET 1 1 1 J1 J3 2 2 NET 2 If the User Preference Fault Location were turned on the short above would be displayed like this An asterisk is added to the pin closest to the short The tester does this using resistance measurements 2 Shorts that occur between points not used in the net list For example this kind of short would be deta
17. more information see Changing Volume and Display Controls on page 86 Factory Defaults Factory Defaults restores the factory defaults for the tester s User Preferences and Learn Settings User 4 Preferences Low Voltage Resistance Settings Changing Learn and Test Parameter Settings Learn Settings affect the way the tester learns a cable After a cable is learned the Learn Settings become the Test Parameter Settings for that cable which determine how a cable is tested Changing Learn Settings 1 From the main menu press Set Up Test Program 2 Press Create New Test 3 Press Set Learn Settings 4 Select the appropriate category of Learn Settings 5 Select the specific Learn Setting you want to change You may need to scroll down w to see all settings in the category 6 Set the desired value for the Learn setting Some Learn Settings toggle between two values and others scroll through a range of values 7 Press ACCEPT or back 4 to exit the specific test setting 8 Press back q to exit the category of Learn Settings 9 Press back 4 to exit the SET LEARN SETTINGS menu Low Voltage Wm SLOE Changing Test Parameter Settings You can only edit the Test Parameter Settings of the loaded test program The cable signature or file name of the loaded test is displayed on the main menu 1 Make sure the test program you want to edit is loaded OR Load a new test progra
18. press Set Digital Output Scroll up or down tothe digital output pin you want to set up Press S set Scroll up or down to the test event needed to start the operation of the output device press Accept Press R reset Scroll up or down to the event needed to stop the operation of the output device press Accept Press back q to return from the Digital Output selection menu Q9 C m i a Ad 7 Sr p api S F a i ICA ails The S event sets or sinks the output pin to ground thereby allowing current to flow through the output circuit The R event resets the output pin to the original no current flowing state Note Two of the outputs are factory enabled with default triggers The pin 7 output is set with Good Light On and reset with Good Light Off Pin 8 is set with Bad Light On and reset with Bad Light Off Deli leOmm 78 Tester Configuration 1100 Upgrade Application The 1100 Upgrade Application allows you to update the tester software and change the interface language of the tester English and Spanish are now available for the1100H tester Other languages may be available in the future To update the software and select an interface language you need to obtain a file containing the 1100 Upgrade Application and the current 1100 tester software You can access this file from the Cirris FTP site or it can be emailed or mailed to you
19. series a foot pedal or a sensor in automated test equipment For more information on wiring a safety switch see Hipot Safety Switch on page 74 Test Count Selections Factory Default GOOD CABLES ONLY ALL CABLES or ALL CABLES Test Count determines the types of tested cable counts listed in the test summary a When Test Count is set to ALL CABLES the test summary includes four counts total cables tested cables tested good cables tested bad and cables tested intermittent a When Test Count is set to GOOD ONLY the test summary includes the count for good cables only The factory default ALL CABLES is more informative However some customers prefer to use GOOD CABLES ONLY User 42 Preferences Auto Print Selections Factory Default ON or OFF OFF Auto Print determines whether the tester will automatically print test results after each test Q When Auto Print is ON you can select one of six reports that will automatically print test results Depending on the type of selected report the report will print after one of the following 1 a good or bad cable is tested 2 a good cable is tested or 3 a bad cable is tested a When Auto Print is OFF the tester will print test results only when an operator presses PRINT TEST SUMMARY Auto Print allows you to select one of three standard reports or one of three custom reports The standard reports are All Standard Good Standard or Bad Standard The All Standard pri
20. the cable for the specified time BEFORE performing the I R test Note Soak For will generally result in a slower hipot test as each net will be soaked for the entire Soak For period Hipot Mode Selections Available only when Hipot Test Advanced is selected May be changed to AC only when the tester is equipped with the AC option AC DC Hipot Mode allows you to select whether the tester will apply AC or DC in the Dielectric Withstand Test If you select AC the Frequency setting is displayed and the Duration setting is set in cycles rather than time Hipot Mode Guidelines Whenever possible use DC for safety and test reliability In many cases you may be allowed to substitute an equivalent VDC for a VAC specification as explained on the next page High Voltage 55 Settings Substituting VDC for a VAC Specification Testing with VDC is generally considered safer for the tested assembly MIL STD 202F April 1980 on testing electronic components states When either alternating current or direct current test voltages are used care should be taken to be certain that the test voltage is free of recurring transients or high peaks Direct potentials are considered less damaging than alternating potentials which are equivalent in detecting flaws in design or construction However the latter are usually specified because high alternating potentials are more readily obtainable Additionally using VDC hip
21. the tester by doing one of the following e From the main menu press Set Up Test Program Then press EDIT View Other Settings and View Adapters e Start a test without an adapter THOOH and press Show Required List The Loaded Test Program and Tester Memory When you power up the 1100H the Cable Signature or file name of the last loaded test program will display on the main menu The last loaded test program changes whenever you a Learn anew cable or a Retrieve a test from memory Internal Memory The C drive is the tester s internal memory and default drive In addition to the last loaded test program the C drive contains up to 99 memory locations that can store test programs For example this screen shows test programs stored in memory locations 4 5 and 6 TIOOH External memory A thumb drive is external memory which expands storage capacity For more information see USB Thumb Drive on page 24 If you are using a thumb or network drive the corresponding drive letter s will be displayed on the screen IGAC 17 Basics Using the Tester Creating a Test Program A test program can be created by learning a sample cable Itis important to ensure the learned sample cable is a good cable To create a test program from a sample cable 1 Attach the sample cable a Remove the J3 J4 cover plate b Install the correct adapters c Replace the cover plate
22. zero voltage potential For operator safety current is limited and dielectric failures are checked as voltage ramps up To illustrate lets say we capped the end of a water hose and turned on the water Water flows into the hose until the pressure in the hose builds up If the hose springs a leak while the pressure builds up we turn off the water Second Dielectric Withstand Test The voltage is maintained at the high voltage setting according to a duration setting which can be varied from 0 01 seconds to two minutes During this period the tester performs a Dielectric Withstand Test which checks for high voltage arcs exhibited Now the hose is full Let s carefully as sudden current spikes This test determines monitor the water flow into the hose whether the cable will grossly fail at a given high for a moment and see if the hose voltage potential An example of an error that would PNT A EAR cause this test to fail is two exposed wires that almost touch each other Third Optional High Voltage Soak Period This optional period is sometimes needed because cable insulation may leak a little when voltage is first applied This often happens as some cable insulating materials Some hoses expand for a moment are susceptible to absorb moisture or other contaminants A is heared sted eer which gradually dissipate as high voltage is applied ea 5 ia a Hat Therefore if this option is used after the Dielectric g P
23. 005 J2 005 Edited Test Program 477BDD MULTI 477BDD MULTI J1 ACEFA1 po 1 J1 001 J2 001 2 J1 004 J2 002 3 J2 007 J2 008 07 42 2 ohm 5 2 RESIS J1 008 J2 00Q6 65 K ohm 5 DAEL T Learned resistor values and default tolerances edited Link command changed to a resistor command Using CTLWIN he Example 3 Adding Components Not Learned Original Test Program 695BAE MULTI 695BAE MULTI J1 ACEFA1 J2 1A59C0 WIRE LIST SI D GNATURE 69D075 A58M0 amp p 1 J1 001 J2 001 2 J1 004 J2 002 CHECK COMPONENTS 1 DIODE J1 007 J2 008 Capacitor and LED diode components added Help for CTLWIN Edited Test Program 695BAE MULTI 695BAE MULTI J1 ACEFA1 J2 1A59C0 69D075 A58M0 1 J1 001 J2 001 2 J1 004 J2 002 3 DIODE J1 008 J2 009 LED You can get more information about CTLWIN by clicking help while in the program You can access context sensitive help by highlighting a field or menu item and pressing F1 Using CTLWIN a Overview of Preferences amp Settings What are Preferences and Settings The way the tester operates is determined by the following a User Preferences a Learn Settings a Test Parameter Settings User Preferences User preferences affect how the tester operates and interacts with the operator For example you may choose whether the operator has to pres
24. 1994 and MIL STD 45662A To verify calibration and functionality you can purchase the 1100H Performance Check Kit The 1100H Performance Check kit has a valid calibration period of 5 years after which it must be replaced In addition to the performance check kit you need a calibrated volt meter and high voltage probe capable of measuring the highest voltage the tester can output Note In the event a Cirris tester is found to be out of calibration there are no adjustable controls The tester or the affected portions must be sent back to Cirris for repair Maintaining Adapters and Fixturing The contacts on Cirris adapters or other fixturing that mate to the device under test may wear due to repeated insertion cycles Contact wear can result in higher connection resistances which increases the measured resistances for the tested device For this reason Cirris recommends customers evaluate the number of mating cycles and the cycle life of fixture contacts to determine maintenance intervals for testing and or replacing fixturing contacts A good way to check fixture contact resistance is to construct and use a shorting block For more information on creating shorting blocks see http www cirris com adapters test adapt html Service All Cirris Testers are designed as modules for easy servicing Should your Cirris tester require service as directed by Cirris support personnel you may need to send the affected module or entire tester bac
25. AC where current surges occur throughout the test period proportionally to the capacitance in the tested device High Voltage 57 Settings HV Insulation Voltage Selections HV Insul Voltage Available only when Hipot Test Advanced Available selections limited by is selected High Voltage Setting 1000V Unit SOV 100V 200V 300V 400V 500V 630V 800V 900V 1000V 1500V Unit 50V 100V 200V 300V 400V 500V 630V 800V 900V 1000V 1100V 1200V 1300V 1400V 1500V HV Insulation Voltage determines the voltage that is applied to each net during the Insulation Resistance Test Note Ihe tester does not permit you to set this voltage higher than the equivalent DWV Voltage This setting specifies a VDC If you do not have a specification for this setting the High Voltage guidelines page 50 are applicable Insulation Resistance Time Salactions Insul Res Time Available only when Hipot Test Advanced 002 017 02 1 10 30 60 is selected seconds Insulation Resistance Time specifies the time period that the insulation resistance measurement must remain below the insulation resistance setting during the Insulation Resistance Test Unless otherwise specified the default setting of 002 second 2ms is typically sufficient High Voltage 5g Settings Component Settings amp Test Learn Components Selections Factory Defaults On or Off for Off for all Resistors Diodes Capacitors
26. Cirris Systems Corporation shall have no responsibility to replace the analyzer or refund the purchase price Defects arising from such causes will be considered a breach of this warranty Cirris Systems Corporation is not responsible for special incidental or consequential damages resulting from any breach of warranty or under any other legal theory including lost profits downtime goodwill damage to or replacement of equipment and property and any costs of recovering materials used with the Signature 1100H Cable Analyzer ANY IMPLIED WARRANTIES ARISING OUT OF SALES OF THE SIGNATURE 1100H CABLE ANALYZER INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE STATED ONE 1 YEAR PERIOD CIRRIS SYSTEMS CORPORATION SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGE EXPENSES OR ECONOMIC LOSS Some states do not allow limitations on length of implied warranty or the exclusion or limitation of incidental or consequential damages so the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state Cirris Systems Corporation Salt Lake City Utah PURCHASE DATE SERIAL NUMBER vers Bl 1100H Cable Documentation Form Cable Signature Cable Description Adapter Signature s Test Parameter Settings Connection Resistanc
27. Component Twisted Pair 4W Kelvin types Learn Components is found in Learn Settings Learn Components determines whether the tester looks for the existence of components when learning a cable From the main menu you can access the Learn Components menu by selecting Set Up Test Program Create New Test Set Learn Settings and Set Components If you learn a cable with components the Parameter Signature the last five digits of the Cable Signature is displayed as MULTI Learning an Assembly with Components After learning a cable assembly the technician should verify the test program page 18 When verifying the test program of a cable assembly with components you must assure that each component in the learned cable assembly is identified with the appropriate component or link command The following topics in this section can help you understand how to do this Components Learned and Tested The 1100H can learn and test resistors capacitors diodes twisted pairs and 4 wire Kelvin Though twisted pairs and 4 wire Kelvin are not technically components the tester interface uses the term component to describe certain electrical characteristics between points Some components may not be learned but can be effectively tested if the test program Is edited The chart below compares learn and test capability for the tester Learn Test Resistors 0 10 to 100KQ gt 100KQ to 5MQ Resistors 0 10 to 1MQO learn as links Capacitors
28. FF 10 5MQO Component Resistance is automatically determined when the Learn Components setting is turned ON and components are sensed in the cable The tester sets component resistance to 20 less than the lowest resistor value found in the cable The figure below shows the Component Resistance setting in relation to the other settings that affect the low voltage test COMPONENTS GOOD HIGH RESISTANCE H OPEN P c Ped PO e o faa Infinite Resistance Connection Component TE Resistance Resistance Setting Setting Changing Component Resistance In some rare instances you may need to change the component resistance by editing a loaded test program Change the component resistance if you have the following a Components with resistance so low that you lose the measurement window between Connection Resistance and Component Resistance settings In this case you potentially have two options Option 1 You can raise the Connection Resistance and Component Resistance settings to test components as connections Option 2 If cable connections have more than 1Q of resistance lower both the Connection Resistance and Component Resistance settings below the cable connection resistance Wires and components will be measured as components a Large capacitors values greater than 10 microfarad In this case you may need to change the Component Resistance setting below 1KQ so the capacitors will not be reported as shorts Low V
29. Rivet 5 Remove the cover piece on the side of the tester push out the four plastic rivets holding the cover piece in place with a screwdriver or hard flat object 6 Carefully place the scanner Scanner Assembly assembly back into the tester Make sure the Add On connector sticks out to the side of the tester Add On Connector 7 Mate the Add On connectors make sure they are fully connected Scanner Add On 8 Push the connectors into the main unit 9 Attach the Add On Scanner to the base tester using the side latches If connecting more than one Add On Scanner repeat steps 1 8 to attach the next Add on Scanner to the previous one Side Latch 10 Re attach the cover plates 11 Label the adapter positions on each additional cover plate with a permanent marker as shown Label the first Add On coverplate Jet oo Lug Label the second Add On coverplate J10 J12 J5 J7 Continue this sequence on J9 Jii subsequent Add Ons Note Labeling the coverplates identifies adapter positions to help you understand tester prompts and error messages Tester Basics Basic Operation Available Buttons q Back Button These symbols change as the Returns to the available buttons on a screen previous menu become active or inactive They A show you which Up Down and x p s Back buttons are active A V Up Down Buttons Scroll menu o
30. SPAM 1100H Users Manual Version 2012 1 0 March 27 2012 Signature 1100H User s Manual Version 2012 1 0 March 27 2012 Copyright by Cirris System Corporation 1991 Parkway Boulevard Salt Lake City Utah 84119 2026 United States of America All Rights Reserved Table of Contents Purpose of this Manual ccccccceccceeeceeeceeeceeeceeeseeeneeenes 1 CirriS Customer SUPPO sienn 1 You Should Have Received cccsececeeeeceeeeeeeeeeseeeeseeeeees 1 You May Have Received cccceccceeeceeeeeeeeeeeeeeeseeeseeeseeees 2 Tester ODUONS snitte eaS a e e e 2 Setting up the Tester ccccccscceteecesceseecceeeteeeeecaseesceees 4 GONNECHNG a PIME esiin a sarees Scone lowered sags 5 Installing Add On Scanners cccceececeeeeeseeeeseeeeeseeeeeeeeeees 6 Basie ONC lOM cis seuessenct ina i 9 Downloading Updates and Changing the Language 9 151 010 1d 8 Ree eee ce ee een A ne ee eee 9 Changing the Speaker Volume cccceccceeeeeeeeeeeeeeeeees 10 Installing Adapters ccccceccsecceeeceeecceeceeeccusceeeeeeeeneeenaes 11 Adapter oZ Sas ner a ee ee eee nee eee eee 13 Duplicating the Adapter Setup cccccceeccseeeeeeeeeeeeeees 15 Cable Sinatre Si stints otew cular cates tends S 16 Adapter Signat re S onee 17 The Loaded Test Program and Tester Memory 17 Creating a Test Program cccccsccccseeeeceeessseeeseeeesaeeeesees 18 Learning
31. Settings 1100H Factory Defaults The tables below list settings in the 1100H and their corresponding factory defaults User Preferences Factory Defaults Test Mode CONTINUOUS External Switch OFF Fault Location OFF Auto Start OFF Automatic Hipot ON High Speed Hipot ON Safety Switch OFF Test Count Good Only Auto Print OFF Digital Outputs Pin 7 Good Light On Pin 8 Bad Light On Volume Medium Low Voltage Settings Factory Defaults Connection Resistance 10 00 LV Insulation Resistance 100KQ Component Resistance OFF High Voltage Settings Factory Defaults Hipot Test STANDARD High Volt ge 50 HV Insulation Resistance 5MO Duration 01 seconds for VDC and 1 cycle for VAC Hipot To ALL PINS High Capacitance Shield NO Max Soak 0 seconds Restoring Factory Default Preferences and Settings The factory defaults for User Preferences and Learn Settings may be restored at any time From the main menu press Set Preferences Scroll down w ndm i Set Factory Defaults Press RESET Overview of Preferences and Settings What Happens When a Cable is Tested To understand how to set the preferences and settings you need to have a basic idea of what happens when a cable is tested When the tester is set up with factory default preferences and settings the test has three parts First Part Second Part Third Part Low Voltage Test High Voltage or Hipot Test Intermittent Test The tester checks
32. Signature The First Part of the Cable Signature 1B4137 4Z020 The first part of the Cable Signature is called the Connection Signature which helps NY identify a particular cable The tester derives the Connection Signature from a The wire pattern of the tested cable oo a The adapters used ee a The position where adapters are installed The Last Part of the Cable Signature The last five digits of the Cable Signature are called the Parameter Signature which __ 24137 42020 identifies Test Parameter Settings for the test Some examples The Cable Signature for each of these cables indicates they have identical connections but different Test Parameter Settings These two cables are tested with the same Test Parameter Settings but have different connections and connectors SO Note If atest program has components the paramater signature is MULTI If a test program has advanced hipot settings or a voltage greater than 1000 V the parameter signature is 00000 IENE 16 Basics Adapter Signatures The tester recognizes the Adapter Signature because of jumpers on the adapter pc board Adapter Signatures identify how many pins are in the adapter where pin 1 is and how the pins are numbered Each adapter has an Adapter Signature The tester uses the Adapter Signature to identify the adapter and ensure the test setup is correct You can view the required adapter signatures in
33. a Cable With No Connections cccceeee 19 Documenting a Test Program ccccceseeeseeeeeeeeeeseeeeeees 20 Tesing a Gable nsigio a ence oc es 21 Test Summae S oana OS 23 USING the Probe sapene pepee p EEE E Ai 23 WSBT AUN DIVE seasea a iA 24 Creating FoldElS iieresecso a a iad eee 25 Managing Test Programs sss e a E 26 Common Uses for CTLWIN ccccceececeeeeeeeeeseeeeeaeeeeeees 29 Running the CTLWIN Software cccccssscesseeeeeeeeeeaeees 29 Editing Test Programs issvitcinrs Getetanctareeias Medetaacuanewane Mehebaiewens 30 ICID TORS TLIN tscetica estas nn oat ile tan tute tana 31 What are Preferences and Settings cccseceeseeeeeeeees 32 1100H Factory Defaults cccccecccecceeceeeeeeeeeeeeeeeeeaes 33 Restoring Factory Default Preferences and Settings 33 What Happens When a Cable is Tested cccceee 34 The High Voltage or Hipot Test cccccceccseeeeeeeeeeeeees 35 User Preferences 38 TeS MOGO saeia Ea EEA Ea 39 External OWC eenen EE 39 Faut POC ALO A cerne E A 40 AO Sa aeaa a ress ieee aden Stiga eens 40 PUTO HIDO becana 41 Pll SPEC HIDO eaen yar teansaiseuarseriext 41 SAE SWIC eerie penai pea Ee aE e E EE EET 42 MESH OUI anena n aA as n e n telastaaenwetnenes 42 AWO PRNG ansan a ee 43 DJa OUDS aa T omer 43 BVO 01 9 neru a a 43 PEC Oly IG AUIS jet sr te acacche ete ahha tee ac tethe e ake cca 43 Low Voltage Resistance
34. a If Test Mode is set to CONTINUOUS the test will start automatically when a cable is connected to the tester After passing the low voltage and hipot test the tester continuously scans the cable for intermittent errors until the cable is removed a If Test Mode is set to SINGLE the test will not start until START TEST is pressed After completing the low voltage and hipot test the tester will not scan for intermittent errors In CONTINUOUS test mode you will hear a ticking sound when a cable passes Each tick signifies a successful low voltage scan of the tested cable If there are errors the tester continuously beeps as it scans the cable to help you find the intermittent errors External Switch ternal Switc Selections Factory Default Selectable only if Test Mode is set to SINGLE ON or OFF OFF External Switch allows the tester s digital I O port to receive an input signal from an external switch to start a test The external switch such as a foot pedal or a button is located away from the tester a If External Switch is ON the tester starts a test from the external switch signal Q If External Switch is OFF the tester does not look for the external switch signal Turning External Switch on does not inhibit your ability to press START TEST on the tester display To turn this setting on the Test Mode must be set to SINGLE For details on using the External Switch setting see Digital I O on page 73 Us
35. and mold release a Cable Length Long cables may need a lower Insulation Resistance setting to accommodate the cumulative effect of small current leakages along their length a Humidity A humid environment can aggravate the effects of contamination between cable contacts and affect cable insulation For more information see Max Soak on page 54 Duration Selections Factory Default VDC 01 1 1 2 5 10 30 01 seconds 60 120 seconds VAC 1 10 60 300 3600 or 1 cycle 7200 cycles Duration determines the amount of time the high voltage is applied to each net during the Dielectric Withstand Test which occurs during the hipot test If using an AC test voltage for the Dielectric Withstand Test the duration typically referred to as dwell is set in cycles rather than seconds If you do not have a Duration Specification use the following guidelines Changing Duration Guidelines a The default setting for this parameter of 0 010 seconds 10 milliseconds should be adequate to test most cables A longer Duration will increase the total hipot test time a A shorter Duration without any Soak Time is more likely to fail due to humidity related problems since absorbed moisture may not have time to be dried out of the cable before the Insulation Resistance Test a A longer Duration provides a more stringent test for predicting dielectric failures exhibited as sudden arcs however equivalent dielectric errors can b
36. are caused by a A high resistance short Q A net with too much capacitance to be raised up to full hipot voltage In this case you may need to adjust the High Voltage setting or turn the High Cap Shield Allowed setting to Yes a The LV Insulation Resistance setting is set so low the tester could not sense a near short a You ve re run the hipot test on a cable that produced a dielectric failure Occasionally the high voltage arc that caused the dielectric failure creates a conductive carbon trail which causes the cable to fail subsequent tests Dielectric Failure This error occurs when high voltage is applied to a cable connection and the tester detects a current spike caused by the discharge of a high voltage arc hl Dielectric Failures are caused by a Exposed cable connections too close to each other which may be related to damaged insulation or terminal spacing problems a Contaminants or condensed moisture on a surface between exposed cable connections which create an electrically conductive path that breaks down in high voltage Surface contamination typically produces a High Volt Leakage error a The Hipot Voltage setting being too high for the tested cable or adapters used for the test Cable Error Messages High Volt Leakage This error occurs when high voltage is applied to a cable connection and the tester detects current flow from the connection This indicat
37. ble is removed The tester counted a cable intermittent in the test summary The tester failed self test when turned on The front panel Good light is on The front panel Good light is off The tester started the delay before the HV test The tester completed the delay before the HV test The tester completed the high voltage test with either pass or fail The high voltage test failed The high voltage test passed The tester started the high voltage test The tester aborted during the hipot test The tester detected an intermittent error in the DUT The tester completed the cable learn process The tester began the cable learn process The tester completed the low voltage test with either pass or fail DPICINLORS 75 LV Test Failed The low voltage test failed LV Test Passed The low voltage test passed LV Test Started The tester started the low voltage test Ready to Test The tester is ready to test the cable may or may not be attached Will Count Good If the cable were removed it would count as Good Will Count Bad If the cable were removed it would count as Bad Output Examples Controlling an LED Let s say you want to light an LED to warn the operator during the hipot test In the User Preference Set Digital Output you can choose to configure one of the outputs In this case choose output pin 10 For this output pin select HV Test Started to set and HV Test Done P F to reset the
38. cally Caution Always use the cover plates Without the coverplates attached the interfacing connectors on the 1100H may become damaged IOGA 12 Basics Adapter Sizes Cirris adapters mate with many industry standard connectors The three sizes of Cirris adapters are Single High Double High and Quad High Single High Adapters are used for connectors with up to 28 test points 4 Double High Adapters are used for connectors with up to 64 points Quad High Adapters are used for connectors with up to 120 points High Voltage Adapters Special High Voltage Adapters are required to do hipot testing above 1000 VDC or above 707 VAC Standard part numbers High voltage part start with an A numbers start with an Standard Adapter High Voltage Adapter Note For more information on which adapters are available with an HV option visit www cirris com or call 1 800 441 9910 ssisjae 13 Basics Adapter Positions The tester recognizes positions for each adapter and refers to test points based on these positions Notice the J1 J2 J3 and J4 labels on the cover plates Single High Double High Quad High Adapter in J1 Adapter in J1 Adapter in J1 Which positions are these three adapters in The Single High Adapters are in positions J1 and J2 The Double High Adapter is in position J3 INGE 14 Basics Duplicating the Adapter Setup If you retrieve a test program from memory t
39. ccessed If you need to access the normal tester interface once Auto Start has been turned on you may do so by turning on the tester and pressing CANCEL before the Auto Test countdown expires User 4 Preferences Auto Hipot Selections Factory Default ON or OFF ON Auto Hipot determines when the high voltage test starts a When Automatic Hipot is ON the high voltage test starts automatically after the low voltage test passes and the Delay for Automatic Hipot has expired see Delay below a When Automatic Hipot is OFF the hipot test starts only when an operator presses START HIPOT Auto Hipot allows operators to avoid having to press START HIPOT to initiate the hipot test However some cable assemblies may have exposed connections conductive connector housings or cable shielding which will become electrified during the hipot test Forcing a button push before the hipot test helps ensure that operators do not have their hands on the cable Delay This setting is enabled when Auto Hipot is turned on You can change the delay to extend the time between the completion of the low voltage test and the beginning of the hipot test The delay may be set from 1 to 2 seconds Hi Speed Hipot Selections Factory Default ON or OFF ON Hi Speed Hipot determines whether the tester will use advanced algorithms to speed the hipot test a When High Speed Hipot is ON the tester uses advanced algorithms The algorithms allo
40. crements Low voltage test lt 5VDC 6mA maximum High voltage test 1000 V Unit 50 1000 VDC 5 1500 V Unit 50 1500 VDC 5 AC Option with 1000 V Unit 50 700 VAC 5 AC Option with 1500 V Unit 50 1000 VAC 5 0 1 100 KQ 41 10 Also 500KQ 1MQ 5MQ 10 0 1 100KQ 1 Also 500KQ 1 MQ 5 MQ 10 5 MQ 10 MQ 20 MQ 50 MQ 100 MQ 200 MQ 500 MQ and 1000 MQ 10 0 0019 to 1 MQ 2 0 0019 Current 1A to 1 20 0 25A to 100 lt 7mA above 100 1mA 2mA 5mA and 1 5A 10 ms to 120 seconds AC Option 1 7200 cycles 35 mJoules Low voltage test 128 test points in 25 seconds High voltage test 01 120 seconds duration per net High speed hipot User selectable 128 0 2uF at 300VDC 80nF at 500VDC 20nF at 1000VDC Low voltage test Tested at 0 6 miles High voltage test Limited by the capacitance at a given voltage Use specification for Maximum capacitance per net and your cable s capacitance ratings to calculate possible length Relative humidity above 75 may adversely affect the hipot performance PNejelclalelham 84 Specifications Continued Component Specifications Resistor Learn 0 1Q to 100 KQ 1 Test 0 1Q to 1MQ Capacitor Learn 400nF to 100 uF 10 Jest 5nF to 100uF 10 20pF relative measurements to 10 pF Diode Learn silicon diodes zeners Test silicon diodes zeners and LEDs Twisted Pair Paired length must be 1 to 6 feet minimum depending
41. d Connect the sample cable 2 Learn the sample cable a From the main menu press Set Up Test Program b Press Create New Test c Press LEARN 3 Verify the sample cable If recreating a previously verified test do the following a Make sure the new Cable Signature or file name matches the previously verified test 1100H Cable Documentation Cable Signature 39E92F 4Z020 J1 Adapter Signature F5B4E0 J2 Adapter Signature O3FAC1 If this is the first time creating the test a Press Verify Test b Scroll down w c Verify that the learned connections match the build list of the cable exactly J1 003 TO J2005 ao J1 007 TO J2 008 ettings J1 013 TO J2013 d Double check the Test Parameter Note If a printer is connected you can verify by printing For more information see Documenting a Test Program on page 20 Using the 13 Tester You ve created a test program 1 Press the back button to return To the CABLE LEARNED menu 2 Remove the sample cable 3 Do one of the following Save the test OR Start testing Learning a Cable With No Connections A test program can be created without connections by learning when no connections are present This is useful when testing assemblies such as connectors or single ended cables 1 Install the correct adapters a Remove the J3 J4 cover plate b Install the correct adapters c Replace the cover plate 2 Learn the test setup
42. d plug the tester into a grounded power outlet The power supply is capable of accepting line voltages of either 120 VAC 60 hertz or 240 VAC 50 hertz Connect the probe to the tester If desired connect the thumb drive to the tester On the back of the 1100H tester you will find two USB ports insert the thumb drive into either port for access Turn on the tester and make sure the main menu displays Power Supply Well grounded power is essential Power for the tester to Cord operate accurately Probe Although not required a thumb drive allows extra storage Capacity and test program mobility A thumb drive is required to set up networking For more information see The USB Thumb Drive on page 24 These digits may be different but the main screen will look similar to this Note If connecting either a printer or Scanner Add ons see the applicable sections that follow otherwise skip to Tester Basics on page 9 ison Connecting a Printer If you connect a printer to the 1100H you will be able to print cable documentation error information and test reports Without a printer as you go through the testing process you will need to handwrite the results What printer will work 1100 testers require a parellel printer with an Epson Centronics style parallel port Printers that require Windows drivers will not work You will need a printer that is DOS compatibl
43. determine the To help dry out moisture the insulation resistance In this Dielectric Withstand Test tester continues to apply high case current flow is l The 1100H watches for high VORGE eee MA UNEN A a A voltage arcs exhibited as large absorbed into the insulation Ifthe hipot voltage therefore the l measured insulation resistance cable passes spikes in current during the Hipot Duration In this example there are no large current spikes because the cable is good becomes less than the insulation resistance setting as shown in this example and the Soak Until Good option is enabled the soak period will end Note This chart shows a single hipot voltage in the High Voltage setting throughout the hipot test However using the Hipot Test Advanced setting allows one voltage to be applied for the Dielectric Withstand Test and another voltage for the Insulation Resistance Test Overview of Preferences and Settings AC Testing AC testing is an available option on the 1100H AC Testing may be required to meet a test specification in which you cannot substitute an equivalent VDC For more information see Substituting VDC for a VAC Specification on page 56 When using AC the hipot test progresses somewhat differently as the graphs below illustrate DWV Voltage Setting in AC RMS IR Insulation Voltage Setting always in DC Voltage Current 0 Insulation Resistance Test Opti
44. e Threshold Component Resistance Threshold LV Insulation Resistance Threshold High Voltage HV Insulation Resistance Threshold Duration Apply Hipot To All Adapter Pins Connections Only Max Soak High Capacitance Shield Yes No Connections RR RR Connections continued C E A a a a a a A ee a a C E o ee O rE eee a Components Notes 1100H Test Program Location Listing Unit Serial Number Cable Signature File Name a D Te a Zz Cable Description Index A AC testing graph of test 37 option 2 Adapter Checking 87 double high 13 high voltage 13 installing 11 position 14 quad high 13 setup 15 Signatures 17 single high 13 sizes 13 Auto Start Test 40 Automatic Hipot 41 B Bad component error 72 Bad LED Light 9 C Cable error messages 65 78 component 72 error tones 65 high voltage 69 71 intermittent 69 low voltage 66 68 viewing 65 Cable Signatures 16 Calculating connection resistance 46 Calibration 87 Capacitors testing 48 59 Component default values 29 errors 72 Resistance Setting 48 test values 30 testing 59 Compressed files wirelists scripts 28 Conditions for Operation 87 Connection Signature 16 Continuous Test Mode 39 Contrast See Display adjustment CTLWIN examples 30 installing 29 Customer Support 1 D Default Point Labels 29 Dielect
45. e and capable of receiving ASCII text You can purchase a compatible printer from Cirris Call 1 800 441 9910 for more information Parallel Printer Cable To connect the tester to the printer you need a standard parallel printer cable available at most computer stores Connecting a Compatible Printer to the Tester 1 Make sure the tester and printer are turned off 2 Connect one end of the parallel printer cable to the tester connect the other end to the printer Caution The 1100H is NOT compatible with serial printers If you plug a serial printer into the serial port you may damage the tester Installing Add On Scanners Each Add On Scanner provides an additional 128 test points You can connect up to seven Add Ons to your tester for a total of 1024 points 1 With the tester turned off use a Hee ore Piel coin or screwdriver to turn the Co fasteners on the removable J1 J2 cover plate to the horizontal va position gt a Horizontal 7 Position wr Note The only time to remove the J1 J2 cover plate is when attaching an Add On Scanner J3 J4 Cover Plate 2 Turn the fasteners on the removable J3 J4 cover plate to the horizontal position i 4 N 2 Horizontal Position 3 Remove both cover plates from the tester 4 Carefully remove the scanner Scanner assembly turn it upside down Assembly and put it next to the tester Cover Piece Plastic
46. e digital I O connector If a DC 5 volt logic high is applied to pin 1 the tester behaves as if START TEST were pressed You can use the DC 5 volts power source on the digital I O connector to supply the DC 5 voltages through the switch circuit as shown below Do not apply an AC voltage to the input Hipot Safety Switch The 1100H allows you to start the hipot test by closing an external hipot safety switch The safety switch might be dual palm switches wired in series a foot pedal or a sensor in automated test equipment To use Hipot Safety Switch input you need to first set the User Preference Safety Switch to ON For more information see Safety Switch on page 42 The Hipot Safety Switch input is on pin 2 of the digital I O connector If a VDC 5 logic high is applied to pin 2 the tester allows the hipot test to proceed You can use the VDC 5 power source on the digital I O connector to supply the VDC 5 through the switch circuit Do not apply a VAC to the input The schematic above shows how a safety switch could be wired and for the safety switch use pin 2 instead of pin 1 Delite Omm 74 Outputs The tester s outputs are sink outputs When activated they will connect or sink a voltage to ground in effect turning ON the output circuit The outputs are capable of sinking up to a nominal 24 volts and 500 milliamps To limit the output current always ensure adequate resistance between power supply and the output When sw
47. e found by compensating a shorter Duration with a higher High Voltage setting a A longer Duration may be better for predicting some types of insulation failures and may increase the chance for detecting a breakdown condition High Voltage 59 Settings Hipot To Selections Factory Default ALL PINS or CONN ONLY ALL PINS Limited to ALL PINS if High Capacitance Shield is YES Hipot To determines which test points the tester applies high voltage to a When Hipot To is set to ALL PINS the tester applies high voltage to all adapter test points regardless of whether they have connections to other points in the test a When Hipot To is set to CONN ONLY the tester applies high voltage only to adapter test points that have connections to other test points in the test lf unused connector pins have loaded contacts metal in the holes you should use the ALL PINS selection This ensures the tester will catch high voltage shorts between unconnected contacts If not using CONN ONLY can save test time Setting High Capacitance Shield to YES forces the Hipot To setting to ALL PINS and cannot be changed This ensures the tester catches a condition where leakage occurs from a high capacitance shield to an unused pin High Capacitance Shield High Cap Shield Selections Factory Default YES NO NO High Capacitance Shield allows a cable to pass with one net too capacitive to pass a hipot test This setting is often u
48. ed automatically by the tester When verifying a learned test program a technician may recognize the tester created links in the test program s net list In some cases the tester may have assigned a component a link because it was outside the tester learn range However in some instances the component can still be effectively tested if the technician uses CTLWIN to edit the links assigned by the tester For example in order to speed the learn process for the majority of cables the tester does not learn component resistances higher than 100KQ However the tester does assign links to resistors with values above 100KQ and below the Low Voltage Insulation Resistance setting which can be set up to 5MQ If the tester creates a link for a resistance in the 100KQ to 1MQ range the technician can use CTLWIN to replace the link with a resistor command thereby allowing the tester to test the resistance value Links created by the technician In some instances the technician setting up the test program may need to use CTLWIN to create links in the test program By linking two or more test points the tester will treat the linked points as one net during the hipot test For example a cable might have three shields Capacitance from shield to each wire During high voltage testing each shield could have substantial capacitance between itself and all the wires it encompasses To avoid an unsafe shock hazard during a hipot test the tester will not co
49. efaults 33 Test Parameter 32 Learn Component Setting 59 LEDs See Components testing Links 29 30 60 Low voltage errors 66 68 LV Insulation Resistance Setting 47 M Max Soak Setting 35 Memory deleting 27 external 17 internal 17 loading 27 saving 26 Missing component error 72 Missing diode error 72 Miswire errors 68 N Net Lists 15 Nets 15 Networking 2 O Open error 67 Outputs 78 events 78 setting up 78 P Parameter Signature See Test Parameter Signature Pins 15 Point Labels 29 Preferences See User Preferences Printer 5 Printing errors 65 labels see Scripting manual p 40 42 2 Test Reports 43 Test Summaries 23 Probe installing 4 R Reports 43 S Saving test programs 26 Saving test programs 26 Scanner Add Ons attaching 5 8 labeling 8 Scripting 2 74 Serial Number 86 Service 87 Short error 66 shorting blocks 87 Shottky diodes See Components testing Signatures Adapter 17 Cable 16 Connection 16 Test Parameter 16 Single Test Mode 39 Soak period See Max Soak Setting Software version 86 SPC Data Collection 84 Speaker Volume See Volume Control Specifications 84 T Test Mode 39 Test Parameter Settings 32 Test Parameter Signature 16 Test Program Location Listing 26 27 28 89 Test programs creating 18 editing with CTLWIN 29 31 Test summary 23 Test Summary C
50. en the 1100 Utilities Application opens the Security Manager tab is active The boxes with a check mark indicate the active security settings that exist in the tester Line retires versn 0 e REE bgs Gee T eee Tester marly Rage foun wagi Status 7 Features affected by Load and Security Save security profiles Transfer a Group profile to and settings from the ood Frew hte emt Pee leet analyzer na a aad at Ser fa he etl eae To change the security settings 1 Select or deselect the checkboxes to adjust the security to the desired settings 2 Click Save To Tester If you want to review the settings that have been saved to the tester click Load From Tester lf would like to duplicate the security settings later click Save To File to save the setting information on the computer you are using Click Load From File to access previously saved security settings The Option Manager tab When you click the Option Manager tab you can see the tester serial number recorded in the tester s hardware To enable purchased options enter the feature access code you obtained from Cirris when the option s was purchased and click Send To Tester The Option Manager window will update to show the enabled option under Enabled Features Tester 81 Configuration 1100 File Compression Utility This utility allows you to compress a group of wirelists and scripts into a bundle and copy them to the tester simultaneously via thu
51. enses that a contact which should have a valid connection is connected to an incorrect contact the error message would look like this For example if this is correct and these were the errors NET 1 1 1 1 J J1 J3 P a PSSI NET 2 As shown in this example the miswire error is indicated as a contact OPEN to where it should go and MISWIRE to where it does go Miswires are caused by Q Wiring errors in the cable High Resistance The tester displays a High Resistance error when a cable interconnection has too much resistance ef High Resistance errors are caused by a Defects in the cable such as partially inserted or dirty connector contacts and poorly crimped wires a High resistance in the adapter or tester connector contacts In this case the tester connectors that interface with the adapters may be worn or damaged and need to be replaced a A Connection Resistance setting too low for the tested assembly In this case the resistance of a wire or contact is greater than the Connection Resistance setting but less than the LV Insulation Resistance setting a A component such as a resistor exists in the cable which has not been learned in the test program Cable Error Messages 68 Intermittent Errors The 1100H looks for intermittent errors in a cable during the Intermittent Test Intermittent errors include the same short and open errors found in the low voltage test as described in the previou
52. er must be located in the directory that you named as DIRECTORY FOR TESTER FILE STORAGE when you set up the network using Networking Made Easy During testing results are stored ina CT temporary file When the test run is Fle Edt View Favortes Tois Help complete you must return to the main Gra E F j eh e rate TE menu for the results to be copied to the Address 2 Gsp data spc_data folder The file will be given a Per name consisting of the tester s serial number oon followed by C_D i e If your tester serial O KAES number is 463658 the file name in the T Uan N spc_data folder will be 00463658 C_D a Removadte Dick E a AD STRE 0G DE 0A i mal Note Subsequent runs of SPC Data will not overwrite previously stored information Newer SPC Data will be appended to the end of the existing data file Retrieving and Analyzing SPC Data Use SPC Link or SPC Made Easy O SPC Link Cirris SPC Data can be read and stored by the SPC Link software that comes with the SPC Data Collection package Instructions for use are included with the PC software 0 SPC Made Easy SPC Made Easy not only reads and stores SPC Data but it allows you to graph and chart specific data making analysis quick and easy SPC Made Easy makes it possible for you to look for defects view production rates measure efficiency and manage data A demonsiration of SPC Made Easy can be obtained from Cirris by calli
53. er 39 Preferences Fault L ion ault Locatio Selections Factory Default ON or OFF ON Fault Location determines which end of the cable has the first displayed open short or miswire in the tested assembly a When Fault Location is ON the tester displays an asterisk next to the pin or pins closest to the open or short a When Fault Location is OFF the fault location information will not be displayed Because finding fault locations in the tester takes more time only the fault locations of the first five errors are displayed If fault locations are required for more than five errors you can correct the errors and retest the assembly In most cases the tester can find the position of the error The tester locates opens using capacitance and shorts with resistance For examples of errors where Fault Location is used see Shorts on page 66 and Opens on page 67 Note For Fault Location to work well the custom test fixturing should be no greater than one half the length of the wires in the tested device Auto Start Selections Factory Default YES or NO NO Auto Start allows the tester to automatically start testing upon boot up a If Auto Start is ON the tester will automatically start testing using the loaded test in memory a If Auto Start is OFF the tester screen will show the main menu This feature can be helpful when the tester is built into automated test equipment where the tester interface cannot be easily a
54. erform an accurate Insulation Resistance test SOAK allows you to meet the required procedure of Mil Std 202F method 302 paragraph 1 3 which states When electrification time is a factor the insulation resistance measurements shall be made immediately after a 2 minute period of uninterrupted test voltage application unless otherwise specified However if the instrument reading indicates that an insulation resistance meets the specified limit and is steady or increasing the test may be terminated before the end of the specified period If you want to apply a forced voltage for a specific period of time before the I R test is done change the Advanced Hipot settings and uncheck the box marked Soak Until Good You can then set a Soak For time that applies voltage for the entire time specified before performing the I R test see the next page for more information Max Soak allows the tester to monitor the insulation resistance for a selected period of time If the I R becomes good i e actual I R reading becomes greater than the Insulation Resistance setting the I R test is deemed good for that net the test immediately stops for that net and moves onto the next net Note When a Max Soak time is set the tester continues to monitor the Dielectric Withstand Current If the Dielectric Withstand Current is exceeded the tester emits a Dielectric Failure Max Soak Guidelines a Max Soak diagnoses certain failure
55. es the resistance of cable insulation is less than the Insulation Resistance setting hl High Volt Leakage Errors are caused by a Contamination on cable connectors or wires which form an electrically conductive path allowing some current to flow a Wire insulation or connector housings loses some insulating value by absorbing moisture from the environment a The insulating material under test has been incorrectly specified Dielectric Failure On Unknown Point This error occurs when the tester finds a dielectric failure a high voltage arc when hipotting a cable with the High Speed Hipot setting turned ON To locate the error the tester automatically changes out of the High Speed Hipot algorithm but cannot locate the error This error is rare If it occurs repeatedly turning the High Speed Hipot setting OFF will allow you to catch arcs that occur only once El User Aborted Hipot Indicates that the operator pressed ABORT before the hipot cable test finished Cable Error Messages 1 Component Errors The tester displays a component error if it senses a problem with an electrical component programmed into the cable test The tester detects component errors during the Low Voltage cable test Bad Resistor and Bad Capacitor The tester displays these messages when it senses a component with a measured value outside the tolerance for the component programmed in the cable test Possible causes a The wrong value com
56. he adapters must be placed in the same positions defined when the test program was created Duplicating the adapter setup for a test keeps test results consistent When you begin a new test the adapters can be placed in any available position When you recall the same test from memory the adapters must be inserted in the original positions RIGHT WRONG Matches the Does not match Original setup the original setup Can t remember where the adapters go Don t worry If you saved the test program the original positions will be displayed in the tester see Adapter Signatures on page 17 or on the documentation used for the test Pins Nets and Net Lists The word pin is generically used in this manual and in the tester interface to describe an individual contact or terminal in a connector An interconnection between two or more pins in a cable is called a net When the tester learns a cable it assigns each net in the cable a net number All of the nets for a cable make up a net list In some Cirris products the term wirelist is used interchangeably with the term net list aKssisjam 15 Basics Cable Signatures When learning a cable the tester mathematically derives an 11 digit alphanumeric code for the cable called a Cable Signature This code helps you quickly identify a proper test setup Note If you change the name of a test program on your PC that name will display instead of the Cable
57. iled like this NET 1 1 1 2 2 oN NET 2 3 4 4 A NET NC SHORT indicates a short exists between two No Connect pins or between a net and a No Connect pin Shorts are caused by a Defects in the cable such as frayed wire strains bridging solder joints or conductive contaminates between exposed connections a The LV Insulation Resistance setting being set above the actual resistance of the insulation between nets therefore nets leaking into each other appear as shorts Cable Error Messages Opens The tester displays OPEN if it does not sense an interconnection that should exist in the cable For example if this is correct and this was the error the error would display like this aA 1 bl 1 J1 93 p NET 2 If the User Preference Fault Location were turned on the open above would be displayed like this An asterisk is added to the pin closest to the open The tester can do this by sensing the lower capacitance of the unconnected pin Opens are caused by a Defects in the cable such as missing or cut wires defective or un inserted connector contacts and cold solder joints Additionally the tester could display an open error when a The LV Insulation Resistance setting is lower than the actual resistance of a wire connection a The Component Resistance setting is lower than an electronic component in the cable Cable Error Messages 67 Miswires The tester displays MISWIRE if it s
58. ired attach the printed test summary to the tested cables to substantiate the test results of the batch wwe tive aon CON ai b aa a i a b Se aM A _ Note You can change the format of the test summary to display the count for good cables only For more information see Test Count on page 42 To Clear or Reset a Test Summary When finish a run of cables and have the Summary data you need press STOP TEST RUN to complete the run The summary counts Total Good and Bad will be reset to 0 in preparation for another run Using the Probe The probe can determine the pin count identify flying leads and locate cable errors in the test cycle When you probe a point in a net the tester initially displays up to six test points of the net For large nets you may have to scroll down to view all points of the net The first listed test point is not always the test point the probe is touching Using the 23 Tester USB Thumb Drive Cirris has supplied you with an external storage device commonly referred to as a thumb drive All 1100H testers released after August 1 2008 are equipped with USB ports If your 1100H was released at an earlier date contact your Cirris representative for upgrade information The thumb drive allows you to do the following a Backup test programs a Copy test programs between 1100 testers a Copy test programs between the tester and a PC Custom File Names for Wirelists
59. itching a voltage between 12 and 24 volts the output will allow a slight current flow about 1mA at 24 volts when the output is OFF Current cannot flow when the normal state of each output is off Using the Digital Outputs settings in the User Preferences tester interface you can set up test events to turn an output ON or OFF One test event sinks the output to ground thereby allowing current flow through the output circuit A second event resets the output line to its original OFF state If you select the same event to set and reset the output the tester will sink the output for a 10 millisecond pulse For step by step instructions on setting up Digital Outputs see Setting up the Events Outputs on page 78 Each of the test events that change output status are listed below Test Event Name Description Bad Light Off Bad Light On Cable Attached Cable Counted Bad Cable Counted Good Cable Removed Count Intermittent Failed Self Test Good Light On Good Light Off HV Delay Started HV Test Delay Done HV Test Done P F HV Test Failed HV Test Passed HV Test Started HV Test Aborted Is Intermittent Learn Completed Learn Started LV Test Done P F The front panel Bad light is off The front panel Bad light is on The tester sensed a connection between 2 or more test points The tester counted a cable bad in the test summary The tester counted a cable good in the test summary The tester sensed the ca
60. k to Cirris for repair During the repair period a loaner tester can be sent to you if needed You should not attempt to service any circuit board at the component level All component level service should be performed by Cirris technicians Conditions for Operation Your 1100H tester is intended to be used indoors at a temperature of 10 C 50 F to 40 C 104 F Best performance can be obtained at a relative humidity less than 75 Insulation Resistance Measurements will degrade over 75 relative humidity The unit can be mounted in a ventilated compartment Be sure not to block the vents on the back of the tester Never apply live voltages to the test points or probe input of your Cirris tester Power supplies and other accessories not approved by Cirris may cause damage or present a hazard If you use a Cirris product in a manner not specified in this manual and the accompanying help system the protection provided by the product may be impaired General 87 Information Appendix Specifications Test Point Capacity Test Voltage Levels Connection Resistance Sensitivity LV Insulation Resistance HV Insulation Resistance Kelvin Four Wire Resistance Dielectric Withstand Current High Voltage Duration or Dwell High voltage energy limit Test rate typical Maximum Test Points per net Maximum capacitance per net Maximum cable length Usable humidity range 128 to 1024 test points expandable in 128 point in
61. m by learning a cable or retrieving the test from memory 2 From the main menu press Set Up Test Program 3 Press Edit to edit the loaded test 4 Select the category of test settings you want to edit 5 Select the specific test setting you want to edit 6 Set the desired value for the Test Parameter Setting When selected some Test Parameter Settings toggle between two values while others scroll to the desired value 7 Press ACCEPT or back to exit the specific Test Setting 8 Press back to exit the category of test settings 9 Press back 4 to exit the Edit menu lf you made changes a screen briefly confirms the changes in the loaded test program Note If you edit a loaded test the test is not updated until you save it back to the same memory location Each Learn and Test Parameter Setting used for setting low voltage resistance thresholds is described on the following pages Low Voltage Ws Settings Connection Resistance Conn Res ealastions Factory Default 1QO 100KQ 500KQ 10 00 1MQ SMO How good are the connections in a cable The Connection Resistance setting specifies the maximum resistance a connection can have and still be considered good as opposed to having high resistance GOOD HIGH RESISTANCE OPEN Zane eS D E Infinite Resistance Resistance Connection Resistance Setting When you learn a cable the cable s connections must be lower in resis
62. mb drive You can also compress individual files Compressed files create more space in the testers memory Another benefit of this utility is if you copy compressed files to the tester via thumb drive custom file names up to 16 characters will display in the tester Without the utility custom file names longer than 8 characters will be truncated in the tester Compressing the Wirelists 1 Select Windows Start gt All Programs gt Cirris System Corporation gt 1100 Utilities and double click on FileCompression1100 exe 2 When the 1100 File Compression 1100 File Compression Utility opens select your desired Compression Mode Select Compression Mode All files compressed and bundled into a single ccb file a All files compressed and bundled into a single ccb file allows you to import multiple compressed fles atone time Sater les Compression Complete Each file compressed into it s own ccf file a Each file compressed into it s own ccf file allows you FL Close to import compressed files individually Note The compressed bundle file extension ccb stands for Cirris Compressed Bundle The compressed single file extension ccf stands for Cirris Compressed File 3 When you have made your selection click Select Tester Files Select Compression Mode All files compressed and bundled into a single ccb file 0 Each file compressed into it s own ccf file Select Tester Files
63. ms into folders and then copy the folders into the tester via thumb drive How folders function a If you copy a folder to the tester it will appear on the tester screen after you select the thumb or network drive letter Press the folder s button to view the _ files in the folder a As with file names folder names longer than eight characters will be truncated in the tester The first six characters will be followed by a right arrow symbol and a number a After you select a folder you can press the button next to this symbol lt gt to take the screen up one folder level CaleRiae 25 Tester Managing Test Programs Saving test programs speeds up test setups and eliminates the need to maintain Known good sample cables to reprogram the tester You can load saved test programs delete unwanted test programs and copy test programs from one location to another You can also import wirelists scripts that have been compressed using the 1100 File Compression Utility Saving a Test Program You can save atest program after learning and verifying a sample cable OR after editing a test program Saving the Loaded Test Program 1 From the main menu scroll down w 2 Press Manage Files 3 Press Save 4 Select the following b A drive letter c A folder The selected drive is d Amemory location _ lt folc displayed here Note Selecting a memory location saves the
64. ng 1 800 441 9910 Tester 85 Configuration Changing Volume and Display Controls If the Set Volume Control in the tester s interface is inadequate you can manually adjust the speaker volume You can also manually adjust the display intensity To manually adjust the speaker volume or display intensity Processor Scanner Assembly Assembly 1 Remove the scanner assembly from the tester for more detailed instructions on removing a scanner refer to Installing Add On on page 6 2 Lift the front edge of the processor assembly as shown 3 Using a small screwdriver adjust the speaker or display control Each control is labeled on the PC board These adjustments need to be made with the tester turned on to observe the results If adjusting the speaker access the speaker volume control on the display menu see Changing the Speaker Volume on page 10 Checking Version Information You may check the 1100H software version hardware version and serial number 1 From the main menu scroll down w 2 Press Version Information The screen will display the hardware software and serial number information Tester 86 Configuration General Information Calibration Each new 1100H tester comes with a complimentary certificate of calibration Cirris recommends the tester be recalibrated on a one year interval In the U S A Cirris offers complete calibration services in compliance with ANSI NCSL Z540 1
65. ntinue to charge a highly capacitive net Turning ON the setting HIGH CAP SHEILD will ignore the hipot failure on one of the shields however the other two shields would continue to fail the high voltage test To avoid this problem use CTLWIN to create two Cennecions links so the tester treats the shields as one net to Shield 1 During the high voltage test high voltage will be a applied simultaneously to all three shields ensuring Connections their isolation from other cable connections During foe one the low voltage test the tester checks that the Connections resistance between the linked shields is higher than to Shield 3 the Component Resistance setting Component Settings amp Test 4 Wire Kelvin The 1100H tester can perform 4 Wire Kelvin resistance measurements This capability allows you to null out fixturing resistance and measure very low resistances down to 001 Q The standard 2 wire resistance measurement requires a single test point for every connection on the device under test The 4 wire measurement requires two correctly paired test points for every connection One test point supplies current typically referred to as force while the other senses voltage typically referred to as sense You may connect force to sense on the contact mechanism to the device under test and see a very small interface resistance However if you bring force and sense together directly on the contact of the de
66. nto a cabinet that does not allow the operator to access the display By using External Switch input you can allow the operator to start a test with a switch on the outside of the cabinet Additionally if the cable doesn t pass the test you can use two of the tester s outputs to activate a buzzer and a red light The digital I O port is located on the back of the tester The location and pin out of the connector are as shown The table below shows each of the signals on the digital I O port Pin Explanation 1 Input External Switch 2 Input Hipot Safety Switch 3 Input 4 Input 5 Output 6 Output 7 Output 8 Output 9 Power 5 VDC 100 mA max 10 Output 11 Output 12 Power 10 VDC 100 mA max 13 Not used 14 Ground 15 Ground DICIR LORE 73 Inputs The 1100H tester has four inputs VDC logic is typically used to control an input however any VDC up to a nominal 24 volts may be used Inputs used for the tester s External Switch and Hipot Safety Switch capability are described below If needed other inputs can be assigned by using the Scripting option External Switch The 1100H has the ability to start a test based on input from an external switch such as a foot pedal or sensor in automated test equipment To use the External Switch input you must set the User Preference External Switch to YES For more information see External Switch on page 39 The External Switch input is on pin 1 of th
67. nts a short one line report after each test whether the cable tests good or bad The Good Standard prints a full page report after a cable tests good The Bad Standard prints a full page report after a cable tests bad The reports autoall rpt autogood rpt and autobad rpt can be customized if you purchased the scripting option Being able to customize reports allows you to put your company name on the report and choose the data displayed on the report Regardless of the type of report selected you can print a test summary after any test when testing a run of cables Remember when you select a report the same report will be used for all test programs until you change the report selection Digital Outputs Selections Factory Default disable enable pins 5 pin 7 Cable Counted Good 6 7 8 10 11 pin 8 Cable Counted Bad Digital Outputs determines how the tester controls the output pins on the the digital I O port The 1100H has six digital outputs which can drive an external device according to various events in the tester These events occur as the tester powers up learns a cable tests a cable and displays test results Controlling an output line requires two triggering events For more information see Digital I O on page 73 Volume Selections Factory Default Off Low Medium High Medium Volume allows you to mute or adjust the volume of the tester If you need louder sound you can make an adjustment inside the unit For
68. obing for Test Points Type With 4 Wire testing turned on you can probe a test point to determine whether it is a type 1 or a type 2 test point When you probe a point the probe type displays as shown 1 From the main menu press Set Up Test Program 2 Press Create New Test 3 Press LEARN 4 Scroll down w and press Probe 4W Point Type Learning a 4 Wire Test Setup Now you can learn a 4 wire test First learn the fixture and then learn the tested device 1 From the main menu press Set Up Test Program Press Create New Test Press Learn Make sure only the 4 wire fixture is connected press Continue to learn the fixture aga dk Note Be sure to turn off the 4W Kelvin setting after learning a 4 wire test This will prevent problems when learning a 2 wire resistance setup Connect the assembly to be tested and press Continue to learn the wiring pattern of the sample tested assembly The tester should make a sound indicating that the assembly has been learned The screen will display CABLE LEARNED Component 64 Settings amp Test Cable Error Messages When an error is found in a tested cable the screen displays a cable error message The four cable error message types are Low Voltage Component High Voltage and Intermittent When a tested cable has an error The tester displays The red LED the type of test error turns on on the screen Error tones sound based on the type of
69. oltage 7 Settings High Voltage Settings Hipot Test Selections Factory Default OFF STANDARD STANDARD ADVANCED Hipot Test determines whether the tester performs the hipot test and if so what settings will be used a When Hipot Test is OFF the tester does not perform a hipot test when the assembly is tested a When STANDARD is selected the hipot settings are simplified The same settings are used for the Dielectric Withstand DW Test and the Insulation Resistance IR Test a When ADVANCED is selected more hipot settings are available The added settings allow increased and independent control over the Dielectric Withstand DW Test and Insulation Resistance IR Test The chart below contrasts the settings for the Standard and Advanced Hipot Test Hipot Test Settings Standard vs Advanced Setting Standard Setting Advanced Setting Hipot Mode VDC Allows operator to select either AC or DC for DWV test Frequency N A Allows operator to select the frequency if a VAC is selected for DWV test DWV Current N A Allows operator to select value from 100uUA to 1 5mA DWV Voltage and HV Sets the same high Allows operator to select separate high Insul Voltage HV voltage for both DWV and_ voltages for DWV and IR tests Voltage IR tests Insulation Resistance Allows operator to select Allows operator to select period Time from 01 1 1 2 5 10 between 2 ms and 60s 30 60 and 120s Soak Until Good and Only Max Soak
70. olume if additional volume is needed call Cirris and ask about the optional Alarm Box 1 From the main menu press Set Preferences 2 Scroll down w TOON 3 Press Set Volume Note If you scroll down from this screen you can change the Date Time and Factory Default setting for the test 4 Press up or down W to change or turn off the volume The speaker selections are OFF LOW MEDIUM and HIGH As you adjust the speaker Need louder sounds volume you will hear audible If the sound selection is inadequate you can make an beeps indicating the change adjustment inside the unit For more information see in volume Changing Volume and Display Controls on page 86 5 Press Accept to save the new volume setting 6 Press back to return to the main menu aKss sjam 10 Basics Installing Adapters 1 Turn both fasteners on the J3 J4 Cover plate cover plate sideways Ll turn sideways 2 Remove the cover plate from the tester 3 Slide in the adapter against the edge of the scanner until it fully seats being careful not to bend the pins Note Adapters should be added with the J1 J2 cover plate in place aKssicjem 11 Basics Important Make sure to first install adapters into the J1 J2 positions and then the J3 J4 positions J1 J2 J3 J4 4 Reattach the cover plate and turn both fasteners to the vertical position to lock it in place rotate verti
71. on electrical characteristics of twisted pair Cable with pairs must have a minimum of 3 wires Digital I O Port 4 inputs 0 24 VDC 6 User programmable outputs Sink 24 VDC 500mA max Source Voltages 5VDC 100mA 10VDC 100mA Parallel Port Standard Epson Centronics type parallel interface Memory Nonvolatile storage of up to 99 test programs Power 100 250 VAC 47 63 Hz maximum 50 Watts Dimensions and weight Main unit 14 25 wide x 6 75 deep x 5 25 high 36 2cm wide x 17 2cm deep x 13 4cm high Weight 9 7 pounds 4 4 kilograms Scanner Add On 6 25 wide x 6 75 deep x 5 25 high 15 9cm wide x 13 4cm deep x 13 4cm high 6 3 pounds Weight 2 8 kilograms PNejellalelyam S85 SHAM e 1100H Warranty Cirris Systems Corporation warrants the Signature 1100H Cable Analyzer to be free of defects in materials and workmanship for a period of one 1 year from the date of delivery as evidenced by receipt of your warranty registration form In the event a defect develops due to normal use during the warranty period Cirris Systems Corporation will repair or replace the analyzer with a new or reconditioned unit of equal value In the event of replacement with a new or reconditioned model the replacement unit will continue the warranty period of the original analyzer The replacement unit will generally ship within one working day for domestic U S lf the analyzer failure results from accident abuse or misapplication
72. on 1 0 Tester Status HAS POWER aj Security Manager Option manager The computer you connect to the tester must have a serial port or use a USB to serial adapter Cirris has qualified the Keyspan USB to serial adapter other adapters may work correctly You can purchase this adapter from a local distributor or from Cirris You must install the 1100 Utilities software on a computer This software can be downloaded from the Cirris FTP site Additionally to utilize this feature the tester must have version 4 5a software or higher installed To download and install the 1100 Utilities software 1 Type the URL ftp ftp cirris com 1100 in your web browser 2 Double click on the file 1100_utilities1 0 exe 3 Inthe File Download dialogue box click Run to install 1100 Utilities or click Save if you will be installing the software on other stations The software installation should take a few seconds When the software is installed an 1100 Utilities icon will appear on your computer desktop To run the 1100 Utilities software 1 You received a serial cable in the CTLWIN kit that came with your tester Connect this cable between the serial interface of your computer and the tester 2 Turn on the tester 3 Double click the 1100 Utilities icon on the desktop When the 1100 Utilities software establishes communication with the tester the tester displays REMOTE Tester 80 Configuration The Security Manager tab Wh
73. onal High Voltage Soak Time Dielectric Withstand Test Using VAC for hipot testing causes current peaks due to cable capacitance These peaks are proportional to how fast the voltage is changing For more information on the differences between DC and AC hipot testing see www cirris com testing guidelines ac_hipot_testing html Overview of Preferences and Settings User Preferences User Preferences affect the way the tester performs and interacts with the operator but do not affect the critical characteristics of the test Changing User Preferences 1 From the main menu press Set Preferences 2 Press the desired User Preference option see below e Set Test Methods allows you to access the following user preferences Test Mode External Switch Fault Location Auto Start O O O O e Set Hipot Methods allows you to access the following user preferences o Auto Hipot o Delay o Hi Speed Hipot o Safety Switch 3 Scroll down to access the following user preferences Auto Print Digital Outputs Volume Date Time Factory Default Each User Preference for the 1100H is described on the following pages User 38 Preferences Test Mode Selections Factory Default CONTINUOUS CONTINUOUS or SINGLE Test Mode determines how the operator will start a test and whether the tester will continually scan a cable for intermittent errors until removed from the tester
74. onn Res with caution A bad sample cable may cause the suggested value to be higher than it should be Low Voltage fir Settings LV Insulation Resistance Selections Factory Default LV Insul Res 0 10 100KQ 100KO 500KQ 1MO SMO LV Insulation Resistance only affects the low voltage test where the basic cable pattern and gross insulation problems are identified This setting determines how high the insulation resistance must be between cable nets to pass the low voltage test The tester displays SHORT for an unintended resistance between nets that is less than the LV Insulation Resistance setting SHORT SHORT PASSES LV PASSES LV Zero Infinite Resistance LV Insulation Resistance Resistance Setting In addition the LV Insulation Resistance setting determines at what resistance intended connections are considered open as opposed to having high resistance GOOD HIGH RESISTANCE OPEN Zero Infinite Resistance Connection LV Insulation Resistance Resistance Resistance Setting Setting LV Insulation Resistance Guidelines The factory default of 100KQ should work well for most cable testing applications The higher you raise the LV Insulation Resistance setting the longer it takes for the tester to perform the low voltage test Note Resistances above the LV Insulation Resistance setting will be ignored during a learn Mol TAVe ittel ma 47 Settings Component Resistance Selections Factory Default automatically set O
75. ot may provide more reliable hipot test results The General Military Specification for wiring harness space vehicle design and testing DOD W 83575A USAF December 1977 states regarding the high potential withstand test This test shall be performed using either a 60 Hz ac test potential or a dc potential Because the wiring capacitance results in higher ac currents that may give erroneous indication of breakdown only the dc test is recommended for cables longer than 3 meters If a VDC is to be used in place of a VAC the equivalent VDC should be at least 1 4 times the VAC RMS specification As stated in DOD W 83575A USAF December 1977 When a DC potential is used the test shall be performed in the same manner as described for the ac test except that the dc potential used shall not be less than 1 4 times the appropriate ac test potential To arrive at a DC duration setting relating to the AC dwell specification divide the AC dwell specification number of cycles by the AC frequency specification in hertz cycles per second This will give you an equivalent DC duration setting in seconds High Voltage 5G Settings Frequency Selections Available only when Hipot Mode AC is selected 25 30 50 60 Hz Frequency defines the frequency of AC waveform cycle when AC is selected for the Hipot Mode setting This setting is often dictated by a customer or engineering specification DWV Voltage DC Selections
76. ount 42 Testing 21 34 37 Thumb drive 17 Twisted paired wires See Components testing U Upgrade Appication 79 User aborted hipot error 71 User Preferences 32 Auto Start Test 40 Automatic Hipot 41 External Switch 39 Fault Location 40 42 High Speed Hipot 41 restoring factory defaults 33 Test Mode 39 Test Summary Count 42 Utilities Appication 80 V Version information 86 Volume control manual adjustment 86 User Preference 10 W Warranty 86 Z Zener diodes See Components testing CRRIS Cable Harness testing made easy
77. output In this example the LED requires only 20 mA so we can use the 5 DC volt supply on the digital I O port to power our circuit Use a resistor in series with the LED to limit the current going through it Resistor Fin 10 LOO OOO O60 ooo0oo0oo0oo0oo0o0 Pin 9 DC 5 Volts How do you choose the resistor The LED in this instance has a forward bias voltage drop of two volts therefore three volts must drop across the current limiting resistor Knowing voltage drop and current through the circuit Ohms Law can be used to determine the resistor value AVAS a a CCE San When the hipot test starts the tester will pull the output to ground allowing current to flow in the circuit and the LED will turn on When the hipot test completes current through the output will stop and the LED will turn off DPICIRLORE 76 Turning on a Light Bulb Let s say instead of an LED you want to turn on a light bulb powered from a 120 VAC wall outlet a relay can be used to control the light bulb In this example we select a relay that has a coil voltage of 12 volts and draws less than 100 milliamps so we can use the 12 volt DC power supply on the tester The relay circuit is as shown Pin 12 12 VDC O000 000 O00009Q 00 Pin 6 Output A diode such as a 1N4002 is added across the relay to protect the digital I O port from the reverse current created from the coil when the output turns off Activating an Air Valve Let
78. period Allows either a defined Soak For Soak For may be used period or Max Soak period High Voltage 49 Settings High Voltage Selections Factory Default 1000V Unit 5OV 100V 200V 300V 400V 500V 50 V 630V 800V 900V 1000V 1500V Unit 50V 100V 200V 300V 400V 500V 630V 800V 900V 1000V 1100V 1200V 1300V 1400V 1500V High Voltage determines the voltage applied to a cable during the hipot test A higher High Voltage setting tests higher levels of insulation resistance between nets however there are limits to the amount of high voltage you should use on a cable assembly High Voltage Guidelines The High Voltage setting may be dictated by a customer or engineering specification If you do not have a specification below are some general guidelines a The spacing between the pins in a connector as well as the separation of the conductors in a cable limits the amount of voltage that can be applied to a cable a Use the manufacturer s specifications for the wire and connectors used in a cable a The High Voltage setting affects the available selections for the Insulation Resistance Settings For more information see the Available HV Insulation Resistance Settings table on the next page Q Highly capacitive cables may limit the amount of high voltage that can be applied to the cable See the 1100H Spec Sheet on the Cirris website for these capacitance limits High Voltage 50 Settings HV Ins
79. points one at each end of the tested device The Kelvin points should be placed as close to the device under test as possible This is because the 4 wire test measures from Kelvin point to Kelvin point so any contact and lead resistance between the Kelvin points is added to the resistance measurement of the device under test The diagram below shows how the location of the Kelvin points will affect the resistance measurement of the device under test KP DUT 2 i Cr V A A y Ea Bn nnnnanaannmnanaannnnnnncannnnnnaannmnanaannnnnnac anne CV E U T 3 Ke m Ail ad DUT 1 DUT 2 DUT 3 The measurement is only The measurement includes part The measurement tests only of the device under test of the fixture Warning If alot part of the device under test This is ideal but in real of the fixture is between a Kelvin For example by using probe situations it may be point and the device under test pins you can eliminate the nearly impossible the 4 Wire Test will be resistance of a connector considerably compromised from the measurement Component Settings amp Test Turning 4 Wire Testing on in the Tester Before learning a 4 wire fixture and tested assembly you must turn on the 4 wire capability in the Set Lrn Components menu 1 From the main menu press Set Up Test Program Press Create New Test Press Set Learn Settings Press Set Components Scroll down and press 4W Kelvin ale ae Pr
80. ponent is installed in the cable a The correct component is installed but is out of tolerance a The connection to the component has high resistance and therefore has affected the tester s ability to correctly measure the component value Missing Resistor Missing Capacitor and Missing Diode The tester displays these messages when it does not sense a component where it should be in the cable Possible causes a A connection to the component is open a The component has not been installed is missing or has a value greater than what the tester can measure Bad Diode The tester displays this message when it senses a defective diode condition Possible causes a The diode s forward or reverse bias voltage drop is out of tolerance a The installed diode is outside the measurement capability of the tester Reversed Diode The tester displays this message when it senses a diode s orientation is reversed Possible cause a The diode is reversed in the cable NOT twisted a Two wires are not twisted that should be No twisted pairs a The tester did not detect twisted pairs in the tested cable Wires are paired incorrectly a A wire is twisted with the wrong wire Cable Error Messages 12 Digital 1 0 Digital I O on the 1100H Digital I O allows you to set up the 1100H to control external devices with tester functions You can also use an input on the tester to start a test For example the tester could be built i
81. ptions and settings Good Bad LED Lights s Green light if cable passes the test ein SS SS Red light if cable has errors Menu Title Selection Buttons Always on the top Select menu options line in capital letters Downloading Updates and Changing the Language 1100H testers come with the newest version of tester software when purchased however new software is released regularly You can connect a computer to a tester using the serial port that comes with the CTLWIN kit and use the 1100 Upgrade Application to update the tester software This application can also be used to change the tester interface language if needed English and Spanish are currently available other languages may be available in the future For more information see 1100 Upgrade Application on page 79 Security When using your 1100H tester you may see a lock symbol next to a menu selection This symbol indicates that the selection cannot be changed By connecting a computer to the tester you can choose to lock or to unlock certain menu selections You may want to use this capability may be used if for Menu Lock example you wanted to keep operators from creating new test programs or Symbol changing tester settings For more information see 1100 Utilities Application on page 80 Tester 9 Basics Changing the Speaker Volume Depending on the environment where the tester is used you may want to change the speaker v
82. r not every hipot test situation is safe Hipot testing is not a danger to healthy individuals although an occasional mild electric shock may be experienced A small shock will only occur during a hipot test when the operator touches an energized connection point A shock from the tester may result in a hipot test failure Medical Warning A child or individual wearing a cardiac pacemaker insulin pump or electronically controlled medical device should NOT perform Hipot testing Improving Hipot Safety e Set Auto Hipot to OFF When this option is set to OFF see page 41 the analyzer does not automatically Hipot test Instead the analyzer s display prompts Ready To Hipot after testing for continuity and resistance This requires the operator to manually press the Function switch or Hipot button to conduct a Hipot test Having manual control of the Hipot test should give the operator ample time to remove their hands from any cable connections and prevent the possibility of shock e Wear Rubber gloves Latex rubber gloves should be sufficient for insulating the operator s hands from electric shock However do not use gloves designed for electrostatic discharge ESD These gloves increase the potential for shock and test failures For more information on improving hipot safety visit www cirris com testing guidelines hipot_safety html Setting up the Tester 1 Connect the power supply and power cord together an
83. r support representative is ready to assist you In the USA call Cirris customer service toll free at 1 800 441 9910 Outside the USA enter the URL www cirris com contact html to find the Cirris Sales Office nearest you You Should Have Received O USB Thumb Drive QO 1100H Tester es CTLWIN Kit Power Supply O Probe Power Cord Plug type varies with country of receipt You May Have Received a Adapters a Scanner Add Ons Interchangeable adapter Each Scanner Add On cards for connecting E provides 128 test points cables to the tester Connect up to seven for a lt A oS total of 1024 test points a Networking Made Easy Kit Contains the Networking Made Easy CD and network setup instructions Tester Options Your 1100H comes standard with 1000 volt DC Direct Current or 1500 volt DC depending on the model you have Additional options are available for purchase such as networking scripting SPC Data Collection and AC Alternating Current capability If you have purchased any of these options a sticker on the back of the tester identifies the option s you received Each option is described below To add any of these options to your 1100H call Cirris customer service at 1 800 441 9910 Networking This option allows you to store test programs in a central location easily collect test results keep track of test programs and make sure each tester on your production floor has access to the same
84. ressed wirelists by name or by content e FILE NAME This option will display the name of the bundled file as a ccb file or for the single file as a ccf file e FILE CONTENT This option will display all files in the bundle or the single files Press Mark Files Select the D drive and press the buttons next to the bundle or file you want to import right arrows indicate that a file is marked for import Use the 1100H Test Program Location Listing or other documentation to verify the correct test program to be imported Press the back button Note Your compressed wirelists will now be in the tester s C drive Using the 29 Tester Using CTLWIN Included with your tester is the CTLWIN kit which contains a software install disk and a PC interface cable CTLWIN is a PC Windows program which allows you to access Test Programs in the testers memory Using CTLWIN you can a Copy move test programs between an 1100H and a computer a Create custom point labels a Edit create and organize test programs on a computer a Create links and define components For installation instructions and PC requirements to run CTLWIN refer to the Cirris Software Installation Guide Common Uses for CTLWIN Copy Test Programs If you have multiple 1100H testers you can create a test program on any tester and use CTLWIN to copy the same test program to other testers Custom Point Label Replace Default Point
85. ric failure errors 70 Dielectric withstand test 36 Digital I O 73 Display adjustment 86 Documenting Cable Documentation Form 87 88 Memory Location Listing 89 Download Utility 79 Duration Setting 52 E Editing Test Parameter Settings 45 Error messages See Cable error messages Error Tones 65 External Switch 39 F Factory Defaults 33 Fault Location 40 42 Fixturing Checking 87 Folders 25 Four Wire Testing 61 buiding fixturing 61 Kelvin Points 63 learning test 64 point types 61 probing point types 64 turning on 64 G Good LED Light 9 H Hardware version 86 High Cap Shield Setting 60 High Speed Hipot 41 High volt leakage 71 High Voltage Setting 50 57 High Voltage Test delay 41 dielectric withstand test 35 36 duration 52 errors 69 71 insulation resistance test 36 soak period 35 voltage ramp up 35 36 Hipot Test See High Voltage Test Hipot To Setting 53 HV Insulation Resistance Setting 51 I I O Port 73 Importing compressed wirelists and scripts 28 Insulation resistance test 36 Intermittent errors 69 L Labels see Scripting manual p 40 42 2 Leaky diode error 72 Learn and Test Settings 44 64 changing 44 Component Resistance 48 Duration 52 High Voltage 50 57 Hipot To 53 HV Insulation Resistance 51 learn 32 Learn Component 59 LV Insulation Resistance 47 restoring factory d
86. s If your cables are failing with a voltage leakage error you might increase Max Soak If the problems disappear the cable likely has a dielectric or moisture absorption problem a lfa cable must exhibit rigorous high voltage resistance in humid environments turn Max Soak off a Use a longer Max Soak setting for measuring best case insulation resistances or for testing the physical properties of insulation independent of environmental degradation a Use a shorter Max Soak setting for detecting corona small current spikes that occur as moisture dissipates from the cable and other humidity related problems in a cable High Voltage 54 Settings Soak Until Good Selections For a description of the SOAK capability see Max Soak on page 54 OFF ON In the Advanced Hipot settings you can turn Soak Until Good ON or OFF a When Soak Until Good is ON the tester displays Max Soak settings and applies voltage to each net in the cable until it either a passes the I R test or b completes the Max Soak time the same behavior occurs when using the Standard Hipot setting a When Soak Until Good is OFF the tester displays the Soak For setting see the next section for details Note Unless specifications require otherwise turning this setting ON can save test time Soak for Selections Available only when Hipot Test Advanced is selected 002 017 02 1 10 30 60 120 Seconds Soak For applies voltage to each net in
87. s a button to start a test or have the test start by itself after the tester senses a connection User Preferences do not affect the critical characteristics of the test Learn Settings Learn Settings affect the way the tester learns a cable For example do you want the tester to learn electrical components in the cable If so you need to change one of the Learn Settings that checks for components Another Learn Setting determines how low the resistance of a connection must be before it is recognized as a connection After a successful learn the Learn Settings become the Test Parameter Settings for that cable until it is changed Test Parameter Settings Test Parameter Settings affect how a cable is tested An example of a Test Parameter Setting is the level of high voltage applied to a cable during the high voltage test The Learn Settings provide the defaults for the Test Parameter Settings To change the Test Parameter Settings for a particular test make the test the loaded test by creating a new test or retrieving one from memory and edit the settings The Test Parameter Settings determine the parameter signature which is the last part of the Cable Signature Most often the settings used to learn a cable will be the same settings used to test it however there are times when these setting need to be different The following sections will help you understand how and why to change the settings Overview of Preferences and
88. s say you want to control an air valve for equipment that will automatically stamp tested good on each assembly that passes a test In the User Preference Set Digital Output you can select Cable Counted Good to both set and reset the output Remember if the same event is selected for set and reset the tester will sink the output for a 10 millisecond pulse In this case a pulse is all we need to make our stamp mechanism function In this example the solenoid for the air piston requires DC 24 volts and 300 milliamps the coil resistance is 80 ohms Note The digital I O port can only supply 100 milliamps at either DC 5 or 10 volts however the output can sink up to 24 DC volts In this case you can use an external power supply for the valve circuit as shown below Valve l Solinoid 24 V DC Power Supply Pins 14 amp 15 Ground ooo0oo0oo0o00 oo0oo0o00000 Pin 5 Output In this example a 1N4002 is added across the relay to protect the digital I O port from the reverse current created from the coil when the output turns off DYfeitmOmm 77 Setting up the Events Outputs The 1100H has six outputs that can drive an external device according to various events in the tester These events occur as the tester powers up learns a cable tests a cable and displays the test results Controlling an output line requires two triggering events 1 2 From main menu press Set Preferences scroll down w and
89. s section What s the difference between Intermittent Errors and Low Voltage Errors To be an Intermittent Error the tester must sense that the cable wire pattern 1 Was good 2 Then changed to bad 3 Then changed back to good Intermittent Errors are caused by a Cable defects that show up only when the cable is moved or wiggled during the test a The same as those described in the previous section for opens and shorts High Voltage Hipot Errors Failed hipot errors occur during the high voltage test Like other error messages press View amp Print Errors to see the detailed error message For example this message for a hipot failure describes 1 The type of hipot failure AND 2 Which net or test point failed Note The High Voltage error message does not show what the error was to only that it happened from the displayed net For example the error message shows First Detail Error Screen two hipot errors therefore we assume these two points were arcing to each other NET NC means the error occurred on an unconnected point in the connector If more than two hipot errors occur Second Detail Error Screen you cannot assume which points were leaking or arcing to each other Cable Error Messages 69 Overcurrent Errors An overcurrent error indicates that the tester could not supply enough current to raise a net or point to the selected hipot test voltage a Overcurrent Errors
90. sed when a shielded cable is hipot tested Cable shields usually have substantially higher capacitance because the shield surrounds and has capacitance to all wires in a cable To avoid an unsafe shock hazard during a hipot test the tester will not continue to charge a highly capacitive net Q If High Capacitance Shield is set to NO the tester reports an Overcurrent Error when it stops charging a highly capacitive net Q If High Capacitance Shield is set to YES the tester ignores a single Overcurrent Error generated by a cable shield as long as all other wires pass High Capacitance Shield Guidelines Q Asingle net hipot failure can be an indication of a net with high capacitance Normally hipot failures show up with at least two failed nets Q By turning on the High Capacitance Shield setting you can successfully test a cable with a highly capacitive shield High Voltage 53 Settings Max Soak Selections Factory Default 0 01 1 1 10 30 0 seconds 60 120 seconds SOAK Overview In some cables the current flow stabilizes quickly when high voltage is applied In other cables the current flow may take longer to stabilize due to humidity dielectric absorption temperature residual charges or other factors To compensate for cables that take longer to become steady Cirris testers have the SOAK capability SOAK applies voltage to the cable for a period of time to dry out or stabilize the current flow so the tester can p
91. tance than the Connection Resistance setting to be learned as connections When you test a cable the cable s connections must be lower than the Connection Resistance setting to pass the test Connection Resistance Guidelines a To allow for cable and tester tolerances you should generally select a connection resistance at least 20 or 0 2 ohms whichever is greater above the resistance of the actual connections a Over time heavily used adapters can develop worn contacts which will add to the connection resistance measurement Cirris recommends replacing worn adapters before they affect the measured connection resistance and create high resistance errors If you must use adapters with substantial wear you will have to increase the Connection Resistance setting to get cables to pass The tester can measure the actual connection resistance and give you a suggested value for the Connection Resistance setting Calculating a Suggested Connection Resistance Setting 1 Attach a sample cable 2 From the main menu press Create New Test Set Learn Settings Set Lrn Res Thrsholds and Calculate Conn Res 3 The tester measures the resistance of each wire and displays a suggested res value which is 20 greater than the highest measured resistance in the sample cable To help determine a better Connection Resistance setting measure the variances of several sample cables connect each cable and press Calc New Sample Note Use Calculate C
92. test information Additionally you can easily back up test information to prevent it from being lost or deleted Ultimately operating multiple testers is more effective and time efficient with a network To implement networking Cirris Networking Made Easy Kit is required SPC Data Collection This option allows you to store specific test information and retrieve that information for analysis To enable the SPC Data Collection option see 1100 Utilities Application on page 80 For more information see SPC Data Collection on page 84 Scripting This option allows you to adapt the tester s behavior to fit your needs add new features and ease automation of tasks in the tester Scripting can also be used to create and print custom labels for wire identification see Create Labels in the Scripting manual To enable scripting see 1100 Utilities Application on page 80 AC Voltage This option allows the 1100H tester to perform hipot tests using up to 700 VAC RMS on the standard 1100H configuration The tester s AC hipot capacity is extended to 1000 VAC RMS if you have the 1500 VDC model Note Special high voltage adapters are required to test at hipot voltages above 1000 VDC and 700 VAC To enable the AC option see 1100 Utilities Application on page 80 Em Hipot Warning Possible electric shock AA Cirris hipot testers are designed to be safe for operators Injuries from hipot test equipment are rare howeve
93. test program in the tester Note Cirris recommends recording the test program information on the 1100H Cable Documentation or 1100H Test Program Location Listing form blank forms in appendix Using the 26 Tester Loading a Test Program 1 From the main menu press Set Up Test Program Press Load Test Select the drive letter and folder where the test program has been saved Select the test program you want to retrieve to make it the loaded test program Deleting a Test Program 1 2 Return to the main menu Scroll down w and press AZ Manage Files ites sy z Press Delete Files Press Mark Files Bn Press the buttons next to the files you want to delete arrows indicate that a file is marked for delete oo Use the 1100H Test srogram BT Location Listing or other documentation to verify the correct test program to be deleted Press the back button Press Delete Marked Cialemiatem 27 Tester Importing Compressed Wirelists Script Files You can only import wirelists or script files if you have used the 1100 File Compression Utility Before attempting to import your files see 1100 File Compression Utility on page 82 1 With your thumb drive plugged in scroll down from the main menu ie and press Manage Files eS From the Manage Files screen scroll down and press Import Files You can press the View button to view your comp
94. to join 4 Wire Pairs While easy the connector adapter pin numbers won t match the pin numbers of the device under test since only the visible point shows in the net list however custom test point labels can be used to remedy the pin out numbering Alternating J2 16 Method Adapter Connectors DLT k 4 Vvire Pair A E 4 Vire Pair y The other way to construct 4 wire fixturing is to use the separate method shown below Although more difficult to construct the separate method will create a Net List which will document correctly without using custom test point Labels A 2 wire Net List can be preserved when converting to 4 wire Note Because the first scanned point of a 4 wire pair becomes the visible point make sure hidden point adapter s are in a higher counting J position than Net List adapter s Separate J Method pint Ti T2 T1 T2 ee Net List lower dx NetList T2 T1 T2 m1 Adapterls Tra T2 T1 72 Net List DUT iG lt q O f aire Pair iN L Hidden AAi pe 4 yire Pair P higher dx UEN eaa T2 Hidden Point Adapter s 2 T2 T1 Component Settings amp Test The Location of Kelvin Points in Fixturing The location where the 4 wire pair physically 4 ire Palir joins the test point connection of the device under test is called a Kelvin point Kp 4 vire Meas Each 4 wire measurement requires two Kelvin
95. ulation Resistance Selections Factory HV Insul Res Default Available selections limited by 10MQ High Voltage Setting 5MQ 10MQ 20MQ 50M0 100MQ 200MQ 500MQ 1GQ How well are the nets in a cable isolated HV Insulation Resistance determines the minimum resistance allowed between nets Nets with insulation resistance less than the Insulation Resistance setting are considered to have leakage and fail the hipot test Nets with insulation resistance higher than the Insulation Resistance setting pass the hipot test SHORT LEAKAGE GOOD CABLE Zero Infinite Resistance HV Insulation Resistance Resistance Setting The HV Insulation Resistance settings are limited by the high voltage settings The table below shows the available Insulation Resistance settings at each of the high voltage settings Available HV Insulation Resistance Settings 1000 Volt Unit Voltage 5 00MQ 10 0MQ 20 0MQ 50 0MQ 100 0MQ 200 0MQ 500 0MQ 1 00GQ WIRE FEER h oeoereogg RRS EL hse EEE SUL SISIN rS J T Hh FF wet Mt att SANs High Voltage 54 Settings HV Insulation Resistance Guidelines Specifications may dictate the Insulation Resistance setting which may be based on some of the following factors Q Allowed Contamination Cables in high voltage and sensitive electronic equipment must have a stringent test because of their ultimate use Other cables may be tested at lower levels to allow for contamination such as fingerprints
96. vice under test you will eliminate all sources of interface resistance This extra effort may not be feasible For more information see Four Wire Kelvin Testing at htto www cirris com testing resistance fourwire html Note 2 wire and 4 wire testing can be put into any combination on the 1100H tester Building 4 Wire Fixturing For the purpose of 4 wire testing the 1100H test points are considered either Type 1 T1 or Type 2 T2 points Each 4 wire pair from the tester must have one of each point The tester uses T1 points as either force or sense it uses T2 points as the compliment While you can use any standard adapter to run 4 wire fixturing from the tester Cirris suggests using one of the Cirris AHED series adapters The AHED adapters map T1 and T2 points in a uniform alternating pattern as shown on the next page The probe can also be used to identify T1 and T2 points as described further in this section Adapter Connector P N AHED 16 SIGNATURE CIRRIS MATES TO The 1100H tester must learn a 4 wire fixture When the fixture is learned the first scanned point of each 4 wire pair becomes the visible point in the Net List Both test points are listed below the Net List in the 4W Wire Kelvin Pairs Component Settings amp Test 4 wire fixturing can be constructed in an alternating or separate method The Alternating method shown below is easy to use With ribbon cable you solder adjacent wires
97. w the tester to perform the hipot test much faster by applying high voltage to several nets simultaneously in a pattern that ensures each net is hipot tested against every other net a When High Speed Hipot is OFF the tester applies high voltage to each net one ata time Note If the tester finds an error during the High Speed Hipot process it switches to the low speed routine to find which wire failed This means a failed hipot test will actually take longer than a passed hipot test The tester may not be able to duplicate a dielectric error found in the high speed routine and displays the error Dielectric Failure Undetermined Net This would be the case if an arc occurred while in the high speed routine which cleared away a conductive path Some specifications may require you to test with High Speed Hipot turned OFF User 41 Preferences Safety Switch Selections Factory Default ON or OFF OFF Safety Switch requires that the tester sees a high signal on pin 2 of the digital I O connector before starting the hipot test Safety Switch can be used to help ensure an operator does not shock themselves during a hipot test a When Safety Switch is ON the tester will look for a high signal on pin 2 of the digital I O connector before starting a hipot test a When Safety Switch is OFF the tester ignores the signal status of input pin 2 on the digital I O connector Safety Switches can be dual palm switches wired in

Setup - Artisan Technology Group

Contents

Download Pdf Manuals

Related Search

Related Contents