ELECTRICAL TEST BOARD

WIRING HARNESS TEST SYSTEM

ETB

USER MANUAL
 ELECTRICAL TEST BOARD
Internal ID Commercial ID Date Version Written by
2012-PR1508 - 10/12/2013 1.0 Engineering department
Engineering Department
USER MANUAL

Document history and versions

Version Date Edited by Changed sections Reason for change
1.0 10/12/2013 J. Cugat - -

Content

1. Safety .................................................................................................................................................... 3
2. Overview and applications ................................................................................................................... 4
3. Specifications ........................................................................................................................................ 5
4. Description ........................................................................................................................................... 5
4.1. Introduction ................................................................................................................................ 5
4.2. Parts ............................................................................................................................................ 5
4.3. Uses of the Station ...................................................................................................................... 7
5. Installation ............................................................................................................................................ 8
5.1. Main power and air connector ................................................................................................... 8
5.2. Interface cards ............................................................................................................................ 8
5.2.1. Types ....................................................................................................................................... 8
5.2.2. Connections ............................................................................................................................ 8
5.3. 01CTC8B card ............................................................................................................................ 10
5.3.1. Description............................................................................................................................ 10
5.3.2. Main power connections ...................................................................................................... 11
The main power connections are done in terminal block J4. ................................................................. 11
5.3.3. Specific connections ............................................................................................................. 11
5.3.4. Connections for EMDEP DT/AT Rack .................................................................................... 11
5.3.5. Connections for other test equipments ............................................................................... 12
6. Test parameters and sequence .......................................................................................................... 13
7. Operation ........................................................................................................................................... 13
7.1. Turning Power ON ..................................................................................................................... 13
7.2. Testing ....................................................................................................................................... 14
7.3. Station Switch Off ..................................................................................................................... 16

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 ELECTRICAL TEST BOARD
Internal ID Commercial ID Date Version Written by
2012-PR1508 - 10/12/2013 1.0 Engineering department
Engineering Department
USER MANUAL

1. Safety
Review the following safety precautions to avoid injury and prevent damage the station or any other
components connected to it.

To avoid potential hazards, use this station only as specified.

The station is designed in order to avoid that the operator can access to dangerous parts, so the station
is equipped with safety components to protect them and the electrification of station is inside the bench
closed by key.

Only qualified personnel should have the keys of the station and can perform technical maintenance.

COMPLIANCE INFORMATION

This section lists the EMC (electromagnetic compliance) and safety standards which the station
complies. Declaration of conformity is attached with the documentation of the station.

EMC Compliance

• Electromagnetic compliance Directive 2004/108/CE.

Safety Compliance

• EC Declaration of Conformity – Low Voltage. Directive 2004/98/CE.

• The essential requirements relative to machines. Directive 2006/42/CE.

Additional Compliances:

• EN 61010-1:2010 [IEC 61010-1:2010/Corr.1:2011]. Safety requirements for electrical

equipment for measurement, control and laboratory use Part 1. General requirements.

CE & IDENTIFICATION INFORMATION PLATE

The station is marked with the identification plate. This plate is outside the station, on the side part, and
shows information about identification of station (Model, Reference, Serial number, Date), the technical
specifications (nominal voltage and current, frequency, pressure) and CE mark.

Picture 1: CE and Identification Information Plate.

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USER MANUAL

CLEANING CONSIDERATIONS

Only qualified personnel should perform cleaning operations. Don’t forget to switch off the power
supply of the station before cleaning.

To avoid electric shock or damage to the station, never get water or other liquids in the station.

To avoid damaging the station, do not apply aromatic hydrocarbons, alcohol, chlorinated, solvents or
methanol-based fluids.

If the station requires cleaning, wipe it down with a cloth that is lightly dampened water or mild
detergent. The station is also equipped with air gun to remove dust of counterparts.

2. Overview and applications

The electrical test boards manufactured by Emdep, can test the isolation and continuity of harnesses,
detections of mechanical parts, leak and vacuum test, resistance and capacitor measurements, diodes,
connectors and components for which the station has been designed.

Picture 2: Example of electrical test board.

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USER MANUAL

3. Specifications
Power supply and air connection:

• Input voltage: 115/240 Vac

• Nominal current: 16 A
• Frequency: 50/60 Hz
• Pressure: 6 bar

Mechanical specifications:

The mechanical design and dimensions of the Electrical Test Board are specified by the customer and
depends on the length and layout of the harness to be tested in it.

Electrical Test:

The test and measurement ranges depend on the equipment. The Electrical Test Board can work with
several Emdep or third party test equipments. Refer to the corresponding product documentation for
further information.

4. Description

4.1. Introduction
There are different standard structures for electrical test. In all structures there is a modular panel
where the counterparts are inserted. The counterparts are the mechanical part that hold the connector
or component to test.

4.2. Parts
Counterparts:

The counterpart is the mechanical part that holds the connector or component to test. This is the part
where test pins (terminals) and sensors (switches, color sensors, etc…) are inserted. Test pins are used
to connect the ways (or terminals) of component under test to the test equipment. The sensors are used
to detect some parts of the component under test, these signals are connected to test equipments too.

Picture 3: Example counterparts.

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USER MANUAL

User interface:

• Keypad: The operator has a keypad for managing the electrical test station.

Picture 4: Keypad.

• Monitor + keyboard + mouse + scanner + printer + etc…: The software supports many of
peripherals.

Picture 5: Peripherals.

Electrical test equipment: Harness test with programmable resistance threshold (isolation and
continuity test). PC controlled through USB and Wintestem software. Up to 8128 test points, for testing
wires, lock signals, detections, diodes, resistors, capacitors and led activations.

Picture 6: AT/DT Series Rack: electrical test equipment (low voltage).

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USER MANUAL

Electrical and pneumatic connections. Inside the station there are the general control box and the
wiring for the interconnection of different cards, safety elements and electrical parts. The connections
and components with 240Vac, like electrical protections (circuit breaker and ICP switch) and the power
supplies are located inside this general control box. Also, inside the bench there is the computer where
the test software is running.

Interface cards: The "01CTC6" allows the connection between the counterparts and the electrical test
equipment. It is used to distribute the power supply to counterparts and connect counterpart test
points to the electrical test equipment.

Picture 7: Electrical and pneumatic connections.

Optional accessories: Depending on the specifications of projects and customers, the station can
include some accessories available that don’t take part of the safety system.

Emdep can use other match components which will withstand the directives and requirements specified
in the declaration of conformity.

4.3. Uses of the Station

The station is designed exclusively for electrical and mechanical test of harnesses, connectors
and components for which has been designed. Any modification of the harness, connectors or
components not considered in the initial specifications cannot be tested without prior review
and approval of Emdep.

The model (ID) of the connectors or components that can be tested in each counterpart are specified. In
the working order the harness references that can be tested are also specified.

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USER MANUAL

5. Installation

5.1. Main power and air connector

Only qualified personnel should perform the connection of the station to the factory power line.

Connecting to power line:

• Verify if the voltage of the factory power line is connected according to the specifications in the
plate that is located inside the station (on the side of the structure). In case of any difference,
please contact Emdep for support.
• To avoid shock hazard and damages, connect the station using the connector and the cord
supplied with it. If the plug connector must be modified, please contact Emdep for support.

Connecting to air line:

• Connect the air inlet of the station to the air line of the factory.
• Check the pressure on the display of the pneumatic unit that is located inside the station. The
pressure should be adjusted to 5-6 Bar through the regulator. If this value cannot be reached,
maybe the pressure of the input line is not enough. Please contact Emdep for support.

Connecting Network

• The station can be connected to the network line. The customer IT department must configure
the network parameters in the computer.

5.2. Interface cards

5.2.1. Types

Depending on the counterpart wiring standard 01CTC6LR, 01CTC6YZ, 01CTC6LN or 01CTC6EM can be
chosen.

5.2.2. Connections

To illustrate the connection of the interface card, the picture of the 01CTC6EM card has been chosen.

Picture 8: General view 01CTC6EM

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USER MANUAL

The different zones of the card can be identified in picture 8.

- 1; Fuses for working lines.

- 2; Power supply connections.
- 3; Power socket for the modules.
- 4; Selector of working line.
- 5; Sixty four test points.
- 6; Flat cable (test equipment connection).
- 7; Led connection for some test equipments.

Picture 9: Power connections

Picture 10: Visual aid electrical connections

In LN, LR and EM models, each power connectors can be connected to L1, L2 or L3 using the jumpers
(Zone 4 of picture 8).

The 01CTC6 card has two Leds. The green Led shines when the signal LED+ has supply and the red Led
shines when the L1 has supply.

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USER MANUAL

5.3. 01CTC8B card

5.3.1. Description

The 01CTC8B is a card prepared to work at 12/24 VDC (changing only relays) with any test equipment.
The card is assembled in a plastic channel to be installed in DIN rail. It has the following components:

1- 1 power terminal block (J4) and 1 I/O terminal block (J3).

2- 2 connectors Sub-D (37 pins) for the I/O cables from the Rack (2 corresponds to in/out 1) (2A
corresponds to in/out 2)
3- Sockets for 10A double contacts relays.
4- 8 fuses (10A) to protect the relay contacts
5- 1 Fuse (6A) to protect the output lines (DC+)
6- 1 Fuse (4A) to protect the output line (LED +)
7- Led indicators for the status of inputs and power DC (+)
8- “Input” jumpers to configure the inputs for C4 card of rack.
9- “Output” Jumpers to link relays K0, K1, K2, and K3 with outputs 0, 1, 2, 3 from the rack.

* The number of used relays depends on the type of test equipment and specifications.

Picture 11: 01CTC8B card

As mentioned, the 01CTC8B card, can work at 12/24V with all types of equipments. As default only 3
relays are used, only in special cases the 4 relays must be used. Refer to the corresponding electrical
diagrams for further details.

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USER MANUAL

5.3.2. Main power connections

The main power connections are done in terminal block J4.

Picture 12: CTC8B general connections

5.3.3. Specific connections

The specific connections must be done in the terminal block J3. In case that our test equipment and
software (WTT) are used the I/O cables must be connected from rack to the Sub-D connectors and the
jumpers in the I/O pins according to the required work configuration. The jumpers in pins I/O make the
connexion between J3 terminal block, relays (K0, K1, K2, K3) and Sub-d connectors.

For other test equipments the connections must be done only in the terminal block J3.

5.3.4. Connections for EMDEP DT/AT Rack

In case that Wintestem and DT/AT Rack are used these electrical connections must be done:

A. Connect the I/O cables with male Sub-D connectors to the female Sub-D connectors in C8B
card.
B. Place the jumpers in I/O pin to make the connexion between J3 terminal block, relays and Sub-
D connectors as showed in the picture 12. If the inputs are used, the jumpers must be put
according to the output signal provided (+/-).
3 jumpers are needed for each output relay.

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USER MANUAL

Picture 13: I/O configurations

A. Make the connections in J3 terminal block according to the definitions bellow and the standard
electrical schemas defined for each customer.
-The Outputs 0, 1, 2, 3 command the relays 0, 1, 2, 3. Don’t connect anything in this terminal
block.

- The other Outputs are free for use. Get the needed power for (COM) or (DC+) from J4 (GND).

- All inputs are free to connect external signal (In+) (IN-), to the terminal block.

The power lines (12/24 V) of C6 cards must be connected to the relays contacts (NC/NO).The
power must be connected to the contact (COM) from J4 (DC+), (GND) or both. For other
applications, you can follow the same procedure.

Note: As general rule K0 is used to command the power lines of C6 cards; K1 to command the
nd
EV of modules to close spacer; K2, to command 2 tests(ex: release modules; fixation,
counters, etc.). K3 is only used for special cases, normally with other test equipments.

Picture 14: J3 terminal connections for AT/DT Rack and WTT

5.3.5. Connections for other test equipments

A. Make the connections in J3 terminal block according to the definitions bellow and the standard
electrical schemas defined for each customer.
- The terminal blocks marked with green, mustn’t be used.

- The power lines(12V/24V) for C6 cards must be connected to the relays contacts (NC/NO).The
power must be connected to the contact (COM) from J4 (DC+), (GND) or both. For other
applications, you can follow the same procedure.

- Connect the outputs to the relay coils.

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Internal ID Commercial ID Date Version Written by
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USER MANUAL

Note: As general rule K0 is used to command the power lines of C6 cards; K1 to command the
nd
EV of modules to close spacer; K2, K3 to command 2 tests(ex: release modules; fixation,
counters, etc.).

Picture 15: J3 terminal connections for other test equipments

6. Test parameters and sequence

The test process in Wintestem is programmable in order to allow all possibilities in the test process.
Usually it is programmed by Emdep, but it can be modified to add new steps or new references. It must
be only done by technicians that have knowledge of programming in Wintestem. Otherwise, please
contact Emdep.

Please, refer to the manual of Wintestem for more information.

7. Operation

7.1. Turning Power ON

Turn on the power switches placed at the front and side parts of the station (“I” position).

After that, the computer will automatically start and the test application called Wintestem will be
launched.

Picture 16: Wintestem initial menu.

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Initially, many options are disabled. When the operator validates himself, these options become
available. For validating, the operator must press 4 “Identify”, and enter the password.

The operator can launch the test by pressing 3 “Test Harness” and choosing the right program.

Picture 17: Launching a test process.

The test process can be programed by the customer (programmer role is necessary). A lot of steps can
be added in the test program, like messages, activate outputs, read inputs states, loops, conditions, etc.
Refer to the manual of Wintestem for further information.

7.2. Testing
After starting the test, the programmed sequence is executed. This sequence depends on the customer
specifications. See below a typical example.

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START

SCAN REFERENCE
Harness / Component

LOCK / DETECTIONS
TEST

ELECTRICAL
TEST

PRINT
LABEL

REPORT /
TRACEABILITY

The operator will usually take part to:

1) Scan the label of DUT (device under test) / choose the reference to test.
2) Insert the harness, connector or component in the sockets.
3) Release the DUT and stick the label.

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7.3. Station Switch Off

The procedure to turn off the station is:

1) Push option 5 “Close System” in Wintestem main menu:

2) Turn off the main switch in the front panel of station:

Note: The station will remain on until the computer will be switched off. For an immediate disconnection,
switch off the main switch on the side.

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