Cablescan 256/PC User manual

MODEL 256/PC
CONTINUITY TESTER

Model 256/PC Instruction Manual Page iii
February 25, 2005
MODEL 256/PC
INSTRUCTION MANUAL
(Part Number 5900379)
Cablescan
A Eubanks Company
3022 Inland Empire Blvd.
Ontario, California 91764
[phone] Fax [phone]
www.cablescan.com

Page iv Model 256/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 256/PC Instruction Manual Page v
TABLE OF CONTENTS
COPYRIGHT NOTICE....................ERROR! BOOKMARK NOT DEFINED.
WARRANTY...................................ERROR! BOOKMARK NOT DEFINED.
CUSTOMER POLICY.....................ERROR! BOOKMARK NOT DEFINED.
SPECIFICATIONS .................................................................................VIII
THE MODEL 256/PC CONTINUITY TESTER............................................1
Major Functions ...........................................................................................1
Tester Features ...........................................................................................2
Signature Codes..........................................................................................2
User Labels..................................................................................................2
PC Interface and Control............................................................................. 3
Program Storage ......................................................................................... 3
USING THE MODEL 256/PC.....................................................................6
PREPARATION .......................................................................................15
Unpacking..................................................................................................15
Initial Hookup.............................................................................................15
Program Cartridge Installation...................................................................15
Power Turn-on and Self Test.....................................................................16
Printer Hookup...........................................................................................17
PC Interface...............................................................................................19
Changing Power Setting............................................................................20
CONTROLS AND DISPLAY....................................................................21
Controls .....................................................................................................21
Key-selected Functions .............................................................................21
Menu-selected Functions...........................................................................24
Display.......................................................................................................26
OPERATING INSTRUCTIONS ................................................................27
Introduction................................................................................................27
Learn Known Good....................................................................................27
Wire List Printing........................................................................................28
Test............................................................................................................29

Page vi Model 256/PC Instruction Manual
TABLE OF CONTENTS - continued
Error List.................................................................................................... 30
Loop Test...................................................................................................31
Saving a Program......................................................................................32
Loading a Program.................................................................................... 33
Deleting a Program....................................................................................34
Sequential Build (Seq Build)......................................................................35
Random Build............................................................................................36
Wire Identification (Search) .......................................................................37
Clearing Working Memory (Clear Memory) ...............................................37
Setting Baud Rate......................................................................................38
Print User List............................................................................................39
OPERATING INSTRUCTIONS - KEYBOARD.........................................40
Introduction................................................................................................40
Entering Commands..................................................................................40
Test Commands ........................................................................................ 41
Build Commands ....................................................................................... 42
Print Commands........................................................................................43
Program Commands..................................................................................44
MODEL 256/PC VERSUS MODEL 256...................................................46
MODEL 256/PC HARDWARE CHANGES...............................................48
Remote Output Signals..............................................................................48
Scanner Board Jumpers............................................................................49
CARE OF THE MODEL 256/PC ..............................................................50
Cleaning.....................................................................................................50
Repair........................................................................................................50
Memory Backup Battery ............................................................................50
Replacement Parts....................................................................................50
PARTS LIST.............................................................................................51
CPU Board Assembly - 5211066...............................................................51
Scanner Board Assembly - 5210869.........................................................52

Model 256/PC Instruction Manual Page vii
LIST OF FIGURES
Figure Description Page
1 Model 256/PC Continuity Tester.................................................................1
2 Model 256/PC layout...................................................................................4
3 Program Storage - Accommodations and Use.............................................5
4 Simplified LEARN KNOWN GOOD Procedure .......................................6
5 Simplified TEST Procedure (Single Test)..................................................7
6 Simplified LOOP TEST Procedure (Continuous Test) ...............................8
7 Simplified SAVE PROGRAM Procedure...................................................9
8 Simplified LOAD PROGRAM Procedure.................................................10
9 Simplified DELETE PROGRAM Procedure.............................................11
10 Simplified ERROR LIST Procedure..........................................................12
11 Simplified SEQUENTIAL BUILD Procedure ..........................................13
12 Simplified RANDOM BUILD Procedure .................................................14
13 Program Cartridge Label Format...............................................................16
14 CPU Board Voltage Select Switch and Jumper Locations........................20
15 Front Panel Keyboard and Display............................................................22
16 Sample Wire List Printouts........................................................................28
17 Sample Error List Printout.........................................................................30
18 Sample User List Printout..........................................................................39
19 Scanner Board Jumpers..............................................................................49
20 Schematic - CPU board..............................................................................53
21 Schematic - Scanner Board........................................................................56

Page viii Model 256/PC Instruction Manual
SPECIFICATIONS
TEST POINT CAPACITY
256 points; 64 points per connector
OPERATING SPEED
Test: : < 1 sec.; Self Test: < 5 sec.; Learn: < 1 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
INTERWIRE CAPACITANCE
.01 microfarads, max.
DISPLAY
16 Character Alphanumeric LCD
PROGRAM STORAGE
Internal Memory: Battery-backed CMOS RAM containing working memory area and 8
program locations without User Labels or 2 program locations with
User Labels.
Removable Memory: EEPROM cartridge containing 16 program locations without User
Labels or 4 program locations with User Labels.
BATTERY LIFE
5 years
POWER REQUIREMENTS
104 to 126 VRMS, 50/60 Hz or
208 to 252 VRMS, 50/60 Hz (internally selectable)
TEMPERATURE
Operating: 32 to 105 °F (0 to 40 °C)
Storage: -40 to 165 °F (-40 to 74 °C)
DIMENSIONS
11.5 in. x 7.4 in. x 5.0 in.
(29.2 cm x 18.8 cm x 12.7 cm)
WEIGHT
7 pounds (3.2 kg)

Model 256/PC Instruction Manual Page 1
THE MODEL 256/PC CONTINUITY TESTER
The Cablescan Model 256/PC (Figure 1) is a microprocessor-based continuity tester with
assembly-aid capabilities. It is self-programming and can retain up to twenty-four programs at a
time in memory. The Model 256/PC tests for both opens and shorts from one point to all other
points in cables and harnesses of up to 256 connections. Circuit types that can be tested include
flat ribbon cables, discrete wiring harnesses, and those having jumpers, daisy chains, and other
interconnect devices.
MAJOR FUNCTIONS
Major functions of the Model 256/PC are as follows:
• Self Programming for circuit testing by "learning" a known good circuit.
• Programming by downloading from a PC.
• Automatic Test of each circuit (cable, harness, etc.) to be tested.
• Printout of Error List.
• Printout of Wire List.
• Assembly assistance by displaying build information.
• Program save and load.
• Identification or location of wires through touch, using wrist strap or probe.
• Self Test of the Model 256/PC.
• Program compatible with Cablescan Models 512 and 4000.
• Alphanumeric test point labels (User Labels).
• Control by PC with Cablescan TERM software.
Figure 1. Model 256/PC Continuity Tester.

Page 2 Model 256/PC Instruction Manual
TESTER FEATURES
Functions of the Model 256/PC are selected through function keys on the front panel (Figure 2).
The function keys are flush-mounted membrane switches that are activated by a gentle but
positive touch. Five functions are represented by their own keys, and fourteen others are
selected through a menu. The LCD display provides the user with test conditions, signature
codes, test point numbers or user labels, build sequences, and error information.
A rear panel (Figure 2) contains a Program Cartridge receptacle, power switch, fuse, enable
receptacle, connectors for footswitch and probe, a printer/PC interface port, and four 64-pin
connectors for interfacing to assemblies under test.
A wrist-strap kit provides the capability to locate wires during assembly and troubleshooting
through body conductance, using either a probe provided in the kit, or touch by fingers.
A foot switch is provided for advancing in assembly modes and restarting the test in TEST
mode.
An optional 80-column serial printer provides hard copies of Error Lists, Wire Lists, and User
Label Lists.
SIGNATURE CODES
Signature codes are used for program/harness traceability. They are produced as follows:
The first harness (usually a "known good") of a specific part number is run through the LEARN
KNOWN GOOD mode on the Model 256/PC, which calculates and then displays a six-digit
signature code unique to that wiring configuration. The signature is then used in identifying the
wire list program when selecting it for loading from memory. The signature code eliminates the
requirement of assigning program names to programs for identification.
If a printer is connected, the signature code is included on the wire list and error list printouts.
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 to verify and identify programs.
USER LABELS
Six-character User Labels can be assigned to test points for each wire list program stored in the
Model 256/PC. Each User Label relates a harness connector/pin to a test point on the rear of the
tester. When User Labels are assigned to point numbers, all displays and printouts will show
User Labels in lieu of the point numbers. Therefore, when an open or short is displayed between
two points, the display will show the error for the exact connector and pin numbers on the
harness. This eliminates the need to have a separate translation chart cross referencing the test
points to the actual harness connector/pin numbers. The Model 256/PC does not have a built-in
wire list/user list editor. An optional PC DOS software program is available which provides
external control and data transfer between the tester and a PC.

Model 256/PC Instruction Manual Page 3
PC INTERFACE AND CONTROL
The Model 256/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 cable, is performed with a PC and
Cablescan’s option PC DOS software program, TERM. TERM provide keyboard control over
the Model 256/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 256/PC.
PROGRAM STORAGE
The Model 256/PC has memory accommodations for either twenty-four programs without User
Labels or six with User Labels, as well as a working memory for the program currently in use
(see Figure 3). The internal memory is a RAM (random-access memory), which holds eight
programs (or two with user labels) and also provides the working memory. An EEPROM
(electrically erasable, programmable, read-only memory) Program Cartridge holds sixteen
programs (or four with user labels). The Program Cartridge receptacle is located either on the
rear panel or the right side of the tester.
A program may be loaded into the working memory from any of the twenty-four/six-program
locations. Conversely, a program currently in the working memory may be saved in any of the
twenty-four/six-program locations. The SAVE INTERNAL and SAVE CARTRIDGE functions
are used for copying a program from the working memory to a storage location, and the LOAD
INTERNAL and LOAD CARTRIDGE functions are used for copying a program from a storage
location to the working memory. Additional cartridges may be used to store programs for future
use. Signature codes are used to identify programs for loading and for program/harness
traceability.

Page 4 Model 256/PC Instruction Manual
250mA/250V
CAUTION!
For continued protection against
risk of fire, replace only with
same type and rating of fuse.
FOOTSWITCH
PROBE ENABLE
PRINTER/SERIAL
J2
J4
127
128
255
256
65
66 64
63
193
194
191
192
1
2
129
130
J1
J3
Rear Panel Layout
SEQ.
BUILD RANDOM
BUILD ERROR
LIST TEST RESET
MENU
RUN MODEL 256
Front Panel Layout
Figure 2. Model 256/PC Layout

Model 256/PC Instruction Manual Page 5
INTERNAL MEMORY
(RAM)
WORKING MEMORY
PROGRAM #1
PROGRAM #2



PROGRAM #8
PROGRAM CARTRIDGE
EEPROM)
PROGRAM #1
PROGRAM #2
PROGRAM #3
PROGRAM #4



PROGRAM #16
• Create Test or Assembly program in Working Memory during "Learn" procedure.
(Program may also be downloaded through the RS-232C serial port into Working
Memory.)
• To store a newly created program for future use, copy it into one of the twenty-four
program locations using either SAVE INTERNAL or SAVE CARTRIDGE mode.
• All test and assembly procedures are conducted from the Working Memory. To use a
program that is stored in one of the twenty-four program locations, copy it into the
Working Memory using either LOAD INTERNAL or LOAD CARTRIDGE mode.
• All programs remain where recorded. SAVE and LOAD functions only copy them.
They are eliminated only by using the DELETE INTERNAL or DELETE CARTRIDGE
mode. The CLEAR MEMORY mode is used to erase the contents from the Working
Memory.
NOTE
Programs with user labels occupy 4 memory locations.
Figure 3. Program Storage - Accommodations and Use

Page 6 Model 256/PC Instruction Manual
USING THE MODEL 256/PC
The Cablescan Model 256/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 256/PC, the user can refer to the abbreviated procedures illustrated in Figures 4
through 12. Detailed procedures are provided in the Operations section.
250mA/250V
CAUTION!
For continued protection against
risk of fire, replace only with
same type and rating of fuse.
FOOTSWITCH
PROBE ENABLE
PRINTER/SERIAL
J2
J4
127
128
255
256
65
66 64
63
193
194
191
192
1
2
129
130
J1
J3
1 2, 6
SEQ.
BUILD RANDOM
BUILD ERROR
LIST TEST RESET
MENU
RUN MODEL 256
3, 4, 5
1. Engage ENABLE plug.
2. Connect known-good harness to connectors on rear panel.
3. Select and initiate LEARN KNOWN GOOD.
4. If printer is connected, select and initiate PRINT WIRE LIST.
5. If learned program is to be saved, select and initiate SAVE PROGRAM (Figure 7).
6. Disconnect harness.
Figure 4. Simplified LEARN KNOWN GOOD Procedure

Model 256/PC Instruction Manual Page 7
250mA/250V
CAUTION!
For continued protection against
risk of fire, replace only with
same type and rating of fuse.
FOOTSWITCH
PROBE ENABLE
PRINTER/SERIAL
J2
J4
127
128
255
256
65
66 64
63
193
194
191
192
1
2
129
130
J1
J3
4
2, 6
SEQ.
BUILD RANDOM
BUILD ERROR
LIST TEST RESET
MENU
RUN MODEL 256
1 3, 5
1. Load program (Figure 8).
2. Connect harness to be tested.
3. Press TEST, and the Model 256/PC will perform one test scan.
4. For a successful test, the display will show: Passed XXXX/YYYY
Where XXXX is the number of tests that have passed and YYYY is the number of tests
that have been run. Loading the program sets these numbers to zero. If an error is found,
display will show O for open or S for short, with From/To points.
5. To continue test beyond failed points, press TEST again.
6. When testing is finished, disconnect harness.
NOTE
If a hard copy of test errors is required, use ERROR LIST (Figure 10).
Figure 5. Simplified TEST Procedure (Single Test)

Page 8 Model 256/PC Instruction Manual
250mA/250V
CAUTION!
For continued protection against
risk of fire, replace only with
same type and rating of fuse.
FOOTSWITCH
PROBE ENABLE
PRINTER/SERIAL
J2
J4
127
128
255
256
65
66 64
63
193
194
191
192
1
2
129
130
J1
J3
4
2, 7
SEQ.
BUILD RANDOM
BUILD ERROR
LIST TEST RESET
MENU
RUN MODEL 256
1, 3, 5
1. Load program (Figure 8).
2. Connect harness to be tested.
3. Select and initiate LOOP TEST.
4. For each successful test, a loop count on the display will increment by one. If an error is
found, testing will stop and the display will show O for open or S for short with the
From/To points.
5. To continue through the current test and display additional errors, press MENU RUN.
6. To restart the Loop Test, press RESET and then MENU RUN.
7. When testing is completed, remove harness.
Figure 6. Simplified LOOP TEST Procedure (Continuous Test)

Model 256/PC Instruction Manual Page 9
250mA/250V
CAUTION!
For continued protection against
risk of fire, replace only with
same type and rating of fuse.
FOOTSWITCH
PROBE ENABLE
PRINTER/SERIAL
J2
J4
127
128
255
256
65
66 64
63
193
194
191
192
1
2
129
130
J1
J3
3, 6
1
SEQ.
BUILD RANDOM
BUILD ERROR
LIST TEST RESET
MENU
RUN MODEL 256
2, 5 4
1. Engage ENABLE plug on rear panel.
2. Select and initiate either SAVE INTERNAL or SAVE CARTRIDGE.
3. The display will read "Are You Sure?"
4. If it is decided not to save the program, press RESET.
5. To save the program, press MENU RUN. The program will be copied from the Working
Memory into a memory location.
6. After the program is saved, the display will show "SAVED XXXXXX," where
XXXXXX is the signature code of the program.
Figure 7. Simplified SAVE PROGRAM Procedure

Page 10 Model 256/PC Instruction Manual
250mA/250V
CAUTION!
For continued protection against
risk of fire, replace only with
same type and rating of fuse.
FOOTSWITCH
PROBE ENABLE
PRINTER/SERIAL
J2
J4
127
128
255
256
65
66 64
63
193
194
191
192
1
2
129
130
J1
J3
2, 6
SEQ.
BUILD RANDOM
BUILD ERROR
LIST TEST RESET
MENU
RUN MODEL 256
1, 3, 5 4
1. Select and initiate either LOAD INTERNAL or LOAD CARTRIDGE.
2. The display will show a signature code of a program stored in memory.
3. Use Up/Down arrows to step to the signature code for the desired program.
4. If it is decided not to load the program, press RESET.
5. Press MENU RUN to load the program into the Working Memory.
6. Verify signature code on display against the code for that location that has been written
on the cartridge label, or against the code otherwise recorded for the internal memory.
Figure 8. Simplified LOAD PROGRAM Procedure

Model 256/PC Instruction Manual Page 11
250mA/250V
CAUTION!
For continued protection against
risk of fire, replace only with
same type and rating of fuse.
FOOTSWITCH
PROBE ENABLE
PRINTER/SERIAL
J2
J4
127
128
255
256
65
66 64
63
193
194
191
192
1
2
129
130
J1
J3
3, 8
1
SEQ.
BUILD RANDOM
BUILD ERROR
LIST TEST RESET
MENU
RUN MODEL 256
2, 4, 5, 7 6
1. Engage ENABLE plug on rear panel.
2. Select and initiate either DELETE INTERNAL or DELETE CARTRIDGE.
3. The display will show a signature code of a program stored in memory.
4. Use Up/Down arrows to step to the signature code for the program to be deleted.
5. Press MENU RUN to delete the program, the display will display "Are You Sure?"
6. If it is decided not to delete the program, press RESET.
7. To delete the program, press MENU RUN.
8. After the program is deleted, the display will show "DELETED XXXXXX," where
XXXXXX is the signature code of the program.
Figure 9. Simplified DELETE PROGRAM Procedure

Page 12 Model 256/PC Instruction Manual
250mA/250V
CAUTION!
For continued protection against
risk of fire, replace only with
same type and rating of fuse.
FOOTSWITCH
PROBE ENABLE
PRINTER/SERIAL
J2
J4
127
128
255
256
65
66 64
63
193
194
191
192
1
2
129
130
J1
J3
45
2, 6 3
SEQ.
BUILD RANDOM
BUILD ERROR
LIST TEST RESET
MENU
RUN MODEL 256
1
1. Load program (Figure 8).
2. Connect harness to be tested.
3. Connect printer per setup instructions in "Preparation" section.
4. Press ERROR LIST.
5. The Model 256/PC will perform a test of the harness, and all errors will be printed, or
"Passed XXXX/YYYY" will be printed for a successful test. (Where XXXX is the
number of tests that have passed and YYYY is the number of tests that have been run.)
6. When testing is finished, disconnect harness.
Figure 10. Simplified ERROR LIST Procedure