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Signature 1000H+ Cable Analyzer User's Guide

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1. ccccceeeeeeeecceeeeeeeeeeeeeeeeeeeesseseeeeeeeeeseaeeaeees 17 Section 3 What the Option Settings Mean essssssssesssennnnneeesenrnrnserrrrnnsserrrrnnnssserrnnne 19 Section 4 Learn a Sample Cable Store it in Memory 2 0 ceeeeeeeeeeeeeeeeeeeeeeeeeneeees 23 Section 5 Test Your First Cable ccccececseceeeeeeeeseeeeeeeeeeseeaaaaeeeeeeeseeaeeeeeeeesesneaeeees 27 Section 6 Retrieve a Cable from Memory ccccceeeeeecceeeeeeeeeeeeeeeeeeeeenaaeeeeeeeeeeeaes 31 Section 7 Delete a Cable from Memory cccccceeeeeeeeeeeeeeeeeeneeeeeeeeeeeueeeeeeeeeeentneeees 33 Section 8 Print a Directory of Cables Stored in Memory eseeeeeeeeeeeeeeeeeeeeeeeeeees 35 Section 9 Cable Documentation and Signatures cccccccceeeeeeeeeeeeeeeeeeeeeeeseeneneeeees 37 Section 10 Select a Test Procedure 0 cceeeeecccceeeeeeeeeeeeeeeeeeeeaaaeeeeeeeeeeeenaaeeeeeeeseaaees 43 Section 11 Rework and Guided Assembly cccceeceeeeeeeeeeeeeeeeeeeeeeeeseeneneeeeeeeeeeeeaas 55 Section 12 Troubleshooting ow cccecese ives ve decesdns dacees pee cede sete ieee eeeee eve ead eee 61 Section 13 Specifications iccchiacecisisisuhiiaatedadbarchiedradeddededaliiinndewhedabeda lela afcdeocddeaatis 71 Section 14 Statement of Warranty 0 0 0 2 eceeecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeesaaeaeeeeseesesenaeeeeees 73 SOCHON TO Glossa sects aceetersciten costes ete tie ae ated a a a tines eee ta eee 75 Section 16 B
2. Auto Print is OFF If you want to go backward through either the options or settings press in and hold the M emory button on the back of the analyzer while pressing Display P rint or Function Note All options or settings will roll over to the beginning when you are going forward or backward Memory button When you set the value you want it is saved once it is displayed on the screen Turn off the analyzer the analyzer will use those settings when you power it up again Touch 1 User s Manual 1500 Volt System page 18 Section 3 What the Option Settings Mean Overview Create Test From Connection Resistance Hipot Voltage The Cirris 1000H has twelve test option settings which you set to meet your testing requirements In this section we ll tell you what each of the settings means Gives you the option to create a new test setup from a new Sample Cable your last test setup or by learning a complex cable that contains resistors and or diodes in addi tion to ordinary wire connections SAMPLE CABLE Use this setting to learn standard simple cables cables that contain only wires and connectors LAST TEST SETUP Use this setting when you need to use the same test setup each time you turn on the analyzer Useful when testing large batches of the same type cable Will help protect your test setup from a power failure or if you accidentally turn on the analyzer with an untested cable connected
3. COMPLEX ASSEMBLY Use this setting to learn a cable that contains resistors diodes or divider networks in addition to ordinary wires and connectors When you use this setting the Connection Resistance refers to the resistance level that definitely separates wires from resistors The analyzer sets this to 5 Q You may change the setting to meet your needs Using the Connection Resistance CALC mode may help you determine a good setting Specifies the maximum resistance a connection can have and still be considered good For example if you set the Connection Resistance to 10 Q the analyzer will consider all connections with resistances less than 10 as good and those with resis tances greater than 10 as bad Range 0 1 to 100 Q 500 Q IMQ 5 MQ AUTO CALC AUTO mode When you set the Connection Resistance to AUTO the 1000H measures the resistance of each connection in your Sample Cable then automatically sets the Connection Resistance threshold to a value 20 higher than the largest resistance measured in the Sample Cable The 20 margin of error is increased for resistances less than 1Q CALC mode Setting the Connection Resistance to CALC causes the 1000H to measure the resistance of the connections in the Sample Cable in the same way you would measure them with an ohmmeter In this mode the analyzer can only measure resistances up to 10KQ After the analyzer calculates the resistance of the Sample Cable it prompts RESISTANCE
4. Main unit 13 w X 6 5 d X 5 h 33 X 16 5 X 13 cm Expansion box 6 w X 6 5 d X 5 high 15 x 16 5 x 13 cm Main unit 9 lbs 4 kgs Expansion box 5 lbs 2 3 kgs 2 line x 16 character LCD 1 year parts and labor Replacement modules available next working day 1000H User s Guide page 71 Section 13 Specifications Warranty 1000H User s Guide page 72 Section 14 Statement of Warranty Cirris Systems Corporation warrants the 1000H Cable Analyzer to be free of defects in materials and workmanship for a period of one 1 year from the date of delivery to you 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 will repair or replace the analyzer with a new or reconditioned unit of equal value For this war ranty to be valid you must complete and return the warranty registration card In the event of replacement with a new or reconditioned model the replacement unit will continue the warranty period of the original analyzer Replacement units will be returned by the same method shipped generally within one 1 working day If analyzer failure results from accident abuse or misapplication Cirris Systems Corporation shall have no responsibility to replace the analyzer or refund the pur chase price Defects arising from such causes will be considered a breach of this war ranty Cirris Systems Corpo
5. Auto Hipot option what it does 21 AUTO mode 19 Auto Print option what it does 21 C Cable documentation how to interpret 38 Sample documentation forms 79 what it is 37 why prepare it 37 Cable signature what it is 39 CALC mode 19 44 Changing the EPROM 13 Complex assembly how to interpret documentation 48 how to learn 46 how to test 49 limitations when testing 50 Complex test First pass check components test 49 hipot test 49 insulation test 49 wires test 49 Complex tests how to determine Connection Resistance setting for 44 Connection Resistance AUTO mode 19 CALC mode 19 Connector adapter signature what it is 39 Count All Cables option what it does 21 Create Test From option what it does 19 D Deleting a cable from memory 33 Dielectric Fail what it means 29 Documentation changing the company name 16 from complex assembly interpreting 48 E EPROM how to change it 13 Error List Print or transcribe 30 Error Message Dielectric Fail 29 what it means 29 Errors Detected 28 what it means 28 Failed Hipot Test 29 what it means 29 Good what it means 21 Has Leakage 29 what it means 29 Intermittent 29 what it means 29 Open Detected 28 what it means 28 Over Current 29 what it means 29 print or transcribe an error list 30 Short Detected 28 1000H User s Guide page 91 what it means 28 While learning a Sample Cable what to do 25 Error Tones option what it does 21 Errors Detected what it means 28 Exp
6. The current flow is monitored during the hipot duration you have set to make sure it does not exceed the maximum allowed current If the current flow stays below the maximum allowed current for the hipot duration the net passes the test If it does not stay below the maximum allowed current the net fails the hipot test and the analyzer labels it Has Leakage Note The analyzer does not check where the current flows it only knows that too much current is leaving the high voltage power supply Current Maximum allowable current Time Hipot Duration Has Leakage error If the current flow spikes above the maximum allowable current during the hipot duration the analyzer shuts off the high voltage and labels the cable as having a dielectric failure Current Maximum allowable current Hipot Duration Time Dielectric Failure Tips on selecting Remember when you select a hipot voltage you are setting the amount of voltage to Hipot Voltage settings be applied between pins that are not connected Remember these things when you select hipot voltage settings e The more voltage you use the more likely the analyzer is to detect contamination between pins or frayed wires that almost create a short circuit However higher test voltages only work well on cables with little pin to pin capacitance e Higher voltage settings require greater pin to pin spacing on cable connectors
7. Types of Tests Typical test 0 52 100MQ 300V 100mS Use these settings when low connection resistance is important and the cable has little capacitance Low connection resistance may require careful adapter maintenance The hipot test will not work on extremely long cables Stringent 0 50 500MQ 630V 10 seconds Use these settings for slow test stringent testing when you need low connection resis tance and extremely good insulation resistance Maintain connector adapters carefully Works only with clean adapters in low relative humidity Complex Ins Resis 100KQ optional optional Set CREATE TEST FROM test or more option to COMPLEX ASSEMBLY to learn an assembly that contains resis tors diodes divider networks When you choose this setting Conn Resis refers to the resis level that definitely sep arates wires from resistors The analyzer sets this toa default 5 ohm level You can set the Conn Resis option to CALC then learn the cable to determine a better setting Connection Resis Default setting 5 ohms Conn Resis must be set to greater than highest wire resis and lower than lowest component resis Complex Tests Complex tests are for cable assemblies that contain components such as diodes or resistors To help you make use of complex tests we will show you these things 1 How to determine the correct Connection Resistance setting for a complex assembly 2 How to set t
8. A a x Pai DISPLAY QZ PRINT a FUNCTION 3 Once you ve corrected all the shorted connections the analyzer will either prompt Good Cable or Connect JX XX If the analyzer prompts Break JX XX you have created another short Go back to step 2 and try again Note The 1000H User s Guide page 57 Section 11 Rework and Guided Assembly Removing shorts between nets analyzer may prompt Intermittents as you rework the connection To clear this prompt press the M emory button on the back of the analyzer GOOD CABLE BREAK JX XX DISPLAY Pi DISPLAY PRINT PRINT FUNCTION FUNCTION You ve created another short Cable has been corrected Go back and try again Removing shorts If the analyzer detects short circuits in the cable or harness you are testing it will tell between nets you where to make cuts to correct the shorts This will happen if two nets should become shorted To correct a detected short do these things 1 The analyzer will prompt Cut JX XX From JX XX where X indicates the adapter positions and pin number CUT JX XX FROM JX XX DISPLAY PRINT FUNCTION 2 Locate the short between the nets and remove it Please see next page 1000H User s Guide page 58 Section 11 Rework and Guided Assembly Correcting opens Correcting opens Guided Assembly If the analyzer prompts Connect JX XX to JX XX indicates that the cable you re testing has an open circuit To corre
9. K This blank area is for writing in the date of the test L This is a section left open for writing in any additional notes You may wish to include a drawing of the cable here M This shows the EPROM revision number your analyzer is equipped with N Will Fail Hipot may or may not appear in the printout depending on what set tings you are using Signatures are the working basis of the 1000H system When the 1000H learns a Sample Cable a cable that you know is built correctly it computes and displays a cable signature for that Sample Cable This signature becomes part of your cable doc umentation for that kind of cable e When the signature prompted by the analyzer matches the signature in your cable documentation you know that your test setup is correct e When the signature of a cable you are testing matches the documented signature during a test you know the cable under test is correctly built The 1000H uses three types of signatures 1 The cable signature 2 The parameter signature 3 The connector adapter signature s The cable signature The first six characters in a signature as displayed by the 1000H are called the cable signature This six character alphanumeric number represents a summary of the interconnections in a cable When the analyzer learns a cable it computes this unique signature based on the cable s interconnections and the connector adapters in use The parameter signature When
10. READY Press the Display P rint switch to display all resistances measured below 10Kohms Specifies what voltage will be applied during hipot testing between pins that should not be connected This determines how effective the insulation on a cable is during a 1000H User s Guide page 19 Section 3 What the Option Settings Mean Insulation Resistance with hipot off Insulation Resistance with hipot off Hipot Duration Apply Hipot To test The higher the voltage you set the higher the insulation resistance the analyzer can detect Voltage settings will affect the range of insulation resistance settings available to you Warning Do not subject cable assemblies to voltages higher than they are designed to handle because this may damage them For example ribbon cable is usually designed to handle up to 300 volts By setting the Insulation Resistance threshold you select the highest resistance that the analyzer will detect during a test For example setting the Insulation Resistance at 50K means the analyzer will detect connections with resistances up to 50KQ Any connections with resistances higher than 50KQ will be ignored Important The Insulation Resistance setting must be equal to or greater than the Connection Resistance setting When you select a hipot voltage the resistance is the level at which a hipot failure will be detected This table shows how the Hipot Voltage setting limits what Insulation Resistance setting
11. RESISTANCE 0 ohm 6 J1 006 J3 006 RESISTANCE 0 ohm 7 J1 007 J3 007 RESISTANCE 0 ohm 8 J1 008 J3 008 RESISTANCE 0 ohm 9 J1 009 J3 009 RESISTANCE 0 ohm 7 Set the Connection Resistance to a value greater than the highest wire resistance and less than the lowest component resistance How to set the options to learn a complex assembly To set the options for learning a complex assembly do these things e Ifthe default Connection Resistance setting of 5 ohms is not appropriate for the cable you want to test set it to a value between the highest wire resistance and the lowest component resistance in the cable e Set the Create Test From option to Complex Assembly then turn off the analyzer How to learn a complex assembly 1 Install the correct cable adapters then connect the assembly you want to learn to the analyzer 2 Turn on the analyzer to learn the cable assembly 1000H User s Guide page 46 Section 10 Select a Test Procedure Types of Tests The analyzer first prompts Learning Cable as it learns all interconnections in the cable which have resistances up to the Insulation Resistance setting you have selected The prompt changes to Learning Complex as the analyzer learns the pattern of wires which have resistances less than the Connection Resistance setting The prompt finally changes to Creating Checks as the analzyer learns the resistors and diodes in the cable The analyzer sets the accura
12. automatically calculated from the voltage drop reading using Ohm s Law The result is the four wire resistance mea surement Limitations of four The accuracy of the analyzer limits the effective range of four wire testing A tester is wire testing less accurate when it tests cables which have over ten ohms of resistance than it is if the fixturing resistance is nulled out using the four wire testing technique Four wire testing may satisfy a testing specification It offers no advantage for quality assurance testing of cables which have more than 10 ohms of resistance Four wire testing does not eliminate problems caused by the resistance of test connec tors Connectors wear a bit with each insertion cycle This wear creates resistance on the test connector which four wire testing does not null out To be certain that your tests remain accurate you must maintain the analyzer s connectors carefully or build special four wire test connectors which use spring loaded contacts These contacts wear less with each insertion cycle than traditional connectors do 1000H User s Guide page 89 Appendix 1 Four Wire Testing on the 1000H Using Cirris Test Language CTL Commands Using Cirris Test Language CTL Commands RESIS CR_TEST CRATEST Specifications Range Accuracy Current used Low current test You can use Cirris Test Language CTL while you re doing four wire testing We ll discuss some
13. beeps The available settings are Off Low and H igh When this option is ON it changes the order that errors appear in a net For example pin J1 01 will always come before pin J1 14 if they are connected in the same net When this option is OFF the order that pins appear in a net is determined by the scanning order of the analyzer Once the analyzer is programmed and you ve begun testing cables the analyzer begins to count the cables you test When this option is ON the printout from your tests shows the total number of cables tested as well as the number of cables which tested as good When this option is OFF the printout will show only the number of cables that tested as good When a printer is connected to the analyzer and this option is ON the system will print a one line report when each cable being tested is disconnected indicating whether that cable tested as good bad or intermittent When this option is OF F the system will not print each result automatically 1000H User s Guide page 21 Section 3 What the Option Settings Mean Auto Print 1000H User s Guide page 22 Section 4 Learn a Sample Cable Store it in Memory Overview Memory in the 1000H Last Learned Learn a Sample Cable In this chapter we will show you how to learn a Sample Cable then store the wirelist from that cable in one of the analyzer s permanent memory locations The Signature 1000H has from 10 to 50 permanent mem
14. e Subjecting a cable assembly to excessive voltage may degrade its future performance Use the lowest voltage setting that still finds insulation problems in a cable Most cables require no more than 630 volts Most ribbon cables are designed to handle a maximum of about 300 volts e The hipot test applies high voltage to a net a group of connected pins and measures the current that flows from the net The analyzer does not determine which net or pin the current is flowing to This means that if several nets have leakage you cannot tell which nets leak to each other 1000H User s Guide page 52 Section 10 Select a Test Procedure Hipot voltage and capacitance problems Hipot voltage and capacitance problems Tips on selecting Insulation Resistance settings Excessive capacitance in a cable assembly is a major consideration when you are deciding on what Hipot Voltage Hipot Duration and Insulation Resistance settings to use If a cable has shielding or a grounded net capacitance problems are more likely to occur Remember these things e In general the higher the capacitance a cable has the lower a hipot volt age setting you ll be able to use See page 20 for further information e Ifyou find that a cable has excessive capacitance first try lowering the H ipot Voltage setting You may also set the S ingle Net Error option to Is Ignored This will cause the analyzer to ignore a single net hipot failure A single net hipot fail
15. from the inside of the chassis and remove the plastic plate e For photographic clarity in the top photo we ve removed the scanner 1000H User s Guide page 10 assembly from the main unit and disconnected it You see the connec tor that plugs into the main unit s scanner assembly and the connector that plugs into the scanner assembly in the expansion box You also see the plastic plate in the main unit s cable routing opening partially removed You should remove the plate completely Make sure the connections to both the main unit s scanner and the scanner in the expansion box are secure Connector goes to main scanner Connector goes to expansion box scanner Remove this plastic plate completely This view shows the cables that connect the main unit to the expansion box as they should appear just before you plug them together Be sure the connectors are well seated and that the connection is secure Gently lower both scanners into their boxes routing the connecting cables through the openings in the side of each box 1000H User s Guide page 11 Section 1 Work With the Hardware How to install an expansion box 3 Slide the two metal boxes together The alignment pins in the side of one box should fit into the round openings in the side of the next box This alignment pin fits into this hole 4 Once the two boxes are in position hook the drawlatches on one box over the keepers on
16. in position J1 should be O3FAC1 The signature for the adapter in position J2 should be F5B4E0 E This blank area is for writing a brief description of the connector adapters F This blank section is for writing a cable description G This section shows the test parameters Our example shows that the Connection Resistance is set on AUTO and that the Insulation Resistance High Voltage option is set to 50 MQ H Each net each group of interconnected pins is identified by a net number The net numbers appear directly under the number heading NO and are immediately fol lowed by the connected points that comprise that net I The interconnections that comprise each net appear after each net number and are shown directly under the heading COMMON CONNECTIONS The numbers J1 J2 1000H User s Guide page 38 Section 9 Cable Documentation and Signatures How signatures work How signatures work Types of signatures J3 and J4 indicate the adapter position The number after the hyphen is the specific pin to which a connection is made J Our example shows that a total of 50 cables has been tested Forty of these tested as good Six cables tested as having intermittent errors and four tested simply as bad This breakdown of good and bad cables appears on the documentation because the analyzer s Count All Cables option was set to ON When this option is set to OFF the printout shows only the number of cables which tested as good
17. lets you keep track of signatures option settings and net lists for each cable you test PHOTOCOPY THESE You should photocopy these forms instead of writing directly on them That way you ll have a fresh supply of blank forms whenever you need them 1000H User s Guide page 79 Section 16 Blank Forms to Photocopy 1000H User s Guide page 80 Master Parts List Cable Part Number Description Signature Copyright 1999 by Cirris Systems Corporation Directory of Wirelists Stored in Analyzer s Memory Memory Location Cable Description Signature Copyright 1999 by Cirris Systems Corporation Cable Documentation Form Memory Location Cirris Analyzer Model Cable Signature Parameter Signature first six characters last five characters Cable Description Adapter Signatures for Main unit 1st Expansion Box 2nd Expansion Box 3rd Expansion Box Jt J5 J9 J13 J2 J6 J10 J14 J J7 J11 J15 J4 J8 J12 J16 Notes Note All of these options may not appear in your particular type of analyzer Create Test From Connection Resistance Hipot Voltage Insulation Resistance Hipot Duration Apply Hipot To Single Net Error Auto Hipot Error Tones Are
18. may have resistances that fall between the Connection Resistance and Insulation Resistance settings e Press Display P rint to locate points with resistance errors and docu ment them If the cable is correctly built change the resistance settings 1000H User s Guide page 25 Section 4 Learn a Sample Cable Store it in Memory What to do if you see an error message to accomodate the cable See To check the option settings do these things on page 17 for details on how to do this e Ifthe cable is not built correctly use another Sample Cable that does not contain the errors and repeat the learning process Note If you discon nect the cable with the error or if you press the M emory button the analyzer will enter the test mode 2 If the error message is Insulation Resis lt Auto XXXX check to see if the Connection Resistance is set to AUTO and the Auto resistance is higher than the Insulation Resistance setting e Change the Insulation Resistance setting to be equal to or higher than the AUTO Connection Resistance setting prompted in the display See page 17 for details on how to change the setting 1000H User s Guide page 26 Section 5 Test Your First Cable How to test your first cable Check the display interpret the sounds Now that you have installed any expansion boxes you will be using have installed your connector adapters have checked the option settings and have programmed the analy
19. press Display Print the analyzer prompts the next unused mem ory location For example if location 1 is empty the display will prompt Mem 1000H User s Guide page 24 Section 4 Learn a Sample Cable Store it in Memory What to do if you see an error message ory Location 1 Is Now Unused Keep pressing Display P rint until you find the memory location you want Note If the display prompts No Memory Available all of the analyzer s memory locations are full You ll have to delete a wirelist to make room available See To delete a cable from the analyzer s memory do these things on page 33 for instructions on how to do this 4 When you have located an available memory position continue holding the Memory button in and press Function to save the newly learned wirelist to that memory location The display will prompt Memorizing Last Learned Cable MEMORIZING LAST LEARNED CABLE DISPLAY PRINT Hold the MEMORY button in while you press here 5 Release the Memory button The display will prompt Last Learned Now Is In Location X The wirelist is now stored in the analyzer s memory LAST LEARNED NOW IS IN LOCATION 1 DISPLAY PRINT FUNCTION What to do if you see If you get an error message such as Learned Cable Resis Error or Insulation an error message Resis lt Auto XXXX while you re trying to learn a Sample Cable check the following 1 Ifthe error message is Learned Cable Resis Error the cable
20. solve the problem go to step 2 2 Turn off the analyzer disconnect the microprocessor from the rest of the system then turn on the microprocessor The analyzer should prompt 10 V LO If it does the analog board or one of the scanner boards is bad Call Cirris to replace it 3 Ifthe problem is not solved after the microprocessor is disconnected the micro processor assembly is probably bad Call Cirris to replace it Problem When a cable is disconnected the display still prompts Please Verify Possible Causes e A cable adapter is bad or adapting cables are bad e The scanner assembly is defective Things to do 1 Remove the cable adapters from the analyzer while the analyzer is still on If the analyzer still prompts Please Verify the scanner is probably defective Call Cirris to replace it 2 If the analyzer prompts Ready To Test after step one is done you have unwanted connections in your cable adapters or adapting cables 1000H User s Guide page 66 Section 12 Troubleshooting General Problems with the Analyzer Problem Connections are not recognized by the analyzer Possible Causes e Bad cable adapters or adapting cables e Bad scanner assembly Things to do 1 Using the hand held test probe as a diagnostic tool use the sharp steel tip of the probe to pierce the insulation on the connecting wire for the connection that is not being recognized The pin which is displayed by the analyzer when t
21. the other box then close the drawlatches to lock the boxes securely together Keeper Drawlatch Once the boxes are together aligned by the alignment pins and holes hook the drawlatches over the keepers on each side of the analyzer then snap the drawlatches shut Replace the coverplates 1000H User s Guide page 12 5 This photo shows your 1000H as it should look with one expansion box installed and the spacer plate and coverplates in place How to change the You may need to change the EPROM on the microprocessor assembly To do this EPROM follow these steps 1 Disconnect the wall transformer from the wall outlet then disconnect the power cable from the socket on the back of the analyzer Disconnect the power cable 2 Unlock the twistlock fasteners remove the spacer plate then gently raise the microprocessor assembly out of the box 1000H User s Guide page 13 Section 1 Work With the Hardware How to change the EPROM 3 Carefully turn over the microprocessor assembly You ll now be able to see the EPROM you are about to change with the speaker wires lying close by EPROM Speaker wires 4 Using a small flat bladed screwdriver gently pry the EPROM out of its socket and remove it Notch 5 Gently align the pins on the new EPROM with the holes in the socket New EPROM Socket Gently place the new EPROM on the socket and align the pins Be careful not to bend the pin
22. 1 there can be as many as 50 of these Continue pressing Display P rint until you see the signature for the kind of cable you want to test MEM LOCATION X SIG XXXXXX XXXX DISPLAY PRINT Continue to hold while you step through the cable signatures 4 When the display prompts the signature for the kind of cable you want to test release the Memory button e Ifthe display prompts Ready To Test the analyzer has retrieved the Sample Cable data the correct adapters are in place and you are ready to test cables e If the display prompts JX Adapter Sig Should Be this means that the adapters you have installed don t go with the Sample Cable you ve retrieved Read the display to get the correct adapters and their positions then install them Note It s OK to install adapters without turning off the analyzer when it is in this mode Once you ve installed the correct adapters the display will prompt Ready To Test READY TO TEST SIG BBF038 0501 DISPLAY PRINT J1 ADAPTER SIG SHOULD BE ACEFA1 DISPLAY PRINT FUNCTION FUNCTION Cable retrieved adapters are Installed adapters are not correct correct You are ready to test Install correct adapters When you ve done that prompt will change to Ready to Test 1000H User s Guide page 32 Section 7 Delete a Cable from Memory Why delete a cable How to delete a cable The Cirris 1000H has a maximum of 50 permanent memory locations for s
23. ADAPTER PINS or 1000H User s Guide page 20 Section 3 What the Option Settings Mean Single Net Error Single Net Error Auto Hipot Error Tones Sorted Wire List Count All Cables Auto Print CONNECTIONS ONLY The CONNECTIONS ONLY setting is generally faster since only connected pins will be hipot tested The range of settings for this option is IS IGNORED or FAILS HIPOT This option allows cables with one oversized net or a net with excessive capacitance that would normally fail to pass a hipot test Most of the time a cable which has insulation resistance problems will show two or more net failures since they will be leaking to each other Caution When Apply Hipot To is set to Connections Only and Single Net Error is set to Ignored the analyzer will not report an error if one net is leaking to any unconnected pin in the adapter This option lets you choose between automatic and manual hipot testing When this option is ON the analyzer will automatically begin a hipot test on a cable as soon as that cable passes a resistance test You can repeat the hipot test by pressing the Function switch When this option is OFF a cable won t be hipot tested after passing a resistance test until you press the Function switch The Function switch becomes a push to test switch on the hipot test When the analyzer detects errors it emits a series of sharp beeps This setting allows you to set the volume of these
24. NNECTIONS 1 J1 001 J3 001 2 J1 002 J3 002 3 J1 003 J3 002 4 J1 006 J3 006 5 J1 007 J3 007 6 J1 008 J3 008 7 J1 009 J3 009 CHECK COMPONENTS NO DESCRIPTION 1 RESIS J1 004 J3 004 20 OHM 10 2 DIODE J3 005 J1 005 O 3 LINK J1 010 J3010 J A This cable signature represents the wirelist combined with a signature for the components B A MULTI parameter signature indicates that this documentation was created with the Create Test From option set to Complex Assembly C The Insulation Test Parameter Signature represents the settings used for the insula tion test D The Wire List signature represents the connections and settings for the wire test It s followed by a list of all wire interconnections E The Wire Resistance is the highest allowable point to point above resistance that is below the Connection Resistance setting F The Component Resistance is the lowest available point to point resistance above the Connection Resistance setting G This is Check Components Each line that follows is an independent test for spec ified points They can be resistors diodes or links 1000H User s Guide page 48 Section 10 Select a Test Procedure First pass of a complex test First pass ofa complex test H This indicates that a resistor is present in the cable It shows two points a resis tance and a percentage The resistance is measured between J1 003 and J1 004 If the measured resistance is more
25. Set the Connection Resistance to a low number typically less than 10Q Depending on the capacitance of the cable set the Insulation Resistance to a higher setting This table will give you general guidelines for setting up simple tests You can adjust the settings to meet your specific needs General Guidelines for Simple Tests continued on next page Conn Ins Comments Resis Resis Test Type Hipot Voltage Hipot Duration CALC N A OFF N A Use CALC to help you determine where to set your onl Conn Resis threshold CALC y several cables then set your own threshold Do not use CALC for testing Calculating resistances Automatic AUTO 100KQ OFF N A AUTO selects a Conn Resis test threshold for you It takes the highest resistance measured between any two points and adds 20 Warning If you get a Sample Cable with a high resistance when learning in AUTO you may be testing at a much higher threshold than you want Use CALC to determine a proper connection threshold then set it yourself Fast test 1KQ 1KQ OFF N A The fastest possible test This setting effectively makes the analyzer act like a continuity tester Long cable 10Q 5 0MQ 100V 100mS These settings are for low test Connection Resistance mild hipot testing They allow you to test cables that are long or that have high capacitances 1000H User s Guide page 43 Section 10 Select a Test Procedure
26. Signature 1000H Cable Analyzer User s Guide Version 3 0 Major Revision 7 September 1999 CIRRIS An ISO 9001 Certified Company Signature 1000H Cable Analyzer User s Guide Version 3 0 Major Revision 7 September 1999 Copyright 1999 by Cirris Systems Corporation 1991 Parkway Boulevard Salt Lake City Utah 84119 2026 United States of America All rights reserved Visit our web site at www cirris com I Need Your Help As Senior Editor it s my responsibility to constantly improve the manuals and other documentation we include with our equipment We try hard but we know we ll never please everyone If you were in my chair how would you change the documentation to make it better Here s your chance to take gripes suggestions and we hope praise directly to the guy who can change things Please fax or mail this form to me or contact me by e mail Thanks Fax Telephone 801 973 4609 e mail vann cirris com Van Nielson Senior Editor Technical Documentation Van Nielson 1000H User s Guide c o Cirris Systems Corporation 1991 Parkway Boulevard Salt Lake City Utah 84119 2026 U S A Attach more pages if needed Visit our web site at www cirris com Table of Contents Introduction to the Cirris 1000H ecxa cn cosetetr ecient ai atl ea nation eked 7 Section 1 Work With the Hardware 0 cccccsceeeeeeeeeeceeeeeeeeeeeaaeeeeeeeeeseeaeeeeeeeeesenaeaaeees 9 Section 2 Check the Option Settings
27. Sorted Wire List is Count All Cables is Auto Print is Net Number ommon Interconnections List continues on back Net Number ommon Interconnections Copyright 1999 by Cirris Systems Corporation Use additional page if necessary Appendix 1 Four Wire Testing on the 1000H Capability and The 1000H can measure resistances from 0 010 ohms to 10 ohms with a tolerance of Tolerances 4 or 5 milliohms whichever is greater The 1000H can make relative measurements down to milliohms 0 001 ohms Adapters To do four wire testing on your 1000H you ll need the appropriate adapters Cirris adapter signature FBEA7D as shown here TT TEE 1 J 001 to J 016 J 017 to J 032 Installi ng Four These are continuous count adapters You must install them in the analyzer starting at Wire Adapters scanner position J1 so that all empty scanner positions are to the right of the slots already in use Correct Installation Unused connector position is to the right of all used connector positions Wrong Installation Unused connector position is not to the right of all unused connector positions 1000H User s Guide page 87 Appendix 1 Four Wire Testing on the 1000H Things you m
28. UST CANT ADJUST CALIB xxx OFFSET COARSE OFFSET FINE Hi lt LO CALIB xxx HI LO vv OPB nnn Problem The analyzer was unable to calibrate the measurement system located on the analog board Possible Causes e Bad analog board Please see next page 1000H User s Guide page 63 Section 12 Troubleshooting Error Messages HV ERROR x nnnnn Problem A problem with the high voltage system located on the analog board was found Possible Causes e The relative humidity in the surrounding environment is above 75 e The analyzer has been exposed to solvents or contamination e Moisture has condensed on the analyzer e A loose cable between the analog board and the scanner assemblies e Bad scanner assembly e Bad analog board SOURCE VOLTAGE lt 3V Problem The current source located on the analog board used to test the scanners is not working properly Possible Causes e A loose cable between the analog board and the scanner assemblies e A loose daughter board on a scanner assembly e Bad daughter board e Bad scanner assembly e Adapter on scanner has pin connected to earth ground MISSING SCANNER FIRST POSITION Problem The first scanner cannot be found Possible Causes e A loose cable between the analog board and the first scanner assembly e The first scanner daughter card is not installed e Loose daughter board in first scanner position e First scanner daughter card is bad e Bad
29. analog board Please see next page 1000H User s Guide page 64 Section 12 Troubleshooting General Problems with the Analyzer SCANNER OUT OF SEQUENCE Problem One of the scanners is missing or is not connected correctly to the analyzer Possible Causes e Scanner boards not installed properly e A loose cable from the analog board to the scanner board e Loose scanner daughter card e Bad scanner daughter card e Bad scanner mother board e Bad cable from analog board to scanner boards e Bad analog board BOX n DB V PTnn BOX n DB V PT nn BOX n DB v PT nn SCR ERR SNK ERR CLR ERR Problem A test point on a scanner board is not functioning properly The point is located on daughter board v on scanner assembly n Possible Causes e Loose scanner daughter board e Cable or harness presently connected to analyzer has a point connected to earth ground or to some power source e A loose cable from the analog board to the scanner assembly e Bad scanner daughter board e Bad analog board General There are problems you may see with the analyzer that are not detected by the Pp y y y y Problems with analyzer s own internal tests We will talk about those here the Analyzer Problem No display and no sound The analyzer s display is totally blank Possible Causes e Bad 10 VAC wall mount transformer e The intensity control for the display is not adjusted correctly e Bad microprocessor assembly T
30. ansion box how to install 10 F Failed Hipot Test what it means 29 Forms blank for photocopying 79 Four wire testing Adapters 87 installing 87 Capability and tolerances 87 Limitations 89 Specifications 90 Testing 87 Using CTL commands 90 value 89 Four wire testing on the 1000H 87 G Getting started 7 Glossary 75 Guided assembly building cables pin to pin 59 building cables with one terminated end 60 H Has Leakage what it means 29 Hipot Test Passed 30 Hipot test Has Leakage error 52 dielectric failure error 52 hipot voltage and capacitance problems 53 interpreting results 28 must pass continuity test first 51 overcurrent error 51 purpose of 51 tips on setting voltage 52 Hipot Voltage option what it does 19 How to install an expansion box 10 How to install connector adapters 9 l Insulation Resistance tips on setting 53 Insulation Resistance option what it does 20 Intermittent what it means 29 L Last Learned what it is 23 Learn Sample Cable 23 M Memory Available in the 1000H 23 How to delete a cable 33 How to print a directory 35 How to retrieve a cable 31 Last Learned 23 Why delete a cable 33 Why retrieve a cable 31 O Open Detected what it means 28 Option settings Apply Hipot To 20 Auto Print what it does 21 Connection Resistance Auto mode 19 CALC mode 19 Count All Cables what it does 21 Create Test From Complex Assembly 19 Last Test Setup 19 Sample Cable 19 Error T
31. ch as you do the next step MEM LOCATION X IS TO BE DELETED DISPLAY PRINT Continue to hold while you press here to select the cable for deletion 4 Delete the Sample Cable you ve selected by first releasing the M emory button then releasing the Function switch When you release the M emory button the prompt will change to Mem Location X Is Now Unused When you release the Function switch the prompt will change to Ready To Learn The memory location is now empty MEM LOCATION X IS NOW UNUSED DISPLAY PRINT FYNCTION First release this button then release this button 1000H User s Guide page 34 Section 8 Print a Directory of Cables Stored in Memory Overview If you have a printer connected to your 1000H you can print a directory that shows all the Sample Cables stored in the analyzer s memory The directory will show the memory location number and the signature of the Sample Cable stored in each mem ory location Important Note For photographic clarity we ve removed the printer cable in the views shown here For your printer to work it must be connected to the analyzer Print out a directory To print out a directory of the Sample Cables stored in the analyzer s memory do these things 1 Make sure the printer is properly connected to the analyzer and is turned on 2 Press and hold in the M MOry button as you turn on the analyzer Continue to hold in the M em
32. ct an open follow these steps 1 2 Locate the open circuit prompted in the analyzer s display CONNECT JX XX TO JX XX DISPLAY PRINT FUNCTION Make the correct connections in the cable as indicated e Once you ve connected all the opens the analyzer should prompt Good Cable e Ifyou should happen to create another short the analyzer will prompt Break JX XX Building cables pin to pin To use guided assembly to build pin to pin cables follow these steps 1 Following the documentation for the kind of cable you want to build install the correct connector adapters onto the 1000H then replace the cover plate Either connect a Sample Cable of the kind you want to build or retrieve the correct wirelist from memory see page 31 for instructions on how to do this If you use a retrieved wirelist skip step 3 and go directly to step 4 Turn on the analyzer and learn the Sample Cable then disconnect the Sample Cable Install the same kinds of connectors used in the Sample Cable onto the cable adapters already installed in the analyzer Make the first connection in your cable that is specified in the documentation The analyzer should prompt Open Detected e Ifthe analyzer prompts Errors Detected you have not connected two points that should be connected you have created a short instead If you have created a short break it and go back to make the first good connection Once the analyzer prompts Ope
33. cy of the resistor check to a default value of 10 You can change this value using CTL or CTLynx from Cirris Systems Important If you change this value the analyzer s accuracy 4 should always be added to the expected accuracy of the resistance How to document a complex assembly When the analyzer has finished learning a complex assembly it prompts SIG XXXXXX MULTI Please Verify Either press Display P rint to print out the documentation or transcribe the documentation by hand SIG XXXXXX MULTI PLEASE VERIFY DISPLAY PRINT FUNCTION Please see next page How to interpret documentation from a complex assembly 1000H User s Guide page 47 Section 10 Select a Test Procedure Types of Tests Documentation from a complex cable assembly differs from that of a simple assembly in some ways We ll go over an example printout in detail SIGNATURE 1000H CABLE ZOCUMENTATION CABLE SIGNATURE CDE01A CABLE PART NO PARAMETER SIGNATURE MULTI J1 ADAPTER SIGNATURE ACEFA1 CONNECTOR DESCRIPTION J2 ADAPTER SIGNATURE ACEFA1 CONNECTOR DESCRIPTION CABLE DESCRIPTION INSULATION TEST PARAMETER SIGNATURE 4X6FJ eS HIPOT VOLTAGE 100V INSULATION RESISTANCE gt 50 M ohm DURATION PER NET 100 mS APPLY HIPOT TO ALL ADAPTER PINS SINGLE NET ERROR FAILS HIPOT D WIRE LIST SIGNATURE 56FE0C 8Z040 E WIRE RESISTANCE lt 2 ohm COMPONENT RESISTANCE gt 15 0 ohm SORTED WIRE LIST NO COMMON CO
34. d J positions first For example if you intend to use adapter positions J2 and J4 first install the connector adapter at position J2 Then install the connector adapter at position J4 If you don t do this especially if you re installing more than one type of adapter you may find that the connector adapters won t fit the scanner assembly correctly Sample wirelist Here is a portion of a cable s printed documentation showing how single high and showing connector double high connector adapters usually appear adapters SIGNATURE 1000H CABLE DOCUMENTATION CABLE SIGNATURE Z06A1 CABLE PARTNUMBER PARAMETER SIGNATURE 6J0A0 J1 ADAPTER SIGNATURE D507F1 CONNECTOR DESCRIPTION J4 ADAPTER SIGNATURE 03FAC1 CONNECTOR DESCRIPTION __ _ _ CABLE DESCRIPTION CONNECTION RESISTANCE lt AUTO 5 ohm HIPOT VOLTAGE 300 V INSULATION RESISTANCE gt 10M ohm DURATION PER NET 100 MS APPLY HIPOT TO ALL ADAPTER PINS NO COMMON CONNECTION LIST 1 J1 01 J4 01 2 J1 02 J4 02 3 J1 04 J4 08 4 J1 05 J4 09 5 J1 03 J4 03 1000H User s Guide page 42 Section 10 Select a Test Procedure Types of Tests Types of Tests Using the Cirris 1000H you can perform three different kinds of tests These are 1 Simple tests 2 Complex tests 3 Hipot tests Simple Tests Simple tests are used for testing cables made up of only wires and connectors These cables have no resistors capacitors diodes or any active circuitry
35. d but the sounds still do not work call Cirris to replace the microprocessor assembly Problem The sounds the analyzer makes disturb others Things to do e Set the Error Tones option to OFF or Low e Place tape over the speaker opening in the metal case to dampen the sounds e Disconnect the speaker from the microprocessor Please see next page 1000H User s Guide page 68 Section 12 Troubleshooting Problems with Printing Problems with Printing Problem Analyzer will not learn a cable Possible Causes e The Create Test From option is set to Last Cable e The Connection Resistance threshold or Insulation Resistance threshold is not set properly Things to do 1 You cannot learn a cable s wirelist when the Create Test From option is set to Last Cable Change the option setting to Sample Cable See page 17 for instructions on how to do this 2 If the Insulation Resistance is set to less than the Connection Resistance which can take place if the Connection Resistance option is set to AUTO then the analyzer will prompt Insulation Resis lt AUTO XXX The Insulatioin Resistance should be raised to a value above the Connection Resistance set ting Printer failures usually take place because of one of four things User error 2 A bad printer 3 Abad cable 4 Abad microprocessor assembly These guidelies will help you solve printing problems Problem Nothing prints Possible Causes e Printer is not on
36. d list scanner assembly If you look at the analyzer from above the scanner assembly is located on the right hand side of the unit s top This assembly contains the J positions onto which you install your connector adapters It also contains the electronics which control conti nuity testing between all connector pins in all possible combinations setup The steps involved in preparing the analyzer to test cables short A kind of interconnection error where there is continuity between two points that are not supposed to be connected A connection is present that does not appear in the master cable documentation 1000H User s Guide page 77 Section 15 Glossary short 1000H User s Guide page 78 Section 16 Blank Forms to Photocopy What are these for We have designed three forms that we believe will help you document the cables you test They are e Master Parts List This form will help you keep track of cables by their part numbers and cable signatures e Directory of Wirelists Stored in Analyzer s Memory This form allows you to easily write down which cable s information is stored in each of the analyzer s permanent memory locations Remember that there are a maximum of 50 memory positions available and that the number of positions actually available depends on the size of the wire list you are storing Large wirelists take up more memory than small ones do e Cable Documentation Form This form
37. d that the problem is a defective microprocessor or scanner assembly or if for some other reason you cannot solve the problem yourself please contact our customer support team at Cirris by calling 1 801 973 4600 or 1 800 441 9910 When you call please have the following information ready e What model of analyzer do you have e Purchase date if you know it e What is the analyzer s serial number e What have you done to try to solve the problem Please have your analyzer set up near your telephone so you can duplicate troubleshooting steps as our customer service team talks with you Please see next page 1000H User s Guide page 61 Section 12 Troubleshooting Error Messages Error Messages Every time you turn on your analyzer it performs a complete self test If there is a problem in one of its systems the analyzer will display an error message If you see any of these error messages call us at 801 973 4600 or 800 441 9910 This section lists all of the possible error messages and some of the possible causes 10 V HIGH 10 V LOW 10 V NOISY Problem The main power supply located on the microprocessor assembly is not working properly This supply is powered from the wall mount transformer cube Possible Causes e A loose cable from the microprocessor assembly to the analog board e Loose or bad wall transformer e Bad microprocessor assembly e Bad analog board e Bad scanner assembly e Incorrect line voltage
38. do each of these steps in this manual Your order should contain these things in addition to this manual e 1000H main unit including a wall transformer with cord to provide power for the analyzer e Hand held test probe e Whatever connector adapters you have ordered usually shipped in a 3 x 5 inch card file You may also have ordered an optional tilt stand or an optional frame stand If so these should be included e Any expansion boxes you have ordered 1000H User s Guide page 7 Introduction to the Cirris 1000H What your order should contain 1000H User s Guide page 8 Section 1 Work With the Hardware How to install connector adapters The Cirris 1000H system consists of a main unit and as many as three expansion boxes To connect the cables you want to test to the analyzer you use connector adapters which match the connectors on the cable you want to test In this section we will explain how to work with the hardware We will show you how to install your connector adapters how to install an expansion box and how to disassemble the analyzer in case you need to replace one of its subassemblies or its EPROM To install connector adapters onto the Cirris 1000H follow these steps 1 Turn the four twistlock fasteners on the adapter cover plate to unlock them and remove the cover plate 2 Plug in the connector adapters Be sure the pins on the bottom of each adapter are lined up properl
39. e correct for the cable into the other cable adapter on the analyzer Plug the probe into the Probe jack on the back of the analyzer Make the first connection specified in your cable s documentation The analyzer should prompt Open Detected e Ifthe analyzer prompts Errors Detected you have created a short instead of connecting the two points that should be connected Break the short check your build list and try again until the analyzer prompts Open Detected Press D isplay P rint to enter rework mode Probe the loose end of one of the wires The display will prompt Probe On JX XXX Connect this wire to the appropriate pin on the empty connector according to your cable documentation If you create an error the display will read Break JX XXX Remove the error then try reconnecting the loose wire at the correct position Continue until the display reads either Good Cable or Ready to Hipot 1000H User s Guide page 60 Section 12 Troubleshooting What is in this section Need more help Call us In this section we will tell you how to deal with three basic kinds of trouble which may occur when you are working with your 1000H These are e Error messages as prompted by the analyzer in its display e General problems with the analyzer e Problems with printing Each section will help you solve problems you might have with your analyzer You may be able to correct some of the problems yourself If you fin
40. e off line switch Changing the company name Yes To use your printer with more than one analyzer use a switchbox To change which analyzer the printer is receiving information from simply change the switch setting on the box If your printer does not happen to have an on line off line switch you can use either of two solutions e Add a switch by placing a switch in the wire to pin 11 of the Epson Cen tronics printer cable When pin 11 on either side of the cable is open the analyzer will see the printer as being off line and will display infor mation rather than send it to the printer When you close the switch so that pin 11 is closed information will be sent to the printer e Ifyou have a switch box available you can connect the cable to the switchbox and use its switch as the on line off line switch To change the company name that appears in the documentation produced by the 1000H you can order an EPROM change from Cirris Systems Replace the EPROM For details on how to do this see page 13 1000H User s Guide page 16 Section 2 Check the Option Settings Overview The Cirris 1000H has twelve test options Before we learn a Sample Cable we ll make sure they are set to their factory defaults How to check the To check the option settings do these things option settings 1 Press in and hold the Display Print switch as you turn on the analyzer by pressing the ON switch Hold Display Print until R
41. eady SIG XXXXXX XXXX MEMORY SIG XXXXXX XXXX PLEASE VERIFY RESISTANCE READY La DISPLAY PRINT Press here FUNCTION DISPLAY PRINT FUNCTION When the prompt changes to Resistance Ready press Display Print A list of the measured resistances in the cable will be printed SIG XXXXXX XXXX RESISTANCE READY DISPLAY PRINT FUNCTION Press here 6 From your printout locate these resistances e The highest measured resistance for nets that you know contain only wires 1000H User s Guide page 45 Section 10 Select a Test Procedure Types of Tests e The lowest resistance for nets that you know containing components which exhibit resistance You can now choose a midrange setting from the high and low resistances shown in your printout For example this printout shows that net 4 contains a resistor and has a resistance of 20 ohms Net 1 which is only a wire connection has a resistance of 1 ohm All other nets have a zero resistance Therefore when you set Connection Resistance for testing a complex assembly you could select any value from 1 ohm to 20 ohms As you can see the automatic default setting of 5 ohms falls well within this range CABLE SIGNATURE 6CEEOD 1 J1 001 J2 001 i i i RESISTANCE 1 ohm M Highest wire resistance 1 ohm 2 J1 002 J3 002 RESISTANCE 0 ohm 3 J1 003 J3 003 RESISTANCE 0 ohm 4 J1 004 J3 004 a f Lowest component resistance 20 ohm RESISTANCE 20 ohm 5 J1 005 J3 005
42. eady To Set Up Options appears Press and hold then press here DISPLAY PRINT FUNCTION 2 Once Ready To Set Up Options appears in the display release Display P rint READY TO SET UP OPTIONS Press to step through options DISPLAY PRINT FUNCTION Press to change option settings 3 Select the Create Test From option by pressing Display P rint e If the setting is SAMPLE CABLE go on to the next option by pressing Display P rint e To change the option setting press Function until SAMPLE CABLE appears then go on to the next option by pressing Display P rint 1000H User s Guide page 17 Section 2 Check the Option Settings What to do if you go past the value you want What to do if you go past the value you want Your option settings are saved 4 Continue stepping through the options by pressing Display P rint changing the settings as necessary by pressing F unction until all the options are set as shown in this table When you are done Ready to Learn will appear on the display Factory Default Option Settings Option Setting Create Test From SAMPLE CABLE Connection Resistance AUTO Hipot Voltage 300 V Insulation Resistance 10 MQ Hipot Duration 100mS Apply Hipot to ALL ADAPTER PINS Single Net Error FAILS HIPOT Auto Hipot OFF Error Tones are LOW Sorted Wire List is OFF Count All Cables is OFF
43. ecification sheet or build list to be sure the cable is a good one 1000H User s Guide page 23 Section 4 Learn a Sample Cable Store it in Memory Store the Sample Cable in memory e If you don t have a printer connected to the analyzer pressing D ispla y Print causes the analyzer to prompt wirelist information in its display Repeatedly press D ispla y Printto step through the wirelist transcribing the information to a blank documentation form see page 79 as you go Compare the transcribed information to the Sample Cable s specifica tion sheet or build list to be sure it s a good cable 3 Disconnect the Sample Cable from the analyzer Store the Sample Now that you ve learned the Sample Cable and verified that the wirelist data is Cable in memory correct you may store the cable in the analyzer s memory To store the cable do these things 1 Press and hold in the Memory button located on the back of the analyzer as shown in this photo Press and hold 2 When you press the Memory button the analyzer will prompt Ready To Save Learned Cable Continue to hold the Memory button in for instructions 3 and 4 READY TO SAVE LEARNED CABLE DISPLAY PRINT FUNCTION Hold in the MEMORY button while you step by pressing here 3 While continuing to hold in the Memory button press D ispla y P rint to select a memory location The analyzer will default to the first unused memory location Each time you
44. est setups This example shows a typical wirelist with the cable signature parameter signature adapter signatures and resistance settings SIGNATURE 1000h CABLE DOCUMENTATION A cABLE SIGNATURE BBFO38 C PARAMETER SIGNATURE KX8NJ J1 ADAPTER SIGNATURE 03FAC1 J2 ADAPTER SIGNATURE F5B4E0 CABLE DESCRIPTION PARAMETER SETTINGS CONNECTION RESISTANCE HIPOT VOLTAGE INSULATION RESISTANCE DURATION PER NET APPLY HIPOT TO SINGLE NET ERROR sao M CABLE PART NO CONNECTOR DESCRIPTION AUTO lt 5 OHM 300 V gt 50 M ohm 100 mS ALL ADAPTER PINS WILL FAIL HIPOT WIRE LIST NO COMMON CONNECTIONS 1 J1 01 J2 01 2 J1 02 J2 03 T 1 03 2 02 4 J1 04 J2 04 J2 20 J TOTAL CABLES TESTED 50 INTERMITTENT CABLES TESTED 6 GOOD CABLES TESTED 40 d NOTES A This example shows a cable with the cable signature BBFO38 Both this signature and the five digit parameter signature see item C below must match those prompted in the display when you are preparing to test cables B This blank area is left so you can write in the cable s part number C This is the five digit parameter signature that represents the voltage and resistance settings you have selected for testing the cable This signature must match the one shown in the analyzer s display for the resistance and voltage levels to be the same D These are the connector adapter signatures In this example the signature for the adapter
45. h the cable were good e Press D isplay Print to show the error condition that existed when the intermittent occurred e Clear the intermittent by pressing the M emory button on the back of the analyzer SIG XXXXXX XXXX INTERMITTENT 1000H User s Guide page 29 Section 5 Test Your First Cable Print or transcribe an error list Print or transcribe an error list Passed Hipot Test If the hipot test is successful the analyzer briefly prompts Passed Hipot Test then cycles to a continuous resistance test and prompts Good R lt XQ The analyzer emits a steady clicking sound after each newly completed continuity conductance test To repeat the hipot test press Function again The conductance test always follows a successful hipot test and continues until you remove the cable PASSED HIPOT TES IG BBF038 6J0A0 GOOD R lt XQ If the analyzer detects errors it can prompt where the error is in a cable To do this press Display P rint while the cable is still connected to the analyzer If you have a printer connected to your analyzer it will automatically print out an error list If you don t have a printer keep pressing Display Print to step through the errors as you transcribe them to a cable documentation form see page 79 1000H User s Guide page 30 Section 6 Retrieve a Cable from Memory Why retrieve a cable How to retrieve a cable Before the 1000H can test cables it has to be programmed with wirel
46. he insu lation is pierced is the pin that makes a connection to the wire The pin that is not displayed is the one that is open Remove the connector and check the connector adapter with the probe to see if the missing pin is recognized there If it is recog nized at the test adapter you may have a worn contact or contaminants such as solder flux on the contacts If you are using an adapting cable move back to the test point on the adapter con nected to the analyzer and see if the analyzer will recognize it there If the ana lyzer recognizes the point the adapting cable is bad Rework the adapting cable If you are using an AUNV 64 or AHR2 64 adapter be aware that some pins are used to identify these adapter s signatures Because they are incorporated into the adapter signature these connections may cause test points to no longer be recognized If this is the case you have miswired your connections and you will have to rework them e To isolate a problem with an AUNV adapter remove all connections to pin 31 32 33 and 34 on a 34 pin connector adapter e Ifyou are using an AHR2 64 adapter make sure there are no connec tions to pins 33 and 34 e If after removing these connections you can now identify these pins with the probe you have found the type of miswire described above Rework your adapting cable e It is possible the adapter is bad Check for worn connectors on the adapter Also check for continuity of the ada
47. he testing options for learning a complex assembly then learn it 3 How to document a complex assembly then interpret that documentation 4 How to test a complex assembly How to determine a Connection Resistance setting for complex tests When you set the option Create Test From to Complex Assembly you must set the Connection Resistance to a value that is greater than the highest wire resistance and less than the lowest component resistance a resistance level that definitely sepa rates wires from resistors The 1000H automatically sets the Connection Resistance to a default value of 5 Q You can change this value to suit your needs Note If you don t know what Connection Resistance setting is appropriate for the cable s you are going to test you can determine a good value by using the analyzer s CALC feature See page 19 for details on how to do this To determine the proper Connection Resistance setting for a cable do these things 1 Set the Create Test From option to Sample Cable 1000H User s Guide page 44 Section 10 Select a Test Procedure Types of Tests 2 Set the Connection Resistance setting to CALC 3 CREATE TEST FROM CONNECTION RESIS SAMPLE CABLE CALC DISPLAY PRINT DISPLAY PRINT FUNCTION FUNCTION Turn on the analyzer and learn the cable 4 When the display prompts Please Verify press the Memory button on the back 5 of the analyzer The prompt will change to Resistance R
48. hings to do 1 Be sure the wall transformer is plugged into a live wall outlet then feel if it is warm If the transformer stays cold it is probably bad If the outlet is good and the transformer is bad call Cirris to replace the transformer 2 Ifthe transformer feels warm check to see if the microprocessor assembly feels warm It should warm up within about five minutes after you turn it on If it is still cold after five minutes the transformer is bad Call Cirris to replace it 1000H User s Guide page 65 Section 12 Troubleshooting General Problems with the Analyzer 3 If the microprocessor assembly feels warm and the display has a blue back ground but is otherwise blank adjust the Display Intensity control at the back of the analzyer by turning it clockwise If the display is still blank call Cirris to replace the microprocessor assembly Display Intensity control 4 Ifthe microprocessor assembly is warm but the display is totally blank or there is no blue background showing in the display call Cirris to replace the microprocessor assembly Problem Display shows a darkened row or gibberish characters Possible Causes e Display Intensity control is not adjusted properly e Scanner assembly is bad e Microprocessor assembly is bad Things to do 1 If both rows of the display are dark try adjusting the Display Intensity control at the back of the analyzer by turning it counterclockwise If this does not
49. ild the cable When you prepare complete documentation you prepare a standard set of information from which future cables will be built The 1000H can help you prepare documenta tion by learning a Sample Cable Once the cable has been learned you can either tran scribe it by hand onto a documentation form see page 79 or print it out if you have a printer connected to your analyzer Once the cable has been completely documented and stored in memory you won t need to keep an array of known good cables handy for comparison If the signature prompted by the analyzer after each test matches the signature in the cable s docu mentation you can be sure the cable is correctly built according to your specifica tions You can store Sample Cable information in the analyzer s memory When you retrieve that information from memory you program the analyzer just as if you d learned a real Sample Cable The analyzer will prompt the Sample Cable s alphanu meric signature and which connector adapters to install See page 24 for information on how to store a Sample Cable in memory and page 31 for information on how to retrieve a cable from memory Please see next page 1000H User s Guide page 37 Section 9 Cable Documentation and Signatures How to interpret cable documentation How to interpret cable documentation The documentation your 1000H produces contains all the information you will need to precisely duplicate t
50. in use for example 120 volts instead of 240 e Line voltage is either too high or too low 8 V HIGH 8 V LOW 8 V NOISY Problem The measurement power supply located on the analog board is not work ing properly Possible Causes e A loose cable from the microprocessor assembly to the analog board e Bad microprocessor assembly e Bad analog board Problem The negative voltage supply located on the microprocessor assembly is not working Possible Causes e A loose cable from the microprocessor assembly to the analog board e A loose cable from the analog board to the scanner boards e Bad microprocessor assembly e Bad scanner assembly e Bad analog board Please see next page 1000H User s Guide page 62 Section 12 Troubleshooting Error Messages 6 2 ma ERROR xxx 110 lt X 180 Problem The current source located on the analog board needed for this test is not working Possible Causes e A loose cable from the microprocessor assembly to the analog board e Bad analog board OFFSET_C BAD xxx OFFSET C_BAD xxx OFFSETF_HxxxLxxx 66 lt X lt 79 X gt 100 ON G8 36 lt X 47 OFFSET COARSE OFFSET FINE CANT GET TO 25 CANT GO TO 23 Problem The measurement system located on the analog board cannot control the input signal Possible Causes e A loose cable from the microprocessor assembly to the analog board e Bad analog board LOW CURRENT CALI OFFSET CAL ERROR e ERROR xxx nnn CANT ADJ
51. ing for 44 Types complex tests 44 simple tests 43 These are the connector adapter signatures 38 Three general adapter types 40 to 27 To print out a directory 35 To retrieve a learned cable s 31 To store the cable 24 Troubleshooting 61 Error Messages general problems with analyzer 65 problems with printing 69 prompted in display 62 Types of adapters 40 1000H User s Guide page 93 W Warranty 73 What to do if you go past the value you want 18 1000H User s Guide page 94
52. ist between pins 5 and 6 but actu ally exists between pins 5 and 7 the error will be reported as a miswire Any group of pins which are connected together The analyzer automatically assigns a number to each group of interconnected pins called nets This number appears on the left hand side of printed documentation and in the left hand side of the analyzer s LCD display A kind of interconnection error where there is no continuity between two connector pins which are supposed to be connected A connection which the cable s master documentation says should exist does not in fact exist in the cable When it displays signatures the analyzer displays a six digit alphanumeric cable signature followed by a hyphen After the hyphen the analyzer displays a five digit alphanumeric known as the parameter signature The parameter signature represents the various test options you have selected for your test setup Two different kinds of cables will always have different cable signatures but they may have the same parameter signature if the option settings for both types were identical An electrical contact point within a connector In this manual the word pin is used in place of terms such as point contact socket termination etc 99 66 99 66 1000H User s Guide page 76 Section 15 Glossary Sample Cable Sample Cable A Sample Cable is a cable you know is built correctly according to your master buil
53. ist data for the cables you intend to test You can avoid having to re learn a Sample Cable each time you want to test by storing the learned information in the analyzer s memory see page 24 for instructions on how to do this Once the information is stored all you have to do to set up for testing is to install the correct cable adapters on the analyzer then retrieve the cable data from memory in order to program the analyzer To retrieve a learned cable s data from memory and program the analyzer for testing do these things 1 Install the connector adapters that mate with the cables you want to test see page 9 for instructions on how to do this 2 Hold in the M emory button as you turn on the analyzer Continue holding in the Memory button as you do the next step The analyzer will prompt Ready To Access Memory Locations READY TO ACCESS MEMORY LOCATIONS DISPLAY PRINT FUNCTION Press and hold as you turn the analyzer on 3 Continue holding in the M emory button while you press Display Print to step through the Sample Cables stored in the analyzer s memory The first time you press the switch the display prompts the signature of the cable in the Last Learned memory location When you press D ispla y Print again the analyzer 1000H User s Guide page 31 Section 6 Retrieve a Cable from Memory How to retrieve a cable prompts the signature for the cable stored in permanent memory location number
54. lank Forms to Photocopy ss gexec ce ekeececeeaees dee ee ees 79 Appendix 1 Four Wire Testing on the 1000H 00 0 cccccceceeeeeeeeeeeessseeeeeeesteneeeaaes 87 1000H User s Guide page 5 1000H User s Guide page 6 Introduction to the Cirris 1000H Lets get started What your order should contain The Cirris 1000H cable analyzer is an easy to use machine that will allow you to test cables quickly and with little fuss In simple terms the process of using your 1000H goes like this 1 Install any expansion boxes you want to use see page 10 for details Once you have installed the boxes the first time you probably won t have to do this again 2 Install connector adapters to match the cables you want to test see page 9 for details 3 Check the test option settings reset the options if you need to see page 17 for details 4 Either e Learn a Sample Cable a cable you know is built correctly of the kind you want to test see page 23 for details or e Retrieve the wirelist data for the kind of cable you want to test from the analyzer s memory see page 31 for details This completes programming the analyzer for testing cables If you have connected a Sample Cable to learn it disconnect it now 5 Connect the first cable you want to test 6 Test the cable see page 27 for details 7 Record and or or print the test results see page 30 for details That s it We ll show you how to
55. line selected e Cable between analyzer and printer is not connected properly e The printer has a serial instead of a parallel interface e A bad cable e A bad printer e A bad microprocessor assembly Things to do 1 Make sure the printer is turned on on line selected and not out of paper 2 Check the cable connections at the analyzer and the printer The cable should be firmly connected to the back of the analyzer where it is marked P rinter P aralle Interface Check the connection at the printer end too 3 Your printer must have a parallel cable interface Do not use a printer with an RS 232 serial interface You will damage the analyzer 4 The cable running from the analyzer to the printer may be bad Try another cable to see if it works 1000H User s Guide page 69 Section 12 Troubleshooting Problems with Printing 5 The printer may be bad Try using another printer or test your original printer and cable with a standard computer If the printer does not work with the PC it is probably bad 6 Ifthe cable and printer work with a PC the microprocessor assembly inside the analyzer is probably bad Call Cirris to replace it Problem Characters missing in printout Possible Causes e Bad printer cable e Printer cable is too long e Printer is incompatible with the analyzer e Microprocessor assembly inside the analyzer is bad Things to do 1 Verify that the printer cable is correctly built Check f
56. lts If a connection is missing The display prompts Open Detected and the analyzer emits a series of single beeps OPEN DETECTED If the analyzer detects a short The display prompts Short Detected and the analyzer emits a series of double beeps If both opens and shorts are detected The display prompts Errors Detected and the analyzer emits a series of triple beeps a If an insulation short is detected The display prompts either Bad R gt XQs or Insulation Short Both prompts indi cate that the measured resistance is higher than the Connection Resistance setting and lower than the Insulation Resistance setting The analyzer emits a series of dou ble beeps If you have set the AUTO H ipot option to ON the analyzer will automatically hipot test each cable after the cable passes the resistance tests If this option has been set to OFF the analyzer will prompt Ready to Hipot and you will have to press F unction to begin the hipot test Note During the test the analyzer prompts the net being hipot tested and Hipot Test If you happen to touch any uninsulated part of the cable under test you may experience a mild but annoying electrical shock and cause the hipot test to fail 1000H User s Guide page 28 Section 5 Test Your Firs
57. ly Hipot stands for HIgh POTential Hipot tests are done to verify that the resistance between pins that are not supposed to be connected is sufficiently high Generally used to check the effectiveness of insulation and or spacing between conductors in a cable The length of time for which hipot voltage is applied to each net during hipot testing Option setting that allows you to select the minimum allowable resistance between points that should not be connected An insulation short occurs when the resistance of a connection is higher than the Connection Resistance setting and lower than the Insulation Resistance setting In other words the connection has a resistance too high for the analyzer to see it as a good connection and too low for the analyzer to see it as effective insulation A situation where continuity exists between two connector pins Continuity most commonly exists here because a wire connects the two pins 1000H User s Guide page 75 Section 15 Glossary intermittent intermittent known good cable last test setup memory location microprocessor miswire net open parameter signature pin The 1000H detects an intermittent fault when a cable is seen to develop shorts opens or excessive resistance after it has already tested as good A known good cable is a cable that you know is built correctly We most often refer to such a cable as a Sample Cable You can program the 1000H
58. me stand with D sub type connectors Types of adapters There are three general adapter types available for the 1000H These are 1 Single high adapters These are for connectors with up to 28 pins They occupy one J position on the analyzer s scanner Single high adapter mounted in Example An ADBP 15 single high scanner position J1 adapter 2 Double high adapters These are for connectors with from 29 to 64 pins They occupy two J positions on the analyzer s scanner Example ADPG 37 double high Double high adapter mounted in adapter scanner postions J1 J2 1000H User s Guide page 40 Section 9 Cable Documentation and Signatures How connector adapters are placed on the analyzer 3 Quad high adapters These are for connectors with up to 120 pins They occupy four J positions on the analyzer s scanner To use more than one of these at one time you must use an expansion box Example AD5P 100A quad high Quad high adapter mounted in scanner adapter positions J1 J2 J3 J4 How connector The 1000H analyzer itself has four connector adapter positions on its scanner assem adapters are placed bly marked J1 through J4 Each position has 32 points for a total of 128 available on the analyzer points J4 How connector Each expansion box has four connector adapter positions on its scanner assembly adapters are placed These positions are not marked They each have a white square on which yo
59. n Detected press Display Print once The analyzer will prompt you with the next set of points you should connect 1000H User s Guide page 59 Section 11 Rework and Guided Assembly Guided Assembly Connect the next set of points prompted by the analyzer If the connection is correct the analyzer willdisplay Attach JX XX to JX XX Repeat the last step by connecting the next set of points prompted If you create a short the analyzer will prompt Break JX XX Continue connecting points as prompted by the 1000H until the analyzer prompts Good Cable or Ready To Hipot This indicates you have finished wiring the assembly Building cables that have one end terminated with a connector To build cables that have only one end terminated follow these steps 1 10 11 Following the documentation for the kind of cable you want to build install the right cable adapters onto the analyzer and replace the cover plate Either connect a Sample Cable of the kind you want to build to the analyzer or retrieve the wirelist for the kind of cable you want to build from the analyzer s memory see page 31 for instructions on how to do this If you use a wirelist retrieved from memory skip step 3 and go directly to step 4 Turn on the analyzer and learn the Sample Cable then disconnect the Sample Cable Insert the connector on the terminated end of the cable into the cable adapter on the analyzer Insert an empty connector of the typ
60. nect a hand held test probe provided with your analyzer to the 1000H It will help you quickly identify test points as you rework or assemble cables Note The probe works only when the analyzer is in the rework mode It will not function when the analyzer prompts Ready to Test or Please Verify Plug the probe into the connector labeled Probe on the back of the analyzer This photo shows the location of the probe jack Plug the probe in here While the analyzer is in the test mode touch the tip of the probe to the connector pin or wire you want to identify For example if you touch the probe tip to position J1 pin 11 the analyzer will prompt Probe On J1 11 PROBE ON J1 11 DISPLAY PRINT FUNCTION 1000H User s Guide page 55 Section 11 Rework and Guided Assembly Displaying multiple interconnected pins Displaying multiple interconnected pins Using the probe to identify an open circuit Rework instructions Up to three different pins can be displayed at the same time If more than three pins are interconnected a plus sign will appear in the lower right hand corner of the display To view any additional interconnections press D ispla y Print PROBE ON J1 09 J1 10 J1 11 DISPLAY PRINT FUNCTION Plus sign here indicates more than three points na 5 are interconnected Press to display additional points Using the probe the analyzer can detect which end of an interconnection has an o
61. o be seen as wires The connection pattern for test points which have resistances below the Wire Resistance must match the wire connections specified in the cable s documenta tion All points in a cable assembly that are not connected by either components or wires must be insulated from each other by resistances which are greater than the Insulation Resistance setting All connections which have resistances that fall between the Component Resis tance setting and the Insulation Resistance setting are seen by the analyzer as components They must have a corresponding Component Check and must pass the test for that check 1000H User s Guide page 50 Section 10 Select a Test Procedure Hipot Testing Hipot Testing The purpose of hipot testing is to test the effectiveness of the insulation on a cable assembly When you hipot test you are making sure that there is extremely high elec trical resistance between points that should not be connected in the cable or harness Important note Before the analyzer performs a hipot test it performs a connection resistance test sometimes called a continuity test to make sure that all connections in the cable are correct If the analyzer finds any open or shorted connections during the continuity test it will not perform the hipot test OPEN 1 1 1 1 2 2 2 2 3 3 3 3 4 NC C 4 4 NC E 4 This is a known good cable Example
62. of the details here RESISQ will perform a four wire test if necessary to establish a resistance value and will check the validity of only the points being accessed CR_TESTQ Q may also perform a four wire test if the low current connection test indi cates that this has to be done to determine an accurate resistance CR4TEST performs a continuity test followed by a four wire test These are the specifications for the 1000H as they relate to four wire testing 0 010 ohm to 10 ohms starting in milliohm increments Can make relative measure ments down to 1 milliohm 0 001 ohms 4 tolerance or 5 milliohms whichever is greater 1 00 amp for fixture and connection resistance less than 1 2 ohms 0 250 amp for fix ture and connection resistance less than 10 ohms Less than 10 milliamps is used to perform a continuous test whenever a cable is con nected to the 1000H The cable is tested using low current four wire techniques to a threshold of 100 milliohms above the high current four wire threshold to look for intermittent short circuits 1000H User s Guide page 90 Index A Adapter signature see Connector adapter signature 39 Adapters how they are placed on analyzer 41 how they are placed on expansion boxes 41 how they are supported 40 how to install 9 order of positions 42 sample wirelist showing them 42 Types double high 40 quad high 41 single high 40 Adding a printer 15 Apply Hipot To option what it does 20
63. of the same cable with all connections intact with an open connection The hipot test cannot be done on this cable Once a cable passes the continuity test the analyzer can begin a hipot test The ana lyzer applies high voltage to a group of connected pins nets The remaining pins are tied together In the example below we see net number 1 being hipot tested Hipot voltage AUN AON no Current meter 1 Remember that each net the analyzer tests has capacitance to every other net That means there is a current surge as this capacitance is charged The analyzer carefully monitors this current surge The amount of current tells the analyzer how much energy is being delivered to the cable If the current delivered is excessive the amount of energy delivered might be dangerous therefore the analyzer shuts off the high voltage and fails that net labeling it Over Current Current Maximum allowable Ff current Time Hipot Duration Overcurrent error If the current surge subsides to an acceptable level the hipot test continues The ana lyzer has already calculated the maximum amount of current it will allow based on the Insulation Resistance and Hipot Voltage option settings you ve chosen see 1000H User s Guide page 51 Section 10 Select a Test Procedure Tips on selecting Hipot Voltage settings page 20
64. ones option what it does 21 hipot duration 1000H User s Guide page 92 what it does 20 hipot voltage 19 how to check 17 Insulation Resistance hipot voltage vs insulation resistance settings 20 what it does 20 setting to learn a complex assembly 46 Single Net Error what it does 21 Sorted Wire List what it does 21 what they mean 19 Options when they are saved 18 Over Current what it means 29 P Packing List what your order should contain 7 Parameter signature what it is 39 Passed Hipot Test 30 what it means 30 pecifies 19 Printer How do I know if I have a parallel printer 15 how to add 15 how to use with more than one analyzer 16 Printing a directory of Sample Cables in memory 35 Probe displaying multiple interconnected pins 56 how to install 55 identifying an open circuit 56 identifying test points 55 Retrieving a cable from memory 31 Rework correcting opens 59 instructions 56 removing shorts within a net 56 57 S Sample Cable how to delete from memory 33 how to learn 23 how to store in memory 24 learning what to do if you see an error message 25 what it is 77 Short Detected what it means 28 Signatures how they work 39 Types cable signature 39 connector adapter signature 40 parameter signature 39 Single Net Error option what it does 21 Sorted Wire List option what it does 21 Specifications 71 T Test procedures Complex tests how to determine Connection Resis tance sett
65. or shorts in pin 11 2 Ifthe printer cable is more than 10 feet long you may have printing problems The electrical signals from the printer become too weak to work well as the cable gets longer Use a shorter printer cable 3 Try using the printer cable with a PC If it works the printer probably is not compatible with the analyzer 4 Ifthe cable and printer work with a PC the analyzer s microprocessor assembly is probably bad Call Cirris to replace it Problem Wrong characters in printout Possible Causes e Bad printer cable e Bad printer e Printer cable too long e Microprocessor assembly inside the analyzer is bad Things to do 1 The printer cable may be bad Check for shorts opens or miswires on pins 2 through 9 Either fix the cable or replace it with a good cable 2 The printer may be bad Try using another printer with the analyzer or test your original printer cable and printer with a PC If the printer does not work with a PC the printer is bad Replace the printer If the printer and cable do work with a PC the analyzer s microprocessor assembly is probably bad 3 The printer cable may be too long Your printer cable should not be longer than 10 feet The printer signals get too weak to work properly if the cable is longer than 10 feet 4 Ifyou have another Cirris 1000H analyzer available it is possible to exchange microprocessor assemblies If using a different microprocessor assembly solve
66. ory button as you do the next step READY TO ACCESS MEMORY LOCATION DISPLAY PRINT FUNCTION Press and hold this button Note Printer cable is not shown as you turn the analyzer on 3 As you continue to hold in the Memory button press Display Print once This causes the display to prompt Press Function To Print Dir READY TO ACCESS MEMORY LOCATION DISPLAY PRINT FUNETION Continue to hold this button in Note Printer cable is not shown as you press here 1000H User s Guide page 35 Section 8 Print a Directory of Cables Stored in Memory Print out a directory 4 When the display prompts Press Function To Print Dir press the Function switch If your printer is properly connected to the analyzer turned on and on line selected it will print a directory showing the signatures of all the cables stored in memory and their corresponding location numbers PRESS FUNCTION TO PRINT DIR DISPLAY PRINT FUNCTION Press here to print a directory 5 Release the Memory button 1000H User s Guide page 36 Section 9 Cable Documentation and Signatures What is cable documentation Why prepare cable documentation Cable documentation is a printed record of a Sample Cable s unique signature the adapters used to test it and the test parameters used to test it It also contains a complete list of the interconnections in the cable and any notes necessary to help you bu
67. ory locations you can store wirelists in How many memory locations are available depends upon the size of the wirelists you want to save Large wirelists take up more memory than small ones You can store wirelists in these locations retrieve wirelists from them and delete wirelists from them There is also one temporary memory location called Last Learned When the analyzer learns a new Sample Cable the wirelist data from that cable is stored in the temporary Last Learned memory location It stays there until you either save it in one of the permanent memory locations or overwrite it by learning another Sample Cable Before you can learn a Sample Cable you must install the right cable adapters on your 1000H see page 9 for instructions on how to do this To learn the Sample Cable do these things 1 Connect the Sample Cable you want to learn to the connector adapters already installed on the 1000H Turn on the analyzer by pressing the ON switch The analyzer will learn the cable then prompt Please Verify SIG 6BECB9 6F350 PLEASE VERIFY DISPLAY PRINT Turn the analyzer on FUNCTION 2 To verify that the Sample Cable has been learned correctly press D ispla y Print e Ifyou have a printer connected to the analyzer when you press D isplay Print the analyzer will print out the cable s wirelist information The printout is your cable documentation Compare the printed information to the Sample Cable s sp
68. pen When the analyzer prompts an open use the sharp metal tip of the probe to pierce the insulation of the wire that should connect between the two pins The pin shown in the display is the pin that has a good connection to the wire The pin that is not displayed is the open Open J1 01 PROBE ON J3 02 DISPLAY PRINT FUNCTION Before you begin reworking a cable assembly remember these things e Ifyou have a printer connected to your analyzer either turn it off or disconnect it e When the analyzer displays errors pressing D ispla y Print once will put the analyzer into rework mode If you press Displa y P rint twice the analyzer will just prompt all the errors it detects Please see next page 1000H User s Guide page 56 Section 11 Rework and Guided Assembly Rework instructions Removing shorts within a net If the analyzer detects a short follow these steps 1 Press D isplay Print once to put the analyzer into rework mode The analyzer will prompt Break JX XX where X indicates the adapter position and the pin number Break all connections indicated in the display Break JX XX BREAK JX XX l DISPLAY PRINT FUNCTION 2 When you break a connection the analyzer will prompt the next short When all the shorts have been broken the analyzer will prompt the net and point to which you should connect JX XX Connect JX XX to the point indicated in the display Connect JX XX Yt SN AA C
69. pter pin on the bottom of the adapter to the test connector on top If you find open or worn connections replace the adapter e Ifyou find a bad pin after all these tests call Cirris to replace the scan ner assembly Please see next page Problem The analyzer stops operating while it is being used 1000H User s Guide page 67 Section 12 Troubleshooting General Problems with the Analyzer Possible Causes e Damage from static electricity e Bad microprocessor assembly e Overheating Things to do 1 If static electricity may be a problem be sure the safety ground on the wall plug is connected Take measures to control static in your work area 2 Ifthe microprocessor is bad call Cirris Systems to replace the microprocessor assembly 3 If overheating may be a problem let the analyzer cool for a few minutes It it comes back on you may want to direct a cooling fan on the analyzer Problem Speaker problem There is no sound but the display works Possible Causes e The Error Tones option is set to OFF e The speaker inside the analyzer is not plugged in e The microprocessor assembly is bad Things to do 1 Ifyou hear clicking sounds for cables that test as good but no sounds for cables that test as bad the Error Tones option is set to OFF See page 17 for instructions on how to change the option setting 2 Connect the speaker wire to the microprocessor assembly 3 If the speaker wire is connecte
70. ration 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 Cirris 1000H Analyzer ANY IMPLIED WARRANTIES ARISING OUT OF SALES OF THE 1000H 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 SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGE EXPENSES OR ECONOMIC LOSS Some states do not allow limitations on length or 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 rights which vary from state to state Cirris Systems Corporation Salt Lake City Utah PLEASE RECORD PURCHASE DATE AND SERIAL NUMBER BELOW DATE SERIAL NUMBER 1000H User s Guide page 73 Section 14 Statement of Warranty 1000H User s Guide page 74 Section 15 Glossary cable signature connection resistance connector adapter connector adapter position control cable documentation hipot hipot duration Insulation Resistance insulation short interconnection A si
71. s 1000H User s Guide page 14 Adding a printer How do know if have a parallel printer 6 Carefully push the new EPROM down into the socket using even pressure Be careful not to misalign or bend the pins 7 Gently lower the microprocessor assembly back into the box Replace the spacer plate then lock the twistlock fasteners Your unit is reassembled The 1000H works with almost any printer that has an Epson Centronics parallel interface WARNING Connecting the analyzer to a printer with an RS 232 serial interface will cause serious damage to the analyer and is not covered by your factory warranty To connect the printer use a standard Epson Centronic parallel interface cable readily available from almost any PC dealer Plug one end of the cable into the printer and the other end into the analyzer s parallel printer socket as shown in the photo Plug the printer in here To see if you have a parallel printer look for the parallel connector on the printer Printers usually have a parallel interface located in back Many printers have both a serial and a parallel connector To work with the 1000H your printer must have a 36 position female ribbon connector similar to the one shown here 1000H User s Guide page 15 Section 1 Work With the Hardware Can use one printer with more than one analyzer Can I use one printer with more than one analyzer How do use a printer without an on lin
72. s the problem the original microprocessor is bad Call Cirris to replace it 1000H User s Guide page 70 Section 13 Specifications Test Point Capacity Test Levels Connection resistance sentisivity Insulation resistance sensitivity Typical test rate Maximum points per net Maximum capacitance per net Humidity HV energy limit Printer output Probe Memory Power Size Weight Display Warranty 128 points expandable to 256 384 or 512 points 5 VDC 6mA max current 0 1 to 100Kohms 4 0 1 ohm also 500K 1M and 5Mohms 20 5M 10M 20M 50M 100M 200MQ 10 and 500 Mohms 20 Tests 512 points in less than 3 seconds 128 points in less than 0 3 seconds speed will change with parameter selection OR 128 points per second typical 50 points 100 points with auxiliary power supply 50V 0 1 microfarad 100 V 0 1 microfarad 200 V 0 03 microfarad 300 V 15 nano farad 400 V 7 nanofarad 630 V 3 nanofarad 800 V 1 5 nanofarad 1000 V 1 nano farad Will test without error in environments with zero to 75 relative humidity Relative humidity above 75 will affect performance Current limited to 6ma max for ten ms duration Standard Epson Centronics type parallel interface Pinout matches IBM PC parallel port For test point identification Nonvolatile storage for up to 50 wirelists Lithium battery backup 105 135 VAC 60Hz 16 Watts 210 260 VAC 50Hz optional
73. s are available Hipot Voltage vs Insulation Resistance Settings Hipot Voltage Available Range of Insulation Resistance Settings OFF From the Connection Resistance value you set to 100KQ then 500 KQ 1 MQ and 5MQ 50 V 5MQ 10MQ 20MQ 100 V 5MQ 10MQ 20M9 50MQ 200 V 5MQ 10MQ 20M9 50MQ 100MQ 300 V 5MQ 10MQ 20M9 50MQ 100M9 400 V 5MQ 10M9 20M9 50MQ 100M 200M9 500 V 5MQ 10M9 20MQ 50MQ 100M 200M9 500MQ 630 V 5MQ 10M9 20M9 50MQ 100M 200M9 500MQ 800 V 10M9 20M9 50M9 100MQ 200M9 500 MQ with special adapters 1000V 10M9 20M 50M9 100MQ 200M9 500 MQ with spe cial adapters Note If you plug in an adapter not spe cially designed for 800 V or 1000 V the analyzer will reset the Insulation Resistance value to 100MQ This setting determines the length of time voltage will be applied to each NET during hipot testing The longer the setting the more likely the analyzer is to detect faults which occur over time intermittents but testing will take longer Important The system will not perform a hipot test until a cable has passed a conductance test Once leakage above the set threshold is detected the high voltage is switched off This setting determines whether the hipot voltage will be applied to all adapter pins whether they have connections or not or only to those adapter pins that are connected to other pins The available settings are ALL
74. t Cable Interpreting hipot test results Failed Hipot Test If the hipot test detects errors the analyzer prompts Failed Hipot Test Press Displa y Print to step through the errors detected The display will prompt the prob lem nets as either Has Leakage or as Over Current FAILED HIPOT TEST 3 J1 05 J2 04 3 J1 05 J2 04 HAS LEAKAGE OVER CURRENT e Has Leakage indicates that there is weak insulation between pins or bare wires that nearly touch These defects have the potential to become short circuits At the most sensitive settings contamination from finger prints or body oils deposited while handling connectors may cause a cable to fail e Over Current indicates that the cable has excessive capacitance for the selected hipot voltage setting or if the resistance of the leak is suffi ciently low approximately 500 Kohms If the cable has too much capacitance try using a lower hipot voltage Dielectric Fail This indicates that the analyzer detected electrical arcing between nets during the hipot test If the analyzer can isolate the nets that are arcing during the test it will prompt them in the display If it cannot isolate the specific nets that are arcing it will prompt Undetermined Net 3 J1 05 J2 04 UNDETERMINED NE DIELECTRIC FAIL DIELECTRIC FAIL Intermittent If a cable develops shorts or opens after it first tests as good the display prompts an intermittent error The analyzer emits a steady series of clicks as thoug
75. ted as close to the actual test point as possible You might tie them together on your harness board right at the test connector for example Testing With your fixturing set up correctly and a Sample Cable a cable you re certain is built correctly installed on your analyzer 1 2 Hold down D ispla y P rint and turn on the analyzer Set the Connection Resistance and Insulation Resistance options to the values you want to use Connection Resistance will be displayed in numbers down to 1 milliohm whenever four wire adapters are installed on the analyzer Begin testing the cable The analyzer will automatically learn the connection pat tern in the cable and check your fixturing setup While the analyzer is in the test sequence press F unction to perform the four wire test If the Hipot option is on the analyzer will hipot test the cable immediately after the four wire test has been successfully com 1000H User s Guide page 88 Appendix 1 Four Wire Testing on the 1000H The value of four wire testing pleted If the Auto Hipot function is turned on the cable will automati cally be four wire tested then hipot tested e Before and after a four wire test the cable is tested for proper continu ity A continuous low current connection resistance test is performed to a level 100 milliohms above the four wire connection threshold e The analyzer checks your fixturing continuously Using the connections test it constan
76. than 22 ohms or less than 18 ohms it falls outside the specified 10 tolerance for the resistor and the analyzer reports an error I This line indicates that a diode is present in the cable It is connected between J3 005 the anode and J12 005 the cathode J This shows two points that were somehow linked in the learned Sample Cable but a specific test was not created for them This occurs when the Insulation Resistance is set higher than 100K and a connection exists between 100KQ and the Insulation Resistance It also occurs in a cable with a complex system of resistors which the analyzer cannot completely unscramble on its own How to test a complex cable assembly To test a complex cable assembly do these things 1 Set the test options see page 17 for instructions on how to do this then connect a Sample Cable a cable that you know is built correctly of the kind you want to test to the analyzer 2 Learn and document the Sample Cable 3 Disconnect the Sample Cable then connect a cable that you want to test Insulation Test First the analyzer does a low voltage insulation test to verify that points which are not supposed to be connected are in fact not connected e Ifyou have set a hipot voltage this test is supplementary to the hipot test that will be conducted later It is used to find gross errors e Ifyou have not set a hipot voltage this test is the insulation portion of the complex test and the analyzer
77. the 1000H displays a signature it first displays the six digit cable signature then a hyphen The five digit alphanumeric number that follows the hyphen is the parameter signature It represents the voltage and resistance settings you have selected Note If you select the same voltage and resistance settings for two different kinds of cables both kinds will have the same parameter signature but different cable signatures The connector adapter signature s The connector adapters you use to connect your cables to the 1000H have unique 1000H User s Guide page 39 Section 9 Cable Documentation and Signatures How connector adapters are supported six character connector adapter signatures Each kind of adapter has its own adapter signature These signatures help you verify that your test setups are correctly done They appear on the labels attached to the adapters and on your cable documentation see item D on page 39 When the adapter signatures match those found on your cable documentation you have installed the correct adapters How connector The 1000H uses connector adapters mounted on small printed circuit boards to adapters are connect the cables you want to test to the analyzer s scanner assembly Cirris Systems supported can provide adapters for nearly all popular connectors You can also make an exterior adapter cable to adapt to any connector with up to 120 pins by using an optional frame mount stand This photo shows a fra
78. tly checks for the presence of intermittent short circuits and fixture wires that should be connected together e Immediately prior to performing each high current measurement the resistance is measured using low current High current is then applied based on that two wire resistance measurement if the two wire resis tance is less than 10 ohms This prevents the analyzer from applying high current that could damage a contact while a cable is being con nected The value of Simply stated a four wire test is a test for wires and contact points The advantage of four wire four wire testing over ordinary two wire resistance testing is that four wire testing nulls out the resistance of the test fixturing Only the resistance of the wire and the testing contact itself is measured How four wire testing In four wire testing a known amount of electrical current flows from point J 001 to works point J 002 To null out the resistance of the test fixturing two wires are connected to each test point One of these wires provides a known amount of current flowing into sourced into point J 001 A second wire is connected to point J 002 It provides a return sink path for the current flowing into J 001 The other two wires one to point J 001 the other to point J 002 work much like the probes on a voltmeter to measure voltage The voltage drop across the two test points J 001 and J 002 is measured The resistance is then
79. to test cables which are supposed to be like the Sample Cable by letting the analyzer learn the Sample Cable When the list of interconnections and the other properties of a cable you are testing are not the same as those of the Sample Cable the signature of the cable you are testing will not match the signature of the Sample Cable This signature mismatch will be reported as a bad cable The last wirelist including all test parameters and adapter information learned by the analyzer This can be loaded into the analyzer for testing either by learning a Sample Cable or by retrieving the wirelist information for a cable from the analyzer s memory The 1000H has one last learned memory location and as many as 50 permanent memory locations The number of available locations depends upon the size of the wirelists being stored Large wirelists take up more memory space than small ones do You can load cable information into the analyzer for testing by retrieving the information from one of these memory locations It is also possible to delete old wirelist information from specific memory locations to free up memory for storing new cable information The electronic assembly which includes the LCD display As you look at the analyzer from above the microprocessor assembly is located to the left A type of interconnection error where a one pin is incorrectly connected to another pin For example if a connection is supposed to ex
80. toring cable information How many locations are actually available depends on the size of the wirelists being stored Small wirelists take up less space than large ones You may need to delete cables to make room for new wirelists or to discard wirelists you no longer use for testing To delete a cable from the analyzer s memory do these things 1 Hold in the M emory button as you turn on the analyzer Continue holding in the button as you do the next step The analyzer will prompt Ready To Access Memory Locations READY TO ACCESS MEMORY LOCATIONS DISPLAY PRINT FUNCTION Press and hold as you turn the analyzer on 2 Continue holding in the M emory button while you press Display Print to step through the Sample Cables stored in the analyzer s memory until you come to the signature of the cable you want to delete Remember the first cable displayed will be the cable in the Last Learned memory location It cannot be deleted When you come to the cable you want to delete the display should prompt Mem Location X Sig XXXXXX XXXx indicating the memory location and signature of the cable MEM LOCATION X SIG XXXXXX XXXX DISPLAY PRINT FUNCTION Continue to hold 1000H User s Guide page 33 Section 7 Delete a Cable from Memory How to delete a cable 3 Continue to hold in the Memory button while you press F unction to select the cable for deletion Continue to hold down the Function swit
81. u may on expansion boxes write in the adapter position number The analyzer recognizes the positions for the first expansion box as J5 through J8 for the second expansion box as J9 through J12 and for the third expansion box as J13 through J16 You can connect up to three expansion boxes to the analyzer s main box for a total of 16 connector adapter positions 512 available test points 1000H with 1 expansion box installed Eight J positions 256 test points are available Expansion box with white squares at all four adapter positions 1000H User s Guide page 41 Section 9 Cable Documentation and Signatures Order of adapter positions Order of adapter In your cable documentation connector adapter positions appear in sequential order positions beginning with J1 However if you install either a double high or a quad high con nector adapter see page 40 some adapter positions are eliminated In this photo position J2 is eliminated because a double high adapter has been installed in positions J1 and J2 A single high adapter has been installed in position J4 In this example the next position sensed by the analyzer during testing will be J4 The cable documenta tion will show interconnections for J1 and J4 but not J2 or J3 Double high adapter in J1 J2 single high adapter in J4 Install adapters When you install connector adapters you must install them beginning with the low lowest numbered first est numbere
82. ure is an indication of the presence of a net with high capacitance a net with too many points or a net that tests as borderline Normally hipot failures show up with at least two failed nets e Ifyou ve set the Apply H ipot option to Connections Only the analyzer will not detect leakage of a single net to any unconnected pins Remember when you select an Insulation Resistance setting you are specifying the lowest resistance that should appear between unconnected points See page 20 for more information on Insulation Resistance versus Hipot Voltage settings Remember these things e Using the highest setting might increase your chances of finding some kinds of errors You might not want to use an extremely high setting Oil solder flux or fingerprints left over from the manufacturing process can become conductive in high relative humidity conditions e Ifyou are testing in relative humidity conditions above 75 you may have more failures when you test at 500 megohms or even 200 mego hms e In general select an Insulation Resistance setting that is lower than the resistance of normal contamination on the cable 1000H User s Guide page 53 Section 10 Select a Test Procedure Tips on selecting Insulation Resistance settings 1000H User s Guide page 54 Section 11 Rework and Guided Assembly The hand held test probe Installing the probe Example Identifying test points using the probe You can con
83. ust remember Things you must remember Because these are four wire type adapters you must not use them in conjunction with other adapter types All of the pins you use for testing must be four wire terminated Any pins that you don t use can be left unterminated but only if they come after all terminated pins A good rule of thumb is to four wire terminate all unused adapter pins You ll get fixture open errors if you don t fol low this rule Note Four wire termination is where the two adapter pins related to a single test point are tied together Tie adapter pins You must be sure that both adapter pins which relate to a single test point are tied together correctly together at the point where you want to make your resistance measurements as shown below Remember these things J 001 a J 001 c Make your resistance measurement where points a and c tie together J 002 a J 002 c For four wire testing to work the total resistance from one test point to another including the resistance of the fixturing and the cable being tested must not exceed 10 ohms Typically fixturing with wires less than two meters about six feet long has less than 0 5 ohms total resis tance If the fixturing and cable resistance is less than 10 ohms four wire testing will null out the fixturing resistance Your resistance measurement begins at the point where the two fixture wires connect together They must be connec
84. will use the insulation test parameters you ve set Wires Test Second the analyzer does a wires test checking connections without resistors using the wirelist test parameters If it detects an error the analyzer loops on this test Check Components Test Third the analyzer tests individual components If it detects an error the analyzer loops on that specific check e Ifthe analyzer detects an error during any of these three tests press Display P rint to print out an error list e Ifthe analyzer detects no errors it will continuously loop on the first three tests until you disconnect the cable Hipot Test If you have set a hipot voltage and the analyzer does not detect any errors during the 1000H User s Guide page 49 Section 10 Select a Test Procedure Limitations when testing complex assemblies Limitations when testing complex assemblies previous tests it will prompt Ready To Hipot e If the Auto H ipot option is set to ON the analyzer will automatically perform a hipot test after the cable has passed all other tests e Ifthe Auto Hipot option is set to OFF the analyzer will prompt Ready to Hipot You must press Function to begin a hipot test When you test complex assemblies remember these things 1 Any connections which have resistances between the Wire Resistance and the Component Resistance are seen by the analyzer as errors The resistances are too low to be seen as components and too high t
85. x character alphanumeric code that changes with any change in interconnections Valid characters include the numbers 0 through 9 and the letters A through F Option setting that allows you to select the maximum allowable resistance that a good connection can have Connector adapters are adapters mounted on small printed circuit boards that allow you to connect the cables you want to test to the 1000H There are three types single high double high quad high Each adapter has its own unique adapter sig nature Adapters are usually kept organized in a 3 x 5 inch card file You identify the adapter by its signature either on the cardboard sleeve in which the adapter is shipped or by the signature printed on the label on the adapter itself Adapters are identified by the connector they mate to not the connector mounted on the adapter The location either on the analyzer s main unit or on an expansion box where con nector adapters are mounted The main unit has four such positions marked as J1 J2 J3 J4 Each expansion box also has four connector adapter positions The regulation of manufacturing or assembly processes particularly the use of a cable signature for verifying the test setup against the documentation The written definition of how a cable should be constructed Usually consists of a wirelist and a complete set of notes on what connectors materials and special techniques should be used to build the cable successful
86. y so they don t bend as they are inserted into the sockets To line the pins up properly press the adapter against the inside edge of the metal frame and have the bottom of the adapter card resting on the plastic adapter support i accept the adapter connector pins on the bottom of each adapter 1000H User s Guide page 9 Section 1 Work With the Hardware How to install an expansion box 3 Replace the cover plate making sure the small alignment pins on its underside fit into the corresponding holes on the scanner s upper surface Each cover plate alignment pin fits into a hole in the scanners _ _ upper surface One Pr ONS 4 Lock the twistlock fasteners to hold the adapters firmly in place How to installan Up to three expansion boxes can be installed on your 1000H to increase the number expansion box of test points available You can set up your system to have as many as 512 test points To install an expansion box follow these steps 1 Unlock the twistlock fasteners on the top of the analyzer s spacer and cover plates and on the top of the expansion box Remove the cover plate and the spacer plate Shere Bele 2 Lift the scanner assemblies out of both the main unit and the expansion box Note Your expansion box may have a black plastic plate covering the opening where you will be routing the scanner cable Once the scanner has been removed push the plastic rivits out
87. zer by learning a Sample Cable see page 23 or by retrieving a cable from the analyzer s memory see page 31 you are ready to test your first cable To test your first cable follow these steps 1 Disconnect and remove the Sample Cable from the analyzer 2 Connect the cable you want to test to the analyzer e Once you have connected the cable the analyzer will automatically begin the test Note If you have set the Auto H ipot option to OFF the analyzer will stop after the continuity and conductance tests prompt Ready To Hipot and wait for you to press Function to begin the hipot test e WARNING Do not connect a powered live cable to the analyzer This will seriously damage your analyzer and will immediately void any stated or implied warranty As the analyzer does cable tests it will display results on its LCD display and will emit sounds Here s how to interpret what you see and hear If a cable is good The display prompts the same alphanumeric signature as the Sample Cable The display will show Good R lt X XQ The analyzer will emit a steady clicking sound SIG XXXXXX XXXX GOOD R lt XXXQ e To continue testing disconnect the good cable then replace it with another cable you want to test 1000H User s Guide page 27 Section 5 Test Your First Cable Interpreting hipot test results Interpreting hipot test resu

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