Futura Apsol PHTM320 User manual

1
USER’S MANUAL(ver4.4)
OF
CABLE HARNESS TESTER
MODEL PHTM320 / PHTM640 / PHTM960
BY
FUTURA APSOL PVT. LTD.
1212/B/2, Apte Road,
Shivajinagar,
PUNE 411 004.
TELE- FAX: [phone]
E-MAIL: [e-mail].
www.futuras.com
Software Version: PHTM_GEN_5.5 and PHTM_320_4k_2.5 (19/12/2012)

2
Cable Harness Tester Models
PHTM320 / PHTM640 / PHTM960
Packing List
1. Cable Harness Tester 1 no.
2. This User’s Manual 1 no.
3. Mains cord 1 no. similar to PC mains cord.
4. A pair of multimeter test probes for board check and continuity check.
5. “Learn” lock key for learning a harness.
6. Cable from tester to board / rig as per number of points or connectors.
7. Futura’s Serial Cable.
8. A CD containing DOS as well as windows based PC software for serial
communication with tester and other details.
9. Enter Serial Number of Tester……………
Important Note: Preserve the packing sent along with the tester which is specially
designed for protection of the tester during transportation. In case tester is to be
sent back to Futura, use the same packing.

3
INDEX
1. IMPORTANT NOTES
1.1. Safety notes.
1.2.Changes in Various versions.
2. INTRODUCTION.
2.1. Description of the system.
2.2. Specifications
2.3. Tester.
2.3.1 Testing Features.
2.3.2 General Features.
2.3.3 Harness Data (Circuit Data).
2.3.4 Input / Output cards (I/O cards).
2.3.5 Keyboard.
2.3.6 Rig.
3. INSPECTION AND INSTALLATION.
3.1. Unpacking the equipment.
3.2. Installation.
4. OPERATION.
4.1. Operating Instructions.
4.2. Setting tester to test: Key LRN.
4.3. Interfacing with PC.
4.4. Testing and Test Results.
4.4.1 Testing.

4
4.4.2 Error types and reporting.
4.5. Interfacing Printer.
4.6. Interfacing Relay output.
4.7. Buzzer.
4.8. Interfacing barcode scanner / reader.
4.9. Analysis.
5. Discription of menus and user general instructions:
5.1 Power on learn menus:
5.2 Normal LRN menu:
5.3 Analyse Menu:
6. TROUBLESHOOTING.
6.1 On power on there is no display.
6.2 Display is “NO CARDS”.
6.3 After passing a harness tester displays “Remove Cable”. Even after
removing cable, tester does not display “Put Cable”.
6.4 How to increase number of points i.e. capacity of tester.
6.5 Tester shows “no point” after selecting a cable number.
6.6 Tester remains in receiving mode even after transmitting data from PC.
6.7 Erratic behavior of tester. Suddenly displays a point number which is not in
the circuit. Suddenly shows any error. Displays “no card”. etc.
6.8 After pressing ‘Test’ key, tester displays ‘Receiving’ and ‘hangs’:
7. HOW TO …
7.1 How to replace I/O card.
7.2 How to add I/O card.
7.3 How to Press / Replace Memory IC, replace program EPROM.

5
8. BASICS OF TROUBLE FREE OPERATION: (PROPER USE OF
TESTER).
9. RIG (BOARD) WIRING FOR FUTURA’S CABLE HARNESS TESTER
MODEL.
10. CALIBRATION OF FUTURA’S CABLE HARNESS TESTER MODEL
PHTM320.
11. OTHER CABLE HARNESS RELATED PRODUCTS
10.1 Harness Assembly Aid / Tester (HAA64).
10.2 One To One Continuity Tester with Parts Counter (CT121).
12. FUTURA’S PROFILE.

6
1: IMPORTANT NOTES:
1.1: Safety notes:
Safety Notes! Please read before putting the system into operation!
This system has been checked for safe and correct functioning before being
shipped. In order to keep this safety, the user has to pay attention to the
corresponding notes and advice of the operating manual.
#Before connecting test samples to the instrument, check for strictly
separation of the sample from power!
Any connection of the test sample to power can be dangerous for the
operator and can damage electronics.
#Before connecting test samples to the instrument, check for static charges of
the test sample, fixtures and operator which are to be eliminated. Otherwise
the test electronics can be damaged.
#Any external continuity meter like buzzer, bulb or multimeter should be
strictly avoided. Use of these will damage the test electronic.
#While changing the board; removal and fitting of D type connectors on the
back side of the tester or centronics connector on the board should be done with
utmost care. These connectors are polarised and hence should not be inserted in
wrong direction. There is a tendency to push the connector hard in the tester
even if polarisation is incorrect. Pushing might damage the connectors on I/O
cards or on the board of the tester.
#Check proper earthing at the power supply input of the Cable
Harness Tester.
Warranty void if equipment is opened by unauthorized person.

7
1.1 : Changes in this versions:
PHTM_GEN_3.0
1) Label data size has been increased to 4k (4096 bytes).
2) Facility to scan two operator codes.
3) On label operator codes can be printed by variables @B & @C.
PHTM_GEN_4.4
1) Provision for second relay is made in software.
2) If Hardware for second relay is present in the tester then second relay can be used.
3) First relay can be set as relay on pass or relay on fail as per the requirements.
4) But Second relay will be compulsory on after harness pass.
PHTM_GEN_4.6
1) New variable i.e. @U is added for label printing
@U followed by two characters will represents single byte hex value.
For ex @UAA i.e. OxAA.
At every @U, following value will be sent to the printer port.
I.e. in above example hex AA will be sent to port.
2) At every harness fail if relay on fail setting is enabled then harness name will be sent
On the serial port by default serial settings.
PHTM_GEN_4.7
1) New modification in variable i.e. @U
For ex @UAA@1
For every date character hex value mentioned, will be sent before that character.
This modification will be applicable to PHTM label variables such as Time,
Serial number etc…for ex@U23@6000@6,@U@2.
PHTM_GEN_5.0 or PHTM_320_4K_2_0
1) During harness testing if extra point settings is enabled and extra point is occurred
Then tester will once display error and declare harness is failed and goes for waiting
into testing of new cycle.

8
PHTM_GEN_5.5 or PHTM_320_4K_2_5
1) @W is added in label printing variable. User details with maximum 16 bytes can be
added through serial port and will be printed via @W. On every power on if valid
user details are present then displayed on LCD.

9
Installation of PHTM960.
1. PHTM960 is similar to PHTM640 except
a. Maximum number of I/O cards can be 15 i.e. 960 points.
b. Keyboard, Learn lock key, Display, Buzzer, continuity and board check
terminals are separated in a hand-held enclosure called MMI (Man-machine Interface)
unit.
2. Along with tester, find enclosed MMI unit and 26 way flat cable of length 1.5 m.
a. Place the tester at a suitable location preferably under the table.
b. Connect MMI unit to the tester using flat cable provided. At the back side of
MMI unit and tester, indicators for connections are provided.
3. Connect cables to board. Switch on supply to the tester. Rest of the connections are
similar as earlier.
To facilitate tracing of assembly and testing operators, facility to enter their codes and
printing them on label is added.
Two operator’s codes are to be entered.
Operator Code length should not be more than 8 characters.
On power off operator codes are not remembered. On every power on these have to be
entered / loaded.
Operator codes are entered through barcode scanner connected at the back side of tester to
‘serial’ port.
Communication parameters for operator barcode scanner are same as that for label
barcode scanner i.e. 2400 band; 8 bit data, 1start, 2stop bits and even parity.
Scanning is in ‘Analysis’ mode i.e. on pressing key ‘A’.
In label printing, @B prints first operator code and @C prints second operator’s code.
Operating sequence:
•Label data has @B and @C at proper places where operator’s codes are to be printed.
•Label data is transmitted to tester in the same way.

10
•When operator code is to be changed, ‘A’ key is pressed. Display is ‘Check
Continuity’.
•Down Arrow key displays ‘Operator codes?’
•‘Enter’ accepts command and display is ‘Receiving code 1’.
•First operator’s code is to be scanned by barcode scanner.
•Display is ‘Receiving code 2’.
•Second operator’s code is to be scanned by barcode scanner.
•Both codes are displayed.
•Tester displays ‘command?’
•Tester is ready for any command.

11
2: INTRODUCTION :
2.1: Description of the system:
Futura’s Cable Harness Tester (CHT), is designed to test Cable Harnesses,
Cable Looms, Cable Forms. CHT locates interchanged connections, shorted
connections, open connection and extra points. CHT facilitates two stage testing of
harnesses.
CHT is a 16 bit Digital Signal Controller based stand alone unit; and
Hence testing speed has been enhanced as compared to older version. Time
taken to test depends on factors such as selected mode (auto / manual), extra point test,
number of points etc.
Minimum test system consists of Harness tester with mounting board / rig.
Complete test system consists of tester, a mounting rig, solid state Floppy, PC, printer or
stamping unit.
Harness tester is connected to the Rig (Jig) through “D” type connectors. Any
point on rig can be connected anywhere; meaning there is no “From” and “To” concept.
This simplifies the rig wiring to a great extent. This concept also facilitates in indirect
saving of space by accommodating different types of harnesses on the same mounting
rig. While designing the rig; care should be taken that all the end points or mountings of
all harnesses are taken on the board. Each mounting is connected to the tester. A harness
is mounted at particular mountings while learning the data as well as testing.
The harness to be tested is mounted on the rig and then tested through tester.
The errors can be seen on tester’s LCD display.

12
Futura Apsol Pvt. Ltd., Pune 411 004, India.
DOC. NAME Cable Harness Tester HTM320 front panel
DOC. NO. HTM320FP DRN BY GSR DATE 18/4/03
DIM IN --------- SCALE -------- MOD
MOD MOD PAGE OF
Keyboard with 6
nos. dome type
keys.
Keys: Meaning
LRN: Learn: Load / change setup, harness data, date time, label data, barcoded number, harness name, two barcode
on flag etc.
TEST: Start testing of harness.
Enter: Accept command.
A: Analyse: continuity, board check, and display count, change cable number, display harness data.
∧: Next command / number.
∨: Previous command / number.
16*1 LCD Display with
backlit.
Learn Lock. Key provi
ded to
be used to unlock. Learn can
be pressed after unlocking
only. Prevents unauthorised
changes in data.
Terminals for probes provided.
Red: Manual Continuity and
board check.
Black: Manual continuity.
Cable Harness Tester PHTM320 Front Panel

13
Futura Apsol Pvt. Ltd., Pune 411 004, India.
DOC. NAME Cable Harness Tester HTM320 / 640 back panel
DOC. NO. HTM320BP DRN BY GSR DATE 18/4/03
DIM IN --------- SCALE -------- MOD
MOD MOD PAGE 1 OF 1
I/O cards. Presently 2 nos.
Tester capacity 128 points.
Each card for 64 points.
Provision for 5 I/O cards in
PHTM320 and 10 in
PHTM
640.
15 pin D type
M. Points 1-15
Mains
Switch.
Relay output.
Potential free.
230Vac, 5A.
Volume
Tone speaker
Serial RS232
To Printer
Cable Harness Tester PHTM320/640 Back Panel
25 pin D type
M. Points 16-39
25 pin D type
M. Points 40-64
Mains power
supply Input
Fuse
, also an additional
fuse is given inside.

14
2.2: Specifications:
Function: The Cable Harness Tester, tests a harness under test by checking each
point with each other point, compares the net-list with the stored net list and displays the
result. If the net lists match then displays “PASS” else displays the faults and the associated
number. Faults searched for and analysed and displayed are open point, open group, short
group, location interchange and extra point. Net-list is stored by learning a good harness or
from PC through serial. It also has a analyse function for continuity checking, board checking,
displaying pass count, changing cable number and displaying the learnt data.
•Power supply.
* Supply Voltage: 230 V AC, 50 Hz. ±10%.
* Power consumption: Maximum 10 Watts.
* Fuse: 750 mA, normal.
•Inputs.
* Test voltage: 5 V DC.
* Test current: In mill Amperes.
•User Inputs: Keyboard input
* Dome type, dust proof keys with good tactile feedback.
* Number of operations: One million.
* Number of keys: 6 nos.
•User Output: Display Output:
* Display used: 16 character LCD display with backlit.
* Buzzer, audio output on pass, with tone and volume control.
*Potential free Relay output up to 230V AC, 5A load.
* Piezo Buzzer, for continuity.
•Interfaces: (PHTM320/PHTM640/PHTM960)
* Printer: Centronics parallel port for printers. Can print learnt data and
label on Pass.
* PC: Standard RS232 serial at 2400 baud, no parity, 8 bit data, 1 start, 2
stop bits through a PC.
•Environmental:
* Working temperature: 0°- 50°C.
•Mechanical:
* Dimensions: 388 mm ×260 mm ×222 mm ±2mm.
* Weight: Approximately 7.5 Kgs.
* Rust and scratch proof: Powder coated.

15
2.3: Tester: The tester is digital signal controller based unit. Refer Figure 1.2 for a view of
tester. It has facility to connect five add on I/O cards. One card is the minimum
configuration and it can test a harness with 64 points. By adding one card the capacity can
be increased by another 64 points; in the same manner maximum capacity can be 320 / 640
points with 5 / 10 cards. The tester stores the data into memory and compares it with the
tested data. If any error is found it reports through the 16 character LCD display. It also
recognizes the key pressed and functions accordingly.
PHTM320 PHTM640 PHTM960
Maximum number of points. 320
Max. 5 I/O cards
640
Max. 10 I/O cards
960
Max. 15 I/O cards
In step of points 64 64 64
Maximum Number of harnesses stored in
EEPROM or battery backed RAM.
25 25 25
Enclosure Size approx. in mm. 388(L) * 260
(D)* 222(H) ±2
500(L) * 260
(D)* 222(H) ±2
500(L) * 260
(D)* 222(H) ±2
2.3.1: Testing Features:
•Tester will display the first occurred fault and will be scanning the harness
continuously and hence keeps on displaying the first occurred fault. Tests and displays
open point, open net, shorted net, interchange i.e. miss-location and extra point.
•By default tests ‘net by net’; starts with first net if found correct does not check
it again. ‘All Circuits’ mode can be selected on power on. All the nets tested in one pass,
if all are found correct, passes harness. For MSSL ‘All Circuits’ mode only.
•Testing can be Automatic (Auto) or manual. In auto mode, ‘TEST’ key is to be
pressed once. After passing a harness, displays “Remove Cable”. On removing harness
from board, displays “Put Cable”. Starts testing automatically when a harness is mounted.
In manual mode ‘TEST’ key is to be pressed for each testing. Mode selection is done once
by pressing ‘LRN’ key when power is switched on. In manual mode testing is faster.
Useful for harness with fewer points on testers with more points.
•Tests extra point which is not in circuit program / harness data but is on
harness. It can be skipped* by pressing ‘LRN’ key when power is switched on. To be set
once.

16
•Facilitates two stage testing. For example for fuse box. First stage complete
harness and second stage only fuses. Does not test for extra points in second stage.
•Switches a relay contact of 230 V AC, 5A capacity on for settable time (1 to 10
seconds) on for any application as stamp printing etc.
•Options available while placing order :
oSmall buzzer on each fault.
oInstead of removing complete harness to start next test; start on
removing a point.
oFirst stage testing twice and second once.
oIn second stage check only for open points, makes second stage
program writing as any two shorted points. Random data entry of
second stage.
2.3.2: General Features:
•Self test by pressing any key and switching on power without harness mounted
on the rig / board. Tests for any shorted points on the board and displays shorted points if
any. Else displays “Pass” and switches on relay and sounds buzzer.
•Based on digital signal controller based advanced technology which increases
speed, reliability and performance.
•Printing of labels on passing a harness on any parallel port printer. Label’s
text
is user programmable, maximum of 4096 characters with real-time date, time, week, month
and year. Option can be set on or *off after selecting Harness under Test, which is
remembered by tester.
•Read barcoded label on a harness before testing each harness, compare it with
loaded barcode and test only if both match. Option can be set on or off after selecting
Harness under Test, which is remembered by tester.
•Two barcode option is also available, read two different barcodes before
testing each harness, compare them with loaded barcodes and test only if both two match.
Option can be set on or *off through LRN menu.
•A harness named up to maximum 16 characters.
•Printing of harness data on a printer.
•Uploading harness data to PC.
•Check continuity of a harness manually.

17
•Check rig / board, as a part of periodic performance check.
•Download harness data, label data, harness name, barcode etc. from a PC
Using DOS as well as windows based software.
•Relay on time is settable through software. (1 to 10 sec).
2.3.3: Harness Data (Circuit Data):
Tester stores harness data in its memory which is retained even on power off.
Type of memory used is EEPROM. Earlier BBRAM (Battery Backed RAM) was used.
Harness data can be loaded either by self learning or downloaded from PC’s
serial RS232 port.
The tester can store data for twenty five harnesses. Harness data in Cable
number 0, cannot be stored on power off. Hence tester can test twenty-five fixed types of
harnesses and one general type of harness. The tester counts the number of points
‘learnt’ or loaded from PC and displays them to help learning as well as loading. Tester
also displays and compares the stored number of points and actual number of points in a
net list / programmes; when a cable number is selected. If they are not same the tester
displays error and disables “test” key. This facility confirms the correctness of data in
memory.
2.3.4: Input / Output cards (I/O cards):
I/O cards are connected to main controller unit, and controller controls them
all. Controller finds out the number of cards present and then displays results
accordingly. Add on card can be added at any time without changing hardware or
software. At one edge of I/O card; two D type 25 pin male connectors and one D type 15
pin male connector is provided. These are the points to be connected to rig. Tester has its
own power supply working on mains supply. The tester is a very handy unit and can be
shifted from rig to rig very easily.
2.3.5: Keyboard:
Keyboard is a sealed keyboard with six numbers dome type keys. It should be
pressed gently. More than one ‘Test’ keys are provided, as it is used frequently, life of
keyboard increases. Keyboard should never be pressed by nail.

18
2.3.6: Rig:
As the testing time reduces to one to five seconds; the harness mounting
time on the rig becomes very significant. All the harness points are to be mounted on
the rig. If connectors are used in a harness then time taken is very less.
We have developed some parts which take less efforts and time mount them on
rig.
All these points are to be brought to the D type connectors’ tester. The errors
give numbers as per D type connector’s connection. The same numbers are to be put on
rig for easy identification of the cable. Some other visual aids such as colored strips are
also on rig for ease of finding location on the rig.

19
3: INSPECTION AND INSTALLATION
3.1: Unpacking the equipment:
The equipment is packed in a corrugated box along with special packing to avoid transit
damages. Retain the packing material which is specific to your equipment. Following is the
list of items packed.
oCable Harness Tester 1 no.
oThis User’s Manual 1 no.
oMains cord 1 no. similar to PC mains cord.
oA pair of multimeter test probes for board check and continuity check.
o“Learn” lock key for learning a harness.
oCable from tester to board / rig as per number of points or connectors.
oSerial Cable with models PHTM320 PLUS and PHTM640.
oA CD containing DOS as well as windows based PC software for serial
communication with tester and other details.
Check for major damages in transport; such as removal of certain parts, bends, dents
etc. and inform FUTURA accordingly.
3.2: Installation:
Connect the tester with your rig as per stickers provided on rig as well as the controller.
Connect ‘D’ type connectors at proper positions such as CON 1. CON 2. etc. The number and
connectors will depend on the number and points.
Fix the “D” type connectors using small flat head screw driver.
Connect mains cord in socket provided on tester and switch on the tester.

20
4: OPERATION
4.1: Operating Instructions:
Key Definitions:
Key operations are as follows.
For any wrong key pressed; message “CHEK KEY” will be displayed.
Key “LRN” : Learn from mounted harness.
Key “TEST” : Test mounted harness and show results.
Key “A” : Analyse; for analysis.
Key “ ∆
∆∆
∆” : Next selection / command / menu / number.
Key “ ∇
∇∇
∇” : Previous selection / command / menu / number.
Key “ ↵
↵↵
↵” : Enter; accept the selection / command / menu / number.
Refer figure for graphic representation of keys and menus and submenus.