Cablescan 64 User manual

CONTINUITY TESTER
ASSEMBLY AID
MODEL 64 & MODEL 64x2
Cablescan

August 29, 2005
MODEL 64 & Model 64x2
INSTRUCTION MANUAL
(Part Number 5900384)
Cablescan
A Eubanks Company
3022 Inland Empire Blvd.
Ontario, California 91764
[phone] Fax [phone]
www.cablescan.com

Page iv Model 64/64x2 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 ©1994 - 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 64/64x2 Instruction Manual Page v
TABLE OF CONTENTS
SPECIFICATIONS .............................................................................................VIII
THE MODEL 64 CONTINUITY TESTER..............................................................1
Major Functions........................................................................................................1
Tester Features ........................................................................................................2
Signature Codes.......................................................................................................2
User Labels...............................................................................................................4
Program Storage ......................................................................................................4
PREPARATION.....................................................................................................6
Unpacking.................................................................................................................6
Initial Hookup............................................................................................................6
Program Cartridge Installation..................................................................................6
Power Turn-on and Self Test....................................................................................8
Printer Hookup..........................................................................................................9
PC Interface............................................................................................................10
CONTROLS AND DISPLAYS.............................................................................11
Controls ..................................................................................................................11
Key-selected Functions..........................................................................................11
Menu-selected Functions .......................................................................................14
Display....................................................................................................................17
OPERATING INSTRUCTIONS - CONTROL PANEL..........................................18
Learn Known Good.................................................................................................18
Wire List Printing.....................................................................................................19
Test.........................................................................................................................20
Error List.................................................................................................................21
Loop Test................................................................................................................22
Saving a Program...................................................................................................23
Loading a Program.................................................................................................24
Deleting a Program.................................................................................................25
Sequential Build (SEQ Build)..................................................................................26
Random Build (Random Build................................................................................27
Wire Identification (Search)....................................................................................28
Clearing Working Memory (Clear Memory)............................................................28
Setting Baud Rate...................................................................................................29
Printing User List ....................................................................................................30

Page vi Model 64/64x2 Instruction Manual
TABLE OF CONTENTS - Continued
OPERATING INSTRUCTIONS - KEYBOARD....................................................31
Introduction.............................................................................................................31
Entering Commands...............................................................................................31
Test Commands .....................................................................................................32
Build Commands ....................................................................................................33
Print Commands.....................................................................................................34
Program Commands ..............................................................................................35
MODEL 64 OUTPUT SIGNALS..........................................................................38
CARE OF THE MODEL 64 .................................................................................39
Cleaning..................................................................................................................39
Repair.....................................................................................................................39
Memory Backup Battery.........................................................................................39
Replacement Parts.................................................................................................39
PARTS LIST........................................................................................................40

Model 64/64x2 Instruction Manual Page vii
LIST OF FIGURES
Figure Description Page
1Model 64 layout...........................................................................................3
2Program Storage Locations..........................................................................5
3Program Cartridge Label Format.................................................................7
4Top Panel Keys and Display......................................................................12
5Program Storage - Accommodations and Use...........................................15
6Sample Wire List Printouts........................................................................19
7Sample Error List Printout.........................................................................21
8Sample User List Printout..........................................................................30
9Schematic - Model 64 CPU Board.............................................................42

Page viii Model 64/64x2 Instruction Manual
SPECIFICATIONS
TEST POINT CAPACITY
Model 64: 64 points, one 64-pin header
Model 64x2: 128 points, two 64-pin header
OPERATING SPEED
Test: < 0.5 sec.; Self Test: < 2 sec.; Learn: < 0.5 sec.
TEST PARAMETERS
Short Threshold: < 100 Ω
Open Threshold: > 1,000 Ω
Continuity Threshold: < 100 Ω
Test Current: < 3 ma
Body Current: < 5 ma
TEST VOLTAGE
10 vdc, max.
INTERWIRE CAPACITANCE
.01 μf, max.
DISPLAY
16-character alphanumeric LCD
6-character test point labels
PROGRAM STORAGE
Internal Memory: Battery-backed CMOS RAM containing working memory area and 8
program locations without test point labels, or 2 program locations with test point labels.
Removable Memory: EEPROM cartridge containing 16 program locations without test point
labels, or 4 program locations with test point labels.
BATTERY LIFE
5 years
POWER REQUIREMENTS
104 to 126 V~, 50/60 Hz or
208 to 252 V~, 50/60 Hz (Power Pack change)
TEMPERATURE
Operating: 32 to 105 °F (0 to 40 °C)
Storage: -40 to 165 °F (-40 to 74 °C)
DIMENSIONS
11 in. x 3.2 in. x 1.75 in. (27.9 cm x 8.1 cm x 4.4 cm)
WEIGHT
2.5 pounds (1.1 kg)

Model 64/64x2 Instruction Manual Page 1
THE MODEL 64 CONTINUITY TESTER
The Cablescan Model 64 and Model 64x2 are microprocessor-based continuity testers with
assembly-aid capabilities. It is self-programming and can retain up to twenty-four programs at a
time in memory. The Model 64 tests for both opens and shorts from each point to all other
points in cables and harnesses of up to 64 connections (128 connections for the Model 64x2).
Circuit types that can be tested include flat ribbon cables and discrete wiring harnesses,
including those having jumpers, daisy chains, and other interconnect devices. As an assembly
aid, it will identify wires touched, indicate termination points, and verify terminations.
A serial interface is provided for connection to a PC for remote control, or to a printer for
printout of test information.
MAJOR FUNCTIONS
Major functions of the Model 64 and Model 64x2 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, Wire List, and Test Point Labels through optional printer.
•Assembly assistance by displaying build information.
•Program save and load.
•Identification of wires or connector pins through touch, using wrist strap or probe.
•Self-test of the Model 64 and Model 64x2.
•Program compatible with Cablescan Models 256/PC, 512, and 4000.
•Assignment of alphanumeric test point labels (User Labels).
•Control by PC with Cablescan TERM or TestRite software.

Page 2 Model 64/64x2 Instruction Manual
TESTER FEATURES
The top panel of the Model 64 and Model 64x2 provides a set of function keys (Figure 1). They
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 labels or user
labels, build sequences, and error information. A Program Cartridge slot accommodates an
EEPROM.
A rear panel (Figure 1) contains a 9VDC power jack, power ON/OFF switch, FUSE, ENABLE
receptacle, connectors for FOOTSWITCH and PROBE, a PRINTER/SERIAL interface port (for
printer or PC), and 64-pin connector(s) for interfacing with assemblies under test.
A wrist-strap kit provides the capability to locate wires by probe or touch, using body
conductance, during assembly and troubleshooting. Either the probe or wrist strap (for touch) is
connected to the PROBE jack. .
An optional foot switch is available for advancing in assembly modes and restarting the test in
TEST mode, when connected to the FOOTSWITCH jack.
An optional 80-column serial printer provides hard copies of Error Lists, Wire Lists, and User
Label Lists, when connect to the PRINTER/SERIAL interface.
An external PC (not supplied by Cablescan) may be connected to the PRINTER/SERIAL
interface for remote control using TERM or TestRite software provided by Cablescan.
The Model 64 and Model 64x2 operates on 9VDC provided by a separate power pack that
connects to the 9VDC power jack on the rear panel.
SIGNATURE CODES
Signature codes are used for program/harness traceability. They are produced as follows:
When the first harness (usually a "known good") of a specific part number is run through the
LEARN KNOWN GOOD function, the Model 64 and Model 64x2 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 loading from memory. The signature code eliminates the
requirement of assigning names to wire list programs for identification.
When the 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.

Model 64/64x2 Instruction Manual Page 3
MODEL 64
TEST RESET
Removeable
Cartridge
SEQ
BUILD RANDOM BUILD ERROR LIST
MENU
RUN
Cablescan
Model 64 & Model 64x2 Top Panel
63
64
1
2J1
PRINTER/SERIAL
FOOTSWITCH
9VDC
PROBE
ENABLE
10
Model 64 Rear Panel
PRINTER/SERIAL
63
64 1
2
J1
FOOTSWITCH
9VDC
PROBE ENABLE
128
127 65
66
J2
10
Model 64x2 Rear Panel
Figure 1. Model 64 layout

Page 4 Model 64/64x2 Instruction Manual
USER LABELS
Six-character User Labels can be assigned to test points for each wire list program stored in the
Model 64. Each User Label relates a harness connector/pin to a Model 64 test point on the tester
interface connector. When User Labels are assigned to point numbers, all displays and printouts
will show User Labels in lieu of the tester 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 tester’s test points to the actual harness connector/pin numbers.
User Labels, along with the test program, are loaded into the tester using the download feature
and a PC running Cablescan's optional TERM software. TERM is a PC DOS program that can
translate ASCII files containing wire list programs and User Labels and then download those
files to the tester. The ASCII files are generally created with a text editor such as Brief or a
word processor such as Word or Word Perfect. (When word processors are used, the files must
be saved with the Text-only or ASCII option.) Instructions for Wire list and User Label off-line
programming are provided in Cablescan’s TERM software manual.
PROGRAM STORAGE
The Model 64 has memory accommodations for 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
2). This total memory capacity is provided by an internal memory supplemented by removable
program cartridges. The internal memory is a RAM (random-access memory), which holds eight
programs (or two with user labels) and also provides the working memory. The Program
Cartridge is an EEPROM (electrically erasable, programmable, read-only memory), which holds
sixteen programs (or four with user labels). The Program Cartridge receptacle is located in the
front 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.
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.

Model 64/64x2 Instruction Manual Page 5
INTERNAL MEMORY PROGRAM CARTRIDGE
(RAM) (EEPROM)
WORKING MEMORY
MEMORY LOCATION #1
MEMORY LOCATION #2
MEMORY LOCATION #1 MEMORY LOCATION #3
MEMORY LOCATION #2 MEMORY LOCATION #4



MEMORY LOCATION #8 MEMORY LOCATION #16
Figure 2. Program Storage Locations Program Storage Locations

Page 6 Model 64/64x2 Instruction Manual
PREPARATION
UNPACKING
Upon unpacking the Model 64 from its shipping carton, inspect it for evidence of abuse during
shipment. If such is found, notify Cablescan and the carrier at once. Save the shipping carton
and packing materials for later use.
INITIAL HOOKUP
When shipped from the factory, the Model 64 is supplied with a external power pack for
operating at a specific voltage. The operating voltages and corresponding power pack labels are
as follows:
Operating Power Pack Label
Voltage Input Output
100 VAC 120 VAC 12.0 VDC
115 VAC 120 VAC 9.0 VDC
220 VAC 220 VAC 9.0 VDC
The power connection on the rear panel (Figure 1) is labeled 9VDC. Connect and apply power
as follows:
1. Verify the power pack is labeled correctly for the intended operating voltage. See
table above.
2. Plug the power pack into the AC power source.
3. Make sure that the power ON/OFF switch on the rear panel is OFF, and then
connect the output plug from the power pack into the connector labeled 9VDC.
4. Turn power ON/OFF switch to ON, and observe that a message is displayed. The
Model 64 is ready for use. (If nothing happens, check power source, power plug
connection, and the fuse on the rear panel.)
PROGRAM CARTRIDGE INSTALLATION
Each Program Cartridge (EEPROM)can store up to sixteen programs. A label on the outside
surface of the cartridge (Figure 3) contains blanks for entering program names and signature
codes according to their storage locations. This label is erasable so it can be updated each time a
change is made in cartridge contents.
CAUTION
Be sure to turn off the power before installing or
removing a Program Cartridge.

Model 64/64x2 Instruction Manual Page 7
To install a Program Cartridge, proceed as follows:
1. Turn power off (power ON/OFF switch on rear panel).
2. Verify cartridge contents on label: locations may be empty, or contain program(s)
that may to be deleted or used (figure 3, below).
3. Slide cartridge into the front slot and press it firmly against the internal connector.
4. Turn power on.
5. Scroll through the menu (using Up and Down arrows) until LOAD CARTRIDGE
is displayed, and then press MENU RUN.
6. Scroll through the signature codes of the programs one at a time. Check the
signature code of each location against the code recorded on the corresponding
locations of the cartridge label. If no programs are present, "MEMORY IS
EMPTY" will be displayed.
Cablescan
PROGRAM CODE
1
2
3
4
5
6
USE ERASABLE MARKER
7
8
FOR RECORDING PROGRAM
TOP
NUMBERS. BE SURE TO
POWER OFF BEFORE
REMOVING UPDATE OR VERIFY LABEL
PROGRAM CODE AT EACH LOAD OR SAVE.
9
10
11
12
13
14
15
16
Figure 3. Program Cartridge Label Format

Page 8 Model 64/64x2 Instruction Manual
POWER TURN-ON AND SELF TEST
Verify that power cord is connected as described under Initial Hookup, then proceed as follows:
1. Turn power on at the unit by moving the power ON/OFF switch on the rear panel
to ON; a “Ready” message will display and the tone will sound. Turn contrast
knob on rear panel to optimize viewing angle.
2. For self test of the Model 64, verify that no circuits are connected to the interface
connector on the rear panel, and then press the Up or Down arrow to step through
the menu to reach SELF TEST.
3. Press MENU RUN to initiate Self Test. (During self test, the software version
number of the tester will display.) If the unit passes self test, the display will show
“Self Test Passed” and the tone will sound; if it fails, the display will show one of
the following:
OPEN, plus the internal connector pin number.
SHORT, plus the internal connector pin numbers.
ERROR, plus an error message.
4. The self test will stop if a fault or error is encountered. To resume the test, press
MENU RUN again.

Model 64/64x2 Instruction Manual Page 9
PRINTER HOOKUP
An RS 232C (PRINTER/SERIAL) port provided on the rear panel (Figure 1) accommodates an
80-column serial printer.
1. Prepare printer for use and connect it to its proper power source, in accordance
with the printer manufacturer's manual.
2. Connect printer interface cable to the PRINTER/SERIAL port on the rear panel of
Model 64.
3. On the printer, turn printer switch ON, and press SELECT switch.
4. Set Model 64 power ON/OFF switch to ON.
5. Press the Up or Down arrow to step through the menu to reach SET BAUD RATE.
6. Press MENU RUN to initiate setting the baud rate.
7. If the display reads "Baud Rate 1200," press RESET to continue.
8. If the display shows: "Baud Rate 9600," press the Down arrow to change to 1200,
and then press MENU RUN.
If the printer was not provided by Cablescan, the following setup data are
required:
Transmission to the printer is at 1200 Baud, with 8 data bits, 1 stop bit, and no parity. Pin
assignments are as follows:
PIN ASSIGNMENT
3 Data Out
7 Signal Ground
* 11 Clear to Send
∗LOW level on pin 11 from the printer indicates printer is ready
to receive data. HIGH level signals tester to stop sending data.

Page 10 Model 64/64x2 Instruction Manual
PC INTERFACE
The RS 232C PRINTER/SERIAL port on the rear panel can be used to connect a Personal
Computer (PC) when not connected to a printer. Cablescan provides an optional PC software
program (TERM), which can be used to control and transfer programs between the Model 64 and
PC. The software can also be used to transfer programs between the Model 64 and other
Cablescan testers.
1. Install the TERM software program in your PC in accordance with the software
instruction manual.
2. Connect an interface cable between the serial port (male D-type connector) on the
PC and the 25-pin female D-type connector labeled SERIAL/PRINTER, on the
rear panel of the Model 64.
3. Set Model 64 power switch to ON.
4. Press the Up or Down arrow to step through the menu to reach SET BAUD RATE.
5. Press MENU RUN to initiate setting the baud rate.
6. If the display reads "Baud Rate 9600," press RESET.
7. If the display shows: "Baud Rate 1200," press the Down arrow to change to 9600
and then press MENU RUN.
8. Execute TERM from the DOS prompt on the PC. A greater-than prompt (>)
should appear on the PC screen.
NOTE
If the prompt does not appear, press ESC. Also verify that the
interface cable is wired according to the pin assignments shown
below and verify the correct baud rate of 9600. The software
automatically sets the format on the PC. The serial port on the
PC must also be set for COM1.
Transmission to the PC is at 9600 Baud, with 8 data bits, 1 stop bit, and no parity. Pin
assignments are as follows:
Function Tester
25-Pin ‘D’ PC 9-Pin ‘D’
(Com 1)
PC
25-Pin ‘D’
(Com 1)
Data In 2 3 2
Data Out 3 2 3
Signal Ground 7 5 7
NOTE
Pin numbers 2 and 3 are crossed when a 25-pin D is
on both ends Pin number 7 is connected directly.

Model 64/64x2 Instruction Manual Page 11
CONTROLS AND DISPLAYS
CONTROLS
All functions are controlled by keys on the top panel (Figure 4). Five of the main functions are
selected by individual keys, and fourteen additional functions are menu-selected through Up and
Down keys and executed by the MENU RUN key.
KEY-SELECTED FUNCTIONS
The five functions that are directly selectable by individual keys are as follows:
Seq Build Test
Random Build Reset
Error List
Seq Build
The SEQ BUILD (Sequential Build) key is selected when a specific assembly sequence must be
followed. In this mode, the Model 64 follows the programmed order of the wire list and displays
the FROM/TO points of each successive open circuit to be assembled. When a proper
termination has been completed, the display advances to the next open pair of points. Body
conductance (Wrist Strap or Probe) can be used in locating the proper wire from a bundle. The
assembly sequence of the wire list is first programmed off-line with a PC and then downloaded
with optional PC software to the Model 64. Once in the tester, the program can be saved to
tester memory.
Random Build
The RANDOM Build key is selected when the sequence of assembly is not important; the tester
waits for the operator to select a wire and then displays the corresponding FROM/TO points of
the open circuit. Body conductance (Wrist Strap) is used to select and display the wire touched
by the operator. Each continuity is then verified when proper termination is completed. The
wire list program can be downloaded with optional PC software, or generated using Learn
Known Good.
Error List
When ERROR LIST is selected, a test scan is initiated and all detected errors are printed. If no
error is located, a "PASSED" is printed.

Page 12 Model 64/64x2 Instruction Manual
MODEL 64
TEST RESET
Removeable
Cartridge
SEQ
BUILD RANDOM BUILD ERROR LIST
MENU
RUN
Cablescan
SEQ BUILD Initiates circuit assembly in step-by-step sequence per wire list
arrangement in memory. Wire list programs arranged in a specific
sequence are downloaded and saved in memory.
RANDOM BUILD Provides continuities for circuit assembly that does not require specific
sequence. Uses continuities program created in LEARN KNOWN GOOD
or downloaded from a PC.
ERROR LIST Initiates test of assembly and produces a printout of errors, or prints
"Passed" if no errors.
TEST Initiates single test of assembly and displays errors.
RESET Terminates current mode and places Model 64 in "wait" state until next
selection is made.
UP/DOWN
ARROWS Used for stepping up and down through menu to select a function. Also used to step through the wire list programs to load or delete.
MENU RUN Initiates the menu function (selected by Up/Down Arrows) that appears in
the display.
DISPLAY 16-digit, alphanumeric LCD (Liquid Crystal Display)
Figure 4. Top Panel Keys and Display