Cablescan 90 Series User guide

Cablescan
Series 90
SETUP MANUAL
9
0
90

May 4, 2015
Series 90
SETUP MANUAL
(Part Number 5900407-00)
Cablescan
A Eubanks Company
3022 Inland Empire Blvd.
Ontario, California 91764
[phone] Fax [phone]
www.cablescan.com

Page iv Series 90 Setup Manual
COPYRIGHT NOTICE
This manual is proprietary, copyrighted material. No part of this manual may be reproduced or
transmitted in any form or by any means, electronic or mechanical, including photocopying and
recording, for any purpose other than the purchaser's personal use, without written permission of
Cablescan Inc.
Copyright 1999 – 2014 Cablescan Inc. All rights reserved.
THIS IS A LIMITED WARRANTY
CABLESCAN (hereinafter “CABLESCAN”) products are warranted to the original owner for a
period of twelve (12) months from the date of shipment from CABLESCAN’s factory, or in the
first 2,080 hours of operation by the customer (whichever comes first), to be free from defects in
material and workmanship for the use for which they are intended by CABLESCAN, under
normal operating conditions and maintenance.
CABLESCAN’s obligation under this Warranty is limited, upon prompt notification, to the
repair or exchange at the CABLECAN factory of any CABLESCAN product or part which
proves to be defective. If a product under warranty is returned to the CABLESCAN factory for
repair or replacement, freight charges will be borne by the customer in accordance with
CABLECAN’s policy of selling F.O.B. the CABLESCAN factory. If repairs are made at the
customer’s factory, the customer will bear the cost of the service person’s travel and living
expenses.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED
OR IMPLIED. THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE. THIS WARRANTY STATES CABLESCAN’S
ENTIRE AND EXCLUSIVE LIABILITY WHETHER IN TORT OR IN CONTRACT AND
BUYER’S EXCLUSIVE REMEDY FOR ANY CLAIM FOR DAMAGES IN CONNECTION
WITH THE SALE OR USE OF CABLESCAN’S PRODUCTS, THEIR DESIGN,
SUITABILITY FOR USE, INSTALLATION OR OPERATION, OR FOR ANY CLAIMED
DEFECTS THEREIN. UNDER NO CIRCUMSTANCES WILL CABLESCAN BE LIABLE
FOR ANY CONSEQUENTIAL, INCIDENTAL, ECONOMIC, DIRECT, INDIRECT,
GENERAL, OR SPECIAL DAMAGES. NO ACTION UNDER THIS WARRANTY MAY BE
BROUGHT BY BUYER MORE THAN ONE YEAR AFTER THE CAUSE OF ACTION HAS
OCCURRED.
This warranty does not apply to equipment or replacement parts that have not been given proper
care and maintenance and does not cover any defect, failure, deficiency, or error that is:
a) Not reported to Cablescan within the applicable warranty period;
b) Due to accident, misapplication, negligence, modification, alteration, disassembly, abuse,
misuse, abnormal conditions of temperature, dirt, or corrosive matter; or
c) Due to operation, either intentional or otherwise, above rated capacities, or in an
otherwise improper manner.
If it is determined that the equipment defect is not the result of original manufacture but is
related to customer negligence or operational error, the customer will pay all incurred charges
including, but not limited to, parts and labor.

Series 90 Setup Manual Page v
TABLE OF CONTENTS
Series 90 Family of Test Systems....................................................... 1
Series 90/Series 90HV ..................................................................................1
Series 90L4/Series 90L8/Series 90H8..........................................................1
System Components ........................................................................... 4
Series 90.........................................................................................................4
Series 90HV...................................................................................................4
Series 90 System Controller ........................................................................4
Expansion Cabinets......................................................................................5
Series 90................................................................................................5
Series 90HV..........................................................................................5
Series 90L4/L8/H8........................................................................................5
Series 90 System Setup....................................................................... 6
Unpacking.....................................................................................................6
Power Connection ........................................................................................6
Grounding the Unit...............................................................................6
Power Cords.........................................................................................6
Series 90/Series 90HV System Controller INterfacing.............................7
Rear Panel............................................................................................7
I/O Board..............................................................................................7
Series 90/90HV Connection Procedure......................................................8
Basic System Hookup............................................................................8
Adding Expansion Cabinets..................................................................9
Series 90L4/Series 90L8/Series 90H8 Scanner Control.....................10
Series 90L4/L8/H8 Connection Procedure.........................................10
Connecting to Serial Port on PC ...............................................10
Connecting to USB Port on PC.................................................11
Adding Scanner Boards.............................................................................12
Series 90E9/Series 90E32 Cabinets ...................................................12
Series 90HV23 Cabinet.......................................................................13
Series 90L4/L8/H8 Cabinet ................................................................14
Low-voltage Scanner Board Jumpers.................................................15
Scanner Board Pins and Test Point Assignments.......................... 16
Series 90 Low-Voltage Systems.................................................................16
Series 90 High Voltage Systems ................................................................17
Interface Cable Assemblies and connectors................................... 18
Low-voltage Interface Cables....................................................................18
5210914-03 Cable Assembly ..............................................................18
5210917-03 Cable Assembly ..............................................................19

Page vi Series 90 Setup Manual
TABLE OF CONTENTS - Continued
5210982 Cable Assembly....................................................................19
High-voltage Interface Cables and connectors........................................21
5211036 Connector Kit.......................................................................21
5211037 Cable Assembly....................................................................21
5211038 Cable Assembly....................................................................22
5211088 Connector Kit.......................................................................22
Remote Signals.................................................................................. 24
Output Signal Timing ................................................................................24
Input Signals...............................................................................................24
Input/Output Connectors..........................................................................25
9 Pin D Connector Serial Port ...........................................................25
25 Pin D Connector Parallel Port......................................................26
15 Pin D Connector I/O Port..............................................................27
Vacuum Fixture Operation.......................................................................27
TestDiag............................................................................................. 28
The TestDiag Program...............................................................................28
Starting TestDiag........................................................................................28
TestDiag Opening Screen ..........................................................................29
Title Bar..............................................................................................30
Control Menu......................................................................................30
Quick Access Tool Bar........................................................................30
Ribbon Menu.......................................................................................30
Status Banner......................................................................................31
Test Selection Window........................................................................31
Test Results Window...........................................................................31
Status Bar............................................................................................31
Application Menu ...............................................................................32
Style Menu ..........................................................................................32
About Menu.........................................................................................32
Application Menu.......................................................................................33
Print....................................................................................................33
Quick Print..........................................................................................33
Print to File ........................................................................................33
Print Preview......................................................................................33
Tester Settings.....................................................................................33
Tester Type ...............................................................................33
Communication Port .................................................................34
High Precision Cap. Model.......................................................34
Ribbon Menu..............................................................................................35
Home Tab............................................................................................35
Self Diagnostics Group .............................................................35

Series 90 Setup Manual Page vii
TABLE OF CONTENTS - Continued
Range Group .............................................................................36
Tester Group .............................................................................36
Calibration Group .....................................................................37
Test Selections Group ...............................................................37
Advanced Tab .....................................................................................38
Output Group ............................................................................38
Factory Testing .........................................................................38
Style Menu ..........................................................................................38
About Menu.........................................................................................39
Register .....................................................................................39
Diagnostic Tests ................................................................................ 40
Test Selection Window...............................................................................40
Low-Voltage Tests......................................................................................41
Application..........................................................................................41
Test Descriptions................................................................................41
Enable........................................................................................41
System Status ............................................................................41
Short Test ..................................................................................41
Sense Line Test .........................................................................41
Raw FET On Test......................................................................41
Raw FET Off Test.....................................................................41
Capacitance Test .......................................................................41
Resistor Bank ............................................................................41
High-Voltage Tests.....................................................................................42
Application..........................................................................................42
Test Descriptions................................................................................42
Enable........................................................................................42
High-Voltage Gen .....................................................................42
High Voltage Dis ......................................................................42
High Current Select...................................................................42
Scanner Relay ...........................................................................42
High Voltage Select ..................................................................42
High Current Gen......................................................................42
Isolation Amplifier....................................................................43
Controller Leakage....................................................................43
System Leakage ........................................................................43
Series 90 Calibration ........................................................................ 44
Purpose........................................................................................................44
Low-voltage Test Procedure...............................................................45
High-voltage Test Procedure..............................................................46
Fuse Replacement............................................................................. 48

Page viii Series 90 Setup Manual
TABLE OF CONTENTS - Continued
Series 90S9 and Series 90S32 Fuse Replacement ....................................48
Series 90L4/H8 Fuse Replacement............................................................49
Care of Series 90 ............................................................................... 50
Maintenance................................................................................................50
Repair..........................................................................................................50
Handling Circuit Boards ...........................................................................50
Shipping and Storage.................................................................................50
Replacement Parts......................................................................................51
Specifications..................................................................................... 52
Appendix A - Scanner Resistor Bank............................................ 55
Appendix B – Calibration Boards................................................... 56

Series 90 Setup Manual Page ix
LIST OF FIGURES
Figure Description Page
1The Series 90 Test Systems .........................................................................2
2The Series 90HV Test System .....................................................................3
3The Series 90 Series 90L4 and 90Series Series 90H8 Test Systems...........3
4Series 90/90HV Simplified Diagram...........................................................4
5Series 90L4/L8/H8 Simplified Diagram......................................................5
6System Controller Rear Panel......................................................................7
7Series 90/90HV Cable Connections ............................................................8
8Multiple Expansion Cabinet Hookup ..........................................................9
9Series 90L4/H8 Cable Connections Serial.................................................10
10 Series 90L4/H8 Cable Connections USB ..................................................11
11 Series 90E9 Scanner Board Locations.......................................................12
12 Series 90HV Scanner Board Locations .....................................................13
13 Series 90L4/H8 Scanner Board Locations.................................................14
14 Scanner Board Jumpers..............................................................................15
15 Low-voltage Scanner Board Layouts ........................................................16
16 High-voltage Scanner Board Layouts........................................................17
17 Low-voltage Cable Assembly –5210914-03 .............................................18
18 Low-voltage Cable Assembly –5210917-03 .............................................19
19 Low-voltage Cable Assembly –5210982...................................................19
20 High-voltage Connector Kit –5211036......................................................21
21 High-voltage Cable Assembly –5211037 ..................................................21
22 Signal Timing Diagram..............................................................................24
23 Fuse Locations – Early Model Expansion Cabinet....................................48
24 Series 90L4/90H8 Fuse Locations.............................................................49

Page x Series 90 Setup Manual
ABOUT THIS MANUAL
This manual provides setup and installation information on all Cablescan Series 90 Test
Systems:
Low Voltage Models High Voltage Models
Series 90 Series 90HV
Series 90L4 Series 90H8
Series 90L8
Information that is not identified by model number(s) pertains to all models. Where information
is identified by certain models, read the portions pertaining to your model.
Before attempting to operate your model of the Series 90, be sure to read this manual until you
understand it. Then, when first using your Series 90, follow the manual as closely as necessary
to achieve proper operation. When you eventually develop mastery of the system, you will
continue to turn to the manual as a reference.
Information in this manual supports a second volume, "Series 90 Software Manual."
If you have a question or problem regarding this manual, please contact Cablescan.

Series 90 Setup Manual Page 1
SERIES 90 FAMILY OF TEST SYSTEMS
SERIES 90/SERIES 90HV
The Cablescan Series 90 (Figure 1) is a high-speed continuity tester that you also can use as an
assembly aid and a final interconnect verifier. The Series 90HV (Figure 2) is a high-voltage
model that typically is used for testing quality of insulation and quality of harness connections.
All test and build features of the standard Series 90 are incorporated in the Series 90HV. You
can apply either model to the test and assembly of:
Cables and harness assemblies
Back planes
Bare printed circuit boards
. . . with up to 131,072 test points (standard Series 90), or 47,104 points (Series 90HV).
You normally operate the Series 90/90HV through a Windows-based system controller using the
keyboard, mouse and monitor. You can create and store your test/build programs on the system
controller’s hard drive or network attached storage devices. You also can obtain and store test
programs through the learn-known-good process, or you can import test programs from other
sources.
SERIES 90L4/SERIES 90L8/SERIES 90H8
The Cablescan Series 90L4 (not shown), Series 90L8 and Series 90H8 (Figure 3) are low and
high-voltage models that are used on small assemblies and require use of your PC as the control
device. All test and build features of the Series 90 and 90HV are incorporated in the Series
90L4, Series 90L8, and Series 90H8. You can apply them to the test and assembly of:
Cables and harness assemblies
Back planes
Bare printed circuit boards
. . . with up to 512 test points.
You operate the Series 90L4/90L8/90H8 through your own PC, which serves as the controller,
running on Cablescan-supplied software. You can create and store your test/build programs on
the hard drive or network attached storage devices. You also can obtain and store test programs
through the learn-known-good process, or you can import test programs from other sources.

Page 2 Series 90 Setup Manual
SERIES 90-S9 (Nine-board Expansion Cabinet)
SERIES 90-S32 (Thirty-two-board Expansion Cabinet)
Figure 1. The Series 90 Test Systems

Series 90 Setup Manual Page 3
SERIES 90HV-S23 (Twenty-three-board Expansion Cabinet)
Figure 2. The Series 90HV Test System
(Controlled by your PC)
(Controlled by your PC)
Series 90L4 (Four-board Cabinet) Series 90H8 (Eight-board Cabinet)
Figure 3. The Series 90 L4 and Series 90H8 Test Systems

Page 4 Series 90 Setup Manual
SYSTEM COMPONENTS
SERIES 90
The Series 90 consists of a system control and one to thirty-two expansion cabinets to
accommodate scanner boards. See Figure 4. There are two models: the Series 90-S9, with a
nine-board Expansion Cabinet (which may be ordered with 1 to 9 boards); the Series 90-S32,
with a thirty-two board Expansion Cabinet (which may be ordered with 1 to 32 boards).
Additional 9 and 32-board Expansion Cabinets can be added, in any combination, to either
model. They may be ordered with partial or full complements of scanner boards.
SERIES 90HV
The Series 90HV consists of the same system control and one to thirty-two expansion cabinets to
accommodate high-voltage scanner boards. There is only one model, the Series 90HV-S23, with
a 23-board expansion cabinet. It may be ordered with 1 to 23 high-voltage, 64-point scanner
boards. Additional 23-board expansion cabinets may house partial or full complements of
scanner boards.
Figure 4. Series 90/90HV Simplified Diagram
SERIES 90 SYSTEM CONTROLLER
The Series 90/90HV system controller is based on an Intel processor. The controller contains a
hard disk drive and a DVD drive. Human interface with the controller is provided by a 101-key
keyboard, mouse, and a monitor. The controller communicates with the expansion cabinets
through its high-speed serial port. USB ports are provided to accommodate an optional printer.
Monitor
System
Controller
KBD/Mouse
Optional
Printer Expansion Cabinet
Expansion
Cabinet
Expansion
Cabinet
Assembly
Under
Test

Series 90 Setup Manual Page 5
EXPANSION CABINETS
Each expansion cabinet holds and interconnects the scanner boards, a scanner control board that
provides communication with the system controller (or PC), and a power supply that converts
line power to voltage levels of DC power required within the system.
Multiple expansion cabinets can be added to the Series 90 and Series 90HV to obtain up to 32
cabinets. Maximum possible test points: 131,072 for the Series 90 and 47,104 for the Series
90HV. The Series 90L4, Series 90L8, and Series 90H8 are single cabinet systems and cannot be
expanded using multiple cabinets. Maximum test points for each of these testers is 512 (1024
test points for the Series 90L8).
Series 90
Two expansion cabinet models are offered in the Series 90:
Series 90-E9: Nine scanner boards with 128 test points each, yielding 1152 maximum
possible test points per cabinet.
Series 90-E32: Thirty-two scanner boards with 128 test points each, yielding 4096
maximum possible test points per cabinet.
Series 90HV
One expansion cabinet model is available for the Series 90HV:
Series 90HV-E23: Twenty-three scanner boards with 64 test points each, yielding 1,472
maximum possible test points per cabinet
SERIES 90L4/L8/H8
The Series 90L4/L8/H8 has no system controller; you control it through your own PC using
Cablescan-supplied software. See Figure 5. There are no provisions for additional expansion
cabinets.
Series 90L4: Four scanner boards with 128 test points each, yielding 512 maximum
possible test points.
Series 90L8: Eight scanner boards with 128 test points each, yielding 1024 maximum
possible test points.
Series 90H8: Eight scanner boards with 64 test points each, yielding 512 maximum
possible test points.
Figure 5. Series 90L4/H8 Simplified Diagram
Your
PC L4/L8/H8
Cabinet
Assembly
Under
Test
Optional
Printer
Optional
USB/Serial
Converter

Page 6 Series 90 Setup Manual
SERIES 90 SYSTEM SETUP
UNPACKING
The major components of the Series 90 are packaged in foam-packed shipping cartons.
Carefully unpack the components, and set the containers aside for future use. Visually inspect
each component for damage or deficiency. Record any damage or deficiency and report it to
Cablescan. In the event the equipment has been damaged because of shipping, notify both the
carrier and Cablescan immediately.
POWER CONNECTION
Before applying power to the Series 90, make sure that the operating voltage is correct and the
unit is properly grounded (see GROUNDING THE UNIT, below).
Grounding the Unit
Each component of the Series 90/90HV is shipped with a three-wire (grounded) power cable.
When the cable is connected to a three-wire (grounded) power receptacle, it connects the chassis
of the unit to ground. WARNING
Continuity of the grounding circuit is vital for the safe operation
of the units. Never operate the Series 90 system through an
ungrounded power connector, or with the grounding conductors
disconnected.
Power Cords
All power cords are supplied with North American-type plugs. The plug ends must be replaced
for countries with other standards. To help make the change easier, the power cord wires are
coded with the International color code standard. A translation table for the North American and
International color code standards is provided below.
INTERNATIONAL
COLOR CODE NORTH AMERICAN COLOR CODE
LINE brown White
NEUTRAL blue Black
GROUND green/yellow Green

Series 90 Setup Manual Page 7
SERIES 90/SERIES 90HV SYSTEM CONTROLLER INTERFACING
Rear Panel
The rear panel of the system controller has seven vertical slots. They are numbered 1 through 7
starting at your right side when facing the rear panel. See Figure 6. Exact placement of the
interface ports and control boards may vary between systems. A typical system controller
contains the following interface ports and control boards:
Cablescan I/O Board (Typically slot 6)
VGA Color Monitor Adapter (15-pin High Density D-type connector)
Serial I/O ports (9-pin male D-type connector, COM 1)
Keyboard connector (Bottom PS2 connector, KB)
Mouse Connector (Top PS2 connector, MOUSE)
USB Ports
Ethernet Port
MOUSE
KB
MONITOR USB
ETHERNET
SPRK
PROBE FOOT
COM1
EXPANSION
COM IN
Figure 6. System Controller Rear Panel
I/O Board
The Cablescan I/O Board is a high-speed communication board used in sending and receiving
test information to the Scanner Control Boards located in Series 90 expansion cabinets. (The
Scanner Control Board controls the Scanner Boards, which contain the test points in its cabinet.)
One of the main purposes of the Scanner Control Board is to allow up to 32 cabinets to be daisy
chained together as one system. The I/O board inserts into a PCI slot on the CPU board. There
are four external connections on the board: Expansion cabinet connector (male 9-pin D-type),
PC/COM port input connector (female 9-pin D-type), footswitch connection (phone jack), and a
wrist strap probe connection (banana jack).

Page 8 Series 90 Setup Manual
SERIES 90/90HV CONNECTION PROCEDURE
Basic System Hookup
Arrange the Series 90/90HV with the system controller alongside the expansion cabinet.
Connect the system as shown in Figure 7, and as described below:
1. Connect power cord (part number 9200016) from INPUT power connector (male) on
rear panel of expansion cabinet to AC receptacle.
2. Connect power cord (part number 9200016) from INPUT power connector (male) on
rear panel of system controller to AC receptacle.
3. Connect LCD monitor power cord from INPUT power connector (male) on color
monitor to AC receptacle. (The color monitor may have an attached cord.)
4. Connect keyboard to bottom PS/2 connector (KB) on System Controller.
5. Connect mouse to top PS/2 connector (MOUSE) on System Controller.
6. Connect VGA monitor to High-density 15-pin D connector (Monitor) on System
Controller.
PROBE FOOT
COM1
EXPANSIONCOM IN
Figure 7. Series 90/90HV Cable Connections

Series 90 Setup Manual Page 9
7. Connect female end of the short (1 foot) 9-conductor cable (part number 9100086) to
bottom connector of Expansion Input/Output Board (COM IN); connect male end to
serial communication port (COM1).
8. Connect female end of 9-conductor cable (part number 9100069) to top connector of
Expansion Input/Output Board (EXPANSION); connect male end to INPUT
connector on the expansion cabinet.
9. Connect terminating plug (part no. 5211116) to OUTPUT connector on expansion
cabinet.
NOTE
Make sure that all interface cables are secured with their mounting
screws. The most common source of trouble is poor connections.
Adding Expansion Cabinets
1. To add a second expansion cabinet, remove terminating plug from OUTPUT
connector on the first expansion cabinet.
2. Connect the female end of another 9-conductor cable (part number 9100069) to the
OUTPUT connector of first expansion cabinet, and male end to INPUT connector on
second cabinet.
3. If the second cabinet is the last in the chain, connect the terminating plug to its
OUTPUT connector. (The terminating plug is attached only to the last expansion
cabinet.)
OUTPUT INPUT
MOUSE
KB
MONITOR
USB
ETHERNET
SPRK
Install Terminating Plug
on output connector of
last expansion cabinet
2
J1
J3
J5
J7
J2
J4
J6
J8
J11
J13
J15
J17
J9
J12
J14
J16
J18
J10
1
OUTPUT INPUT
J1
J3
J5
J7
J2
J4
J6
J8
J11
J13
J15
J17
J9
J12
J14
J16
J18
J10
Figure 8. Multiple Expansion Cabinet Hookup

Page 10 Series 90 Setup Manual
Series 90L4/Series 90L8/Series 90H8 Scanner Control
The Scanner Control Boards in the Series 90L4, Series 90L8 and Series 90H8 are designed to
communicate through a serial port (COM) instead of a Cablescan I/O board. Since a PC serial
port cannot be daisy chained, the Series 90L4, Series 90L8 and Series 90H8 are limited to one
cabinet (512 test points or 1024 test points for the Series 90L8). For Series 90L4, Series 90L8
and Series 90H8, the other external signals, which include the footswitch and wrist strap
connections, and the remote signals, are available on the PC’s parallel (LPT) ports or secondary
serial port(COM), controlled by Series 90 TestRite software. Refer to the section on Remote
Signals for pin assignments.
Series 90L4/L8/H8 Connection Procedure
A Series 90L4/90L8/90H8 can be connected to a PC using either a serial port or USB port on the
PC.
Connectingto SerialPort onPC
Arrange the Series 90L4/90L8/90H8 alongside your PC. Connect the power cords as shown in
Figure 9, and as described below:
1. Verify power switch on rear panel is in OFF position.
2. Connect power cord (part number 9200016) from power connector (male) on rear
panel to an AC power source (100 to 220V~).
3. Connect PC serial port to and tester serial port with 9-conductor cable (9100069).
4. Connect PC to appropriate power source in accordance with PC instruction manual.
F
U
S
E
F
E
F
U
S
E
Figure 9. Series 90L4/L8/H8 Cable Connections