Cablescan 128/PC User manual

i
MODEL 128/PC
CONTINUITY TESTER
AND FIXTURE

Model 128/PC Instruction Manual Page iii
February 25, 2005
MODEL 128/PC
INSTRUCTION MANUAL
(Part Number 5900389)
Cablescan
A Eubanks Company
3022 Inland Empire Blvd.
Ontario, California 91764
[phone] Fax [phone]
www.cablescan.com

Page iv Model 128/PC Instruction 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 ©1996 - 2005 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.

Model 128/PC Instruction Manual Page v
TABLE OF CONTENTS
Specifications.............................................................................................. viii
System Overview............................................................................................1
The Model 128/PC.....................................................................................................1
Major Features............................................................................................................1
Front Panel Controls and Display ..............................................................................2
Display Format...........................................................................................................3
Rear Panel Layout......................................................................................................3
Interface Fixture.........................................................................................................4
Signature Codes..........................................................................................................4
Program Storage.........................................................................................................5
User Labels.................................................................................................................6
Quick Start .....................................................................................................7
Tester Setup................................................................................................................7
Adapter Card Installation...........................................................................................7
Learn Cable Assembly...............................................................................................7
Test Cable Assembly..................................................................................................7
Program Storage.........................................................................................................8
Simplified Instructions..................................................................................9
Operating Instructions................................................................................14
Front Panel Modes ...................................................................................................14
Learn...............................................................................................................14
Search.............................................................................................................15
Error List........................................................................................................16
Test..................................................................................................................17
Reset................................................................................................................18
Menu-selected Modes and Functions.......................................................................19
Save Program .................................................................................................19
Load Program.................................................................................................20
Delete Program ..............................................................................................21
Clear Memory.................................................................................................22
Set Baud Rate..................................................................................................22
Print Wire List ................................................................................................23
Print User List ................................................................................................24
Loop Test ........................................................................................................25
Self Test...........................................................................................................26

Page vi Model 128/PC Instruction Manual
TABLE OF CONTENTS- CONTINUED
PC Keyboard Operating Instructions .......................................................27
Introduction..............................................................................................................27
Entering Commands.................................................................................................27
Test Commands........................................................................................................27
Print Commands.......................................................................................................28
Program Commands.................................................................................................28
System Setup ................................................................................................30
Unpacking ................................................................................................................30
Initial Setup..............................................................................................................30
Power Turn-On and Self Test...................................................................................30
Return of Faulty Unit ...............................................................................................31
Printer Setup.............................................................................................................31
PC Interface..............................................................................................................33
Changing Power Setting...........................................................................................34
Remote Output Signals ...............................................................................36
Adapter Cards..............................................................................................37
Selection...................................................................................................................37
Installation................................................................................................................37
Custom Adapter Cards.............................................................................................37
Setting Adapter Codes..............................................................................................39
Adapter Card List.....................................................................................................40
Care of the Model 128/PC...........................................................................43
Maintenance.............................................................................................................43
Repair.......................................................................................................................43
Memory Backup Battery..........................................................................................43
Replacement Parts....................................................................................................43

Model 128/PC Instruction Manual Page vii
LIST OF FIGURES
Figure Description Page
1 Front Panel Controls and Display............................................................................2
2 Rear Panel Layout....................................................................................................3
3 Interface Fixture.......................................................................................................4
4 Program Storage - Accommodations and Use.........................................................5
5 Simplified Self-programming (LEARN) Procedure................................................9
6 Simplified Test Procedure .....................................................................................10
7 Simplified Wire Identification (SEARCH) Procedure ..........................................11
8 Simplified Save Program Procedure......................................................................12
9 Simplified Load Program Procedure .....................................................................13
10 Sample Error List Printouts ...................................................................................16
11 Sample Wire List Printouts....................................................................................23
12 Sample User List Printout......................................................................................24
13 Power Switch and Jumper Locations.....................................................................35
14 Schematic - Model 128 CPU/Scanner Board ........................................................44

Page viii Model 128/PC Instruction Manual
SPECIFICATIONS
TEST POINT CAPACITY
128 points, 64 points per connector
OPERATING SPEED
Test: < 0.5 sec.; Self Test: < 2 sec.; Learn: < 0.5 sec.
TEST PARAMETERS
Short Threshold: < 100 Ohms
Open Threshold: > 1000 Ohms
Continuity Threshold: < 100 Ohms
Test Current: < 3 milliamps
Body Current: < 5 microamps
TEST VOLTAGE
10 VDC, max.
INTERWIRE CAPACITANCE
.01 microfarad, max.
DISPLAY
16-character Alphanumeric LCD
PROGRAM STORAGE
Battery-backed CMOS RAM containing a test program area and 112 stored program locations
without User Labels, or 28 program locations with User Labels.
BATTERY LIFE
5 years
POWER REQUIREMENTS (INTERNALLY SELECTABLE)
104 to 126 VRMS, 50/60 Hz or
208 to 252 VRMS, 50/60 Hz
TEMPERATURE
Operating: 32 to 105 °F (0 to 40 °C)
Storage: -40 to 165 °F (-40 to 74 °C)
DIMENSIONS
13.75 x 11.25 x 3.5 in. (34.4 x 28.6 x 8.9 cm)
WEIGHT
7.0 lbs. (3.2 kg)

Model 128/PC Instruction Manual Page 1
SYSTEM OVERVIEW
THE MODEL 128/PC
The Cablescan Model 128/PC is a microprocessor-based continuity tester with a built-in
interface fixture. It tests for both opens and shorts from one point to all other points in cables
and harnesses of up to 128 connections. Testing is programmed by the Learn method or by
programs downloaded from a PC. Up to 112 programs may be stored in memory for future use.
The built-in interface fixture enables testing of a wide variety of connector types and sizes, using
Cablescan's library of test adapter cards. Circuit types that can be tested include flat ribbon
cables, discrete wiring harnesses, and those having jumpers, daisy chains, open contacts, and
other interconnect devices.
An RS-232C interface accommodates either an optional printer, or a personal computer (PC).
MAJOR FEATURES
Major features and functions of the Model 128/PC are as follows:
• Self programming by "learning" a "known good" or sample harness from a batch.
• Programming by downloading from a PC.
• Automatic test of each cable or harness to be tested, and display of error locations.
• Built-in interface fixture for quick and inexpensive connection of test cable.
• Program save and load.
• Identification or location of wires through touch, using wrist strap or probe.
• Self test of the Model 128/PC.
• Alphanumeric test point labels (user labels).
• Memory for 112 wire list programs (without user labels) or 28 programs (with user
labels).
Optional features are:
• Printout of wire list learned during self programming.
• Printout of errors encountered during test.
• Control by PC with Cablescan TERM software.

Page 2 Model 128/PC Instruction Manual
FRONT PANEL CONTROLS AND DISPLAY
The Model 128/PC employs a 16-digit alphanumeric backlighted LCD (Liquid Crystal Display).
The display provides the user with test conditions, signature codes, adapter codes, and error
information.
All modes and functions of the Model 128/PC are controlled by keys on the front panel. Six
modes are selected by individual keys, and nine menu modes and functions are selected through
Up and Down keys and executed by the Menu Run key. See Figure 1, below.
LCD Display Front Panel Mode Keys
LEARN SEARCH ERROR
LIST TEST RESET
MENU
RUN
MODEL128
Menu-select Keys
LEARN - Initiates a scan on a known-good cable (harness assembly, ribbon cable,
etc.), and stores the resultant wire list data in the Test Memory. A 4-digit
signature code is calculated based on the wire list stored in memory and the
adapters cards installed, and it is displayed for program identification.
SEARCH - Initiates a continuous scan of the adapter card connectors and displays each
point that is touched with the wrist strap or probe. (See Figure 2 for
location of the probe input.)
ERROR LIST - Initiates a test on a connected cable assembly and produces a printout of
errors, or prints "Passed" if no errors.
TEST - Initiates a continuous test of the connected cable and displays errors, or
displays "Passed" if no errors.
RESET - Terminates current mode and places Model 128/PC in "wait" state until next
mode selection is made.
MENU RUN - Initiates the menu mode selected and currently displayed. Also used to
advance a menu mode and to respond “yes” to a menu prompt.
UP/DOWN
ARROWS
- Used for stepping up and down through menu to select one of nine available
functions or modes. (Refer to Menu-selected Modes and Functions in the
Operating Instructions section.) .
- Also steps through Program Memory to select wire list to load
Figure 1. Front Panel Controls and Display

Model 128/PC Instruction Manual Page 3
DISPLAY FORMAT
The Model 128/PC has 128 test points, which are divided between two adapter card locations;
side A and side B, with 64 test points on each side. When displaying from/to information during
test, an A or a B prefix is attached to the pin number to identify the connector. Therefore, an
open between pin 5 on A side and pin 10 on B side is displayed as:
O A-05 B-10.
The relationship between test point and adapter card connector/pin numbers is provided in the
table below:
Description Left Side Right Side
Adapter Connector Side A Side B
Adapter Pin # 1 to 64 1 to 64
Test Point # 1-64 65 to 128
Displayed Connector/Pin # A-01 to A-64 B-01 to B-64
NOTE
User labels (Test point labels) can be programmed to replace the
displays A-01 through B-64. This requires a PC for programming the
labels in a text editor and then downloading the labels to the tester
using an optional software program.
REAR PANEL LAYOUT
The rear panel contains a power switch; an AC receptacle for line power connection; a power
fuse; Probe connector for either a probe or wrist strap, an Enable receptacle; a serial port
connector for a printer or personal computer (PC).
A wrist-strap kit provides the capability to locate wires during troubleshooting through body
conductance, using either a probe provided in the kit, or touch by fingers.
An optional 80-column serial printer provides hard copies of error lists, wire lists, and user label
lists. Refer to Printer Setup instructions in the System Setup section.
Probe/Wrist Strap Learn/Save Enable
PROBE ENABLE
CAUTION!
For continued protection against
risk of fire, replace only with
same type and rating of fuse.
250mA/250V
F
U
S
E
F
U
S
E
F
U
S
E
Power Switch AC Receptacle Power Fuse PC/Printer Interface
Figure 2. Rear Panel Layout

Page 4 Model 128/PC Instruction Manual
INTERFACE FIXTURE
The interface fixture (Figure 3) has cam-operated ZIF connectors for easy exchange of adapter
cards, and rapid connection and disconnection of cable assemblies being tested. Information on
Cablescan adapter cards and configurations is provided in the Adapter Cards section. Cards are
replaced by simply lifting the ZIF levers and sliding the cards up
A SIDE B SIDE
Adjustable Adapters Adjustable
Hold-down Bar Cards Hold-down Bar
1
78910
1112
23456
1
78910
1112
23456
A-01/Pin #1 (Top) ZIF Levers B-01/Pin #65 (Top
Figure 3. Interface Fixture
SIGNATURE CODES
The Model 128/PC is designed for the use of signature codes in achieving harness identification,
tracebility, and configuration control, as follows:
• When the first harness (usually a "known good") of a specific part number is run through
the Learn mode, the Model 128/PC calculates and displays a four-digit signature code
unique to the cable wiring configuration and the adapters used.
• If a printer is connected, that signature code are included on the wire list printout.
• Whether in hard copy (printout) form, or recorded manually, the signature code is paired
up with the part number for that harness, and kept on file for identification of future
batches.
• Every time a batch of the same part number is to be tested, a random sample of that
batch is run through Learn for self programming, and the displayed signature code must
match the signature code on file.
• Since the Model 128/PC can also store multiple wire list programs in memory, the
signature is used in identifying the wire list program when loading from memory.
• Signature codes eliminate the need to assign names to wire lists for identification.

Model 128/PC Instruction Manual Page 5
PROGRAM STORAGE
The Model 128/PC has memory accommodations either for 112 wire list programs without user
labels or for 28 programs with User Labels, as well as a Test Memory location for the wire list
currently in use (see Figure 4).
A program may be loaded into the Test Memory from any one of the 112/28 Program Memory
locations, and the program in the Test Memory may be moved to a Program Memory location.
These modes and functions are accomplished through four of the Menu-selected modes. (Refer
to Menu-selected Modes and Functions.) Signature codes are used to identify wire lists in
Program Memory for loading and for identifying the wire list currently in Test Memory.
TEST MEMORY LOCATION
PROGRAM #1
PROGRAM #2



PROGRAM #112
• Create test program in Test Memory during
Learn procedure. (Program may also be
downloaded through the RS-232C
Printer/Serial port into Test Memory.)
• To store a newly created program for future
use, copy it to Program Memory using the
Save Program function (Menu-selected).
• All tests are run from Test Memory. To use a
program that is stored in Program Memory,
copy it into the Test Memory using the Load
Program function (Menu-selected).
• All programs remain in Program Memory.
Save Program and Load Program functions
only copy them to and from Test Memory.
Programs are eliminated only by using the
Delete Program function (Menu-selected).
The Clear Memory mode (Menu-selected) is
used to erase wire lists from the Test Memory
only.
NOTE
Each program with a user label occupies 4 Program Memory locations.
Figure 4. Program Storage - Accommodations and Use

Page 6 Model 128/PC Instruction Manual
USER LABELS
The Model 128/PC does not have a built-in user label or wire list editor. Programming of user
labels, as well as programming wire lists without learning a wire list, is performed with a PC and
Cablescan’s optional MS DOS-based software program, TERM. TERM provides keyboard
control over the Model 128/PC through the printer/serial port. The TERM program is basically a
terminal emulation program that allows keyboard entry and control over the tester. The program
also has features to allow wire lists and user labels to be transferred to and from the Model
128/PC.
Six-character user labels can be assigned to test points for each wire list program stored in the
Model 128/PC. Since testing on the Model 128/PC using adapter cards is typically limited to
two-ended cables, user labels are not generally necessary. User labels are more useful when the
Model 128/PC is interfaced to a harness board or external fixture. These applications usually
have more than two connectors and, therefore, locating specific connector/pin locations using the
standard display of the Model 128/PC is more difficult since the display refers to side A and side
B connectors. When user labels are assigned to test points, all displays and printouts will show
user labels in lieu of the A and B connector identification on the interface fixture. Once user
labels are assigned, connector/pin locations are displayed between the actual connector and pin
numbers on the wire harness. This eliminates the need to have a separate translation chart cross
referencing the test points to the actual harness connector/pin numbers.

Model 128/PC Instruction Manual Page 7
QUICK START
Ordinarily, the setup and operation of the Model 128/PC requires a thorough understanding of
this manual. This section, however, is provided for situations where immediate use is required.
When using this procedure, refer to the sections indicated within the procedure when more detail
is required for specific steps.
TESTER SETUP
Refer to the System Setup section for details.
1. Remove Model 128/PC from shipping container and set on suitable work station.
2. Connect line cord between rear panel and a properly grounded outlet. (See Figure 2.)
3. Turn power on by moving switch on rear panel to 1 (on). A Ready message will display
and a short tone will sound.
4. Press Down arrow to step through menu modes until Self Test is displayed.
5. Press MENU RUN to initiate Self Test. Passed Self Test will display.
ADAPTER CARD INSTALLATION
Refer to the Adapter Cards section for details.
1. Select cable assembly to be tested and match an adapter card to each end of the cable.
2. Open ZIF connector levers, slide adapter cards in from the top and all the way laterally
into their respective connectors. Each adapter card is designed to fit only the right or left
side.
3. Close ZIF connectors and install the cable to be tested between A and B adapter cards.
LEARN CABLE ASSEMBLY
Refer to Learn mode in the Operating Instructions section for details.
1. Press RESET, and then press LEARN.
2. A 4-digit signature will display after learn is complete. (See Signature Codes in System
Overview.)
TEST CABLE ASSEMBLY
1. Press RESET, and then TEST. The cable is good when Passed is displayed. Tests are
continuously run until the cable is removed.
2. Remove the cable from the adapter cards. (As soon as the cable is removed, an open
circuit will display.)
3. Test the remaining cables.

Page 8 Model 128/PC Instruction Manual
PROGRAM STORAGE
Refer to Save Program (menu-selected) in the Operating Instructions section for details.
1. The 4-digit signature code is used to identify wire list programs in memory. Record the
signature code for the cable assembly. (Refer to Signature Codes in System Overview
section.)
2. Insert the supplied microphone plug into Enable jack on rear panel.
3. Press RESET, and then arrow down to step through the menu until Save Program is
displayed.
4. Press MENU RUN to initiate Save Program. (Refer to Save Program in Operating
Instructions section.) After the program is saved, the display will show "Saved
XXXXXX," where XXXXXX is the signature code of the program.

Model 128/PC Instruction Manual Page 9
SIMPLIFIED INSTRUCTIONS
The Cablescan Model 128/PC Continuity Tester is simple and easy to use. As with any
microprocessor-based device, however, the user first should become familiar with its features
and functions, how to operate it, and how to care for it. After becoming properly acquainted
with the Model 128/PC, the user can refer to the abbreviated procedures illustrated in Figures 5
through 9. Detailed procedures are provided in the Operating Instructions section.
2 3, 6 2
1
7 8 9101112
23 4 56
1
7 8 9101112
23 4 56
LEARN SEARCH ERROR
LIST TEST RESET
MENU
RUN
MODEL128
4 5 1
1. Press RESET.
2. Install appropriate adapter cards for the cable to be tested.
3. Install sample, or known-good cable or harness assembly.
4. Press LEARN. Signature code will display after Learn is complete.
5. Select and Print Wire List from the menu, or record signature code manually.
6. Remove sample, or known-good cable or harness assembly.
Figure 5. Simplified Self-programming (LEARN) Procedure

Page 10 Model 128/PC Instruction Manual
2 3, 5 2
1
7 8 9101112
23 4 56
1
7 8 9101112
23 4 56
LEARN SEARCH ERROR
LIST TEST RESET
MENU
RUN
MODEL128
4 5b 4, 5a 1
1. Press RESET.
2. Install appropriate adapter cards for the cable to be tested.
3. Install cable or harness to be tested.
4. Press TEST; observe Passed on Display.
5. Remove tested cable or harness, and install the next cable to be tested.
If Failure Encountered (Open or Short):
5a) Repair fault, or press TEST again to view additional errors.
5b) To get a hardcopy of the errors, press RESET, and then ERROR LIST.
Figure 6. Simplified Test Procedure

Model 128/PC Instruction Manual Page 11
3
PROBE ENABLE
CAUTION!
For continued protection against
risk of fire, replace only with
same type and rating of fuse.
250mA/250V
F
U
S
E
F
U
S
E
F
U
S
E
2
1
7 8 9101112
23456
1
7 8 9101112
23456
LEARN SEARCH ERROR
LIST TEST RESET
MENU
RUN
MODEL128
4 1
1. Press RESET.
2. Install appropriate adapter cards for the cable to be tested
3. Connect wrist strap or probe to Probe receptacle.
4. Press SEARCH.
5. Touch wire end with fingers or probe. Pin numbers will be displayed. Repeat for each
wire or circuit point to be identified.
Figure 7. Simplified Wire Identification (SEARCH) Procedure

Page 12 Model 128/PC Instruction Manual
2
PROBE ENABLE
CAUTION!
For continued protection against
risk of fire, replace only with
same type and rating of fuse.
250mA/250V
F
U
S
E
F
U
S
E
F
U
S
E
1
7 8 9101112
23 4 56
1
7 8 9101112
23 4 56
LEARN SEARCH ERROR
LIST TEST RESET
MENU
RUN
MODEL128
4, 7 3, 6 1, 5
1. Press RESET.
2. Engage Enable plug on rear panel.
3. Select and initiate Save Program.
4. The display will read Are You Sure?
5. If it is decided not to save the program, press RESET.
6. To save the program, press MENU RUN. The program will be copied from the Test
Memory into a Program Memory location.
7. After the program is saved, the display will show SAVED XXXXXX, where XXXXXX
is the signature code of the program.
Figure 8. Simplified Save Program Procedure