3eetr Manual en v2012.1.0

TESTEM-R
COMPACT STAND-ALONE HARNESS ANALYSER
3EETR-v2012
USER MANUAL
USER MANUAL
Internal ID Commercial ID Date Version Written by
IM041 - 02/01/2012 1.0 Joan de Magriny
Engineering Department
3EETR TESTEM-R V2012
Document history and versions

Version Date Edited by Changed sections Reason for change
1.0 02/01/2012 Joan de Magriny - Initial version
Contents
Contents
1. Overview and applications ................................................................................................................... 4

2. Technical specifications ........................................................................................................................ 4
3. Installing the Testem-R ......................................................................................................................... 6
3.1. Testem-R main parts ................................................................................................................... 6
3.2. Input/output connectors ............................................................................................................ 7
3.3. Serial ports .................................................................................................................................. 7
3.4. Ethernet connection ................................................................................................................... 8
3.5. Test board and counterparts ...................................................................................................... 8
3.6. Installing the software ................................................................................................................ 8
4. Programming with Wintestem ............................................................................................................. 9
4.1. Set-up .......................................................................................................................................... 9
4.2. Harness compilation ................................................................................................................... 9
4.3. Process editor ........................................................................................................................... 10
4.3.1. Main screen .......................................................................................................................... 10
4.3.2. Process instructions .............................................................................................................. 11
4.3.3. Variables ............................................................................................................................... 19
4.4. Data Manager ........................................................................................................................... 20
4.4.1. The Data Manager main screen............................................................................................ 20
4.4.2. Adding new references ......................................................................................................... 21
4.4.3. Compilation .......................................................................................................................... 22
5. Control panel ...................................................................................................................................... 23
5.1. Test Menu ................................................................................................................................. 23
5.1.1. Starting to test a reference................................................................................................... 23
5.1.2. Electrical test details ............................................................................................................. 24
5.1.3. In-test maintenance options ................................................................................................ 27
5.1.4. Capacitor test ....................................................................................................................... 27
www.emdep.com 2 / 36
3EETR_MANUAL_EN_v2011.1.0.docx - EMDEP 2012
USER MANUAL
5.2. Maintenance menu ................................................................................................................... 29

5.2.1. Test probe ............................................................................................................................. 29
5.2.2. Inputs .................................................................................................................................... 31
5.2.3. Outputs ................................................................................................................................. 31
5.3. Set-up ........................................................................................................................................ 31
5.3.1. Test data ............................................................................................................................... 32
5.3.2. Reference selection mode .................................................................................................... 34
5.3.3. RS-232 Display ...................................................................................................................... 34
5.3.4. User Id. required ................................................................................................................... 35
5.3.5. Password .............................................................................................................................. 35
5.3.6. Language............................................................................................................................... 35
5.3.7. Time/Date Set-Up ................................................................................................................. 36
6. Firmware update ................................................................................................................................ 36
USER MANUAL
1. Overview and applications
Testem-R is a standalone equipment appropriate for the electrical test of small wiring harnesses, clips
tables or assembly stations. Main features:
Analog test mode (programmable resistance threshold).

Complete range of errors (opens, shorts and detections).
Components test (diodes, resistors and capacitors).
8 inputs and 8 outputs.
2 serial ports for printer, scanner and 1 parallel port.
USB port for program upload using a standard pen drive.
Ethernet port.
The equipment is programmed with Wintestem, using its popular graphical environment and taking
advantage of its modular programming capabilities. It includes a specific process editor with instructions
such as display manipulation, buzzer control, counters control, etc.
2. Technical specifications
Power supply Voltage 88 ~ 264VAC, 47 ~ 63Hz
AC current 1.3A/115VAC 0.8A/230VAC
Electrical test Hardware self-test Yes
Connector locks test Yes
Detections test Yes
Open circuit test Yes
Short-circuit test Yes
Resistance threshold Programmable 50 - 100k ( 5%)
Diodes Polarity, Vf* (0-5V)
Resistors* 50 - 100k ( 5%)
Capacitors 10nF 1mF ( 5%)
Test modes Normal, Once OK, Once OK Sequential
Test points Test points 128 std version, up to 256
Test voltage/current 0 - 5V / 0 2.2mA
Counterpart Leds All test points can drive Leds
Led power supply voltage 5V
USER MANUAL
Connectivity Inputs 8 optocoupled inputs
Outputs 8 relay outputs
RS-232 for printers/scanners 2 ports
Parallel Printer port 1
Ethernet 10/100 Mbps
USB 2.0
Operator interface Display Alphanumeric LCD 4x20
Acoustic signals Included buzzer
Buttons Numeric keypad
Languages English, Spanish, French, Portuguese, Romanian, Polish

and Slovak
Programming and variables Software Wintestem
Test process Programmable, full command set.
Variables Counters and string variables
RTC Included
Data transfer Standard USB pen drive
Internal memory 2GB (microSD)
Firmware upgrade Standard USB pen drive
* Supported by Hardware, not implemented in current firmware
USER MANUAL
3. Installing
Installing the Testem-
estem-R
3.1. Testem-
Testem-R main parts
Hexadecimal
keypad
Display
Test Probe
socket
Figure 1: Front view
Parallel printer port
Serial Ports
COM1/COM2
115/230VAC
socket & switch
Slots for test

point cards
Ground socket USB

Ethernet
Inputs/Outputs
(see next page for pin
(see next page
(see next page for pin
Figure 2: Rear view
USER MANUAL
3.2. Input/output
Input/output connectors
Connector pin out:
Figure 3: I/O connector
Pin Description Pin Description

1 Input 0 + 20 Input 0 -
5 Not used 24 Not used
10 Not used 29 +15V
11 Not used 30 GND
12 Not used 31 +5V
13 Not used 32 Output 1 Com
14 Output 2 Com 33 Output 1 NC
15 Output 2 NC 34 Output 1 NO
16 Output 2 NO 35 Output 0 Com
17 Output 3 Com 36 Output 0 NC
18 Output 3 NC 37 Output 0 NO
19 Output 3 NO
Table 1: I/O pinout
Inputs and outputs from 0 to 3 are available in the first connector, and 4 to 7 in the second.
This picture shows pin description for the first connector.
The use of the Emdep standard I/O interface card reference 01CTC8BM is highly recommended.
Ask Emdep for further details.
3.3. Serial ports

ports
Some notes about the use of the serial ports:
Default parameters: 9600 bauds/8 data bits/1 stop bit/No parity

The scanner must be connected to the serial port COM1.
USER MANUAL
3.4. Ethernet connection

Testem-R includes an Ethernet port which is not functional at the moment (December 2011). It will be
functional in future firmware versions. If you think Ethernet is enabled in your Testem-R, look for newer
versions of this manual.
3.5. Test board and counterparts

Testem-R includes the analog test card "01CTC5D". So, it is completely compatible with Emdep AT series
USB rack.
Notice that, since the voltage of the test card is 5V, the power supply for the leds must be 5V
also. It means that, when replacing an old Testem-R equipment by a Testem-R v2011, that
power supply should be replaced.
The use of Emdep standard interface cards reference 01CTC6xxM is highly recommended. Several
variants with different connector types are available, adapted to the standards of each customer. Ask
Emdep for further details.
3.6. Installing the software

software
Testem-R is programmed with Wintestem; an office version of the license is available.
USER MANUAL
4. Programming with Wintestem
4.1. Set-
Set-up
Before starting to program the harnesses, there are some important questions about Wintestem set-up
to consider:
The number of test cards can be up to four (256 test points).

There can be up to thirty-two defined colors, and the code of each color can be up to two
characters.
4.2. Harness compilation

Harnesses can be compiled for Testem-R by selecting the corresponding option in the compilation form:
Figure 7: Harness compilation
During the compilation, the connector and detection names are truncated to 8 characters,
and wire names to 16 characters. In the same way, the ways are renamed to correlative
numbers.
For each compiled harness, an .rhn extension file will be created. This file will contain all the
information about the harness and the board.
Notice that the board definition has to be identical for all the compiled harness. If different
board definitions have to be used in the same Testem-R, consider the possibility to compile
them in different projects (different Wintestem folders, different ".tr" compiled files). Several
projects can be stored in the internal memory of the Testem-R. See 5.3.1 in this manual for further
information about test data management.
USER MANUAL
4.3. Process editor
4.3.1. Main screen
A new process editor graphical environment has been created for Testem-R, located in Programming,
Extras, Testem-R, Process Editor.
Figure 8: Process editor
General options:
NEW PROCESS: Create a new process.
LOAD PROCESS: Open a created process.
SAVE PROCESS: Save the current process.
PRINT PROCESS: Send the process to the default printer.
DELETE INSTRUCTION: Delete an instruction line.
QUIT: Quit the process editor.
USER MANUAL
4.3.2. Process instructions
Although the capabilities of Testem-R are limited in relation to WinTestem, similar process commands
are available. The following is the instruction set for Testem-R processes:
SCREEN & SOUND
SHOW: Show a message on the screen during the test. The messages are written
line by line (four lines, with twenty characters per line). Variables can be used in
this instruction (see 3.3.Variables).
Example:
The result will be:
INSERT HARNESS
Notes:
Usually a sleep instruction must be inserted after a show to keep the

message visible for a while.
Messages are left-justified.
The screen lines are 20 characters long.
CLS: Clear the Testem-R screen.
BEEP: Activate the internal buzzer during a specified time.
USER MANUAL
SLEEP: Stop the process during a configurable selected time.
INPUT KEY: Wait until a key is pressed and then store it in memory.
IF KEY: Conditional jump which occurs if last pressed key (input key command) is
the one selected in this instruction.
STRING MANIPULATION
INPUT STRING: Wait for data from a scanner or from the keypad and then store it
in a volatile string variable.
When the keypad is selected, a screen like the following will be shown:
--------------------
USER MANUAL
The first line can be filled previously using a show instruction to ask to operator
what information is required (e.g. show Input batch code)
INPUT BATCH CODE

--------------------
Press left arrow to delete, and return to accept. Pressing Esc the string will be
empty. The maximum number of characters is 64 (max. size of the strings).
SET STRING: Assign a value to a string variable.
CUT STRING: This instruction is used to cut a string. It is necessary to introduce the
first character number and the number of characters to be cut.
IF EQUAL STRINGS: conditional jump to a process line. It jumps if both selected

strings are equal.
USER MANUAL
PIN MANAGEMENT
SET PIN: This instruction is used to activate or deactivate a test-point.
IF PIN: This instruction is a conditional jump to a different process line. It jumps

according to the state of a test-point: 1(activated) or 0 (deactivated).
PROCESS CONTROL
GOTO: This instruction is used to jump to another line in the process (pointed by a
flag).
USER MANUAL
PRINT LABEL: Prints a label selecting the label filename and the printer port.
NOTE:
Serial printing does not check communication whereas parallel printing

does.
END: ends the process execution.
INPUT/OUTPUT
OUTPUT: This instruction is used to activate or deactivate one of the eight Testem-
R outputs.
IF INPUT: Conditional jump to a different process line. It jumps according to the

state of an input.
USER MANUAL
ELECTRICAL TEST
TEST: This instruction is used to test a harness. To test the harness is necessary to
choose the compiled harness file name, the test mode (Normal or Once OK) and
the parts to test (Hardware, Locks, Detections and Wires).
The Harness file path can contain @REF. During compilation time @REF will be
changed to the reference name (it is necessary to use the same test process in
different references).
See 5.1.2. Electrical test details for more information about electrical test
options.
IF TEST RESULT: This option is a conditional jump to a different process line. It

jumps if the result of the last test is correct or not. This instruction can be affected
by a Test or a Test capacitor instruction.
USER MANUAL
TEST CAPACITOR: This instruction is used to test capacitors between two test-
points, indicating the nominal value of the capacitor and the tolerance value.
Nominal Value: capacitor nominal value (for instance in Farads).

Calibration value: value obtained in calibration mode for this capacitor.
Calibration mode: if the calibration mode is selected, during the
execution of this command only the calibration value will appear on the
screen until Esc key will be pressed.
See 5.1.2. Electrical test details
SET LED: This instruction is used to light all the leds of the connectors that are
included in a harness.
Status: light (ON) or turn off (OFF) the leds.

Harness: path and file name of the harness compiled file. Notice that, like
TEST command, @REF can be used instead of a fixed reference.
COUNTERS
RESET COUNTER: Initialize to zero a reference or global counter.
USER MANUAL
INCREASE COUNTER: Increases a reference or global counter.
SET COUNTER: Initializes a counter with a numeric value. Selecting value it will be
initialized to the specified constant value. If one numeric type variable from the
list is selected (counters, date and date), it will take the current value of this
variable.
IF COUNTER: Conditional jump to a different process line. It jumps according to the

value of a reference or global counter.
USER MANUAL
4.3.3. Variables
The following is a list of all the variables available in the Testem-R.
@YR[Fx] Year (2 digits by default).

@MH[Fx] Month (2 digits by default).
@MHFT Text month (Jan,Feb,Mar,..).
@DY[Fx] Day (2 digits by default).
@DAYJUL[Fx] Day of the year.

st
@WEEK[Fx] Week of the year (the first week is the one which contains Jan 1 . Monday first
day of the week).
@HR[Fx] Hour (2 digits by default).
@MN[Fx] Minute (2 digits by default).
@SC[Fx] Seconds (2 digits by default).
@REF Current testing reference name.
@BOARD Test board name.
@USER Users id.
@RSTR0 to @RSTR7 Static Reference Strings. They are stored in flash memory until a new
memory card is downloaded. They can be initialized in WinTestem (Testem-R -> File Manager).
There are 8 strings available for each reference, 16 characters long each one.
@STR00 to @STR15 Volatile Strings. They are 64 characters long and are erased always at
the process beginning.
@RC0[Fx] to @RC2[Fx] Specific counters for each reference. Stored in Flash memory and
only erased when a memory card is downloaded.
@C0[Fx] to @C2[Fx] Global counters, modifiable from all references test processes. Stored
in Flash memory until a memory card is downloaded.
If these variables are used during process execution, they will be replaced by their current value. They
can appear in the following cases:
In a label file: variables will be replaced by their value when a print label command starts.
In a show command, variables will also be replaced by their actual value.
In a Set string command.
The [Fx] after a numeric variable name is used to define its format (number of characters). For instance,
suppose that @C1 has the value 21, then:
@C1F7 would be 0000021

@C1F3 would be 021
@C1F0 would be 21.
If [Fx] is not written, numeric variables will be printed in their default format (2 digits for date/hour
variables and like F0 for the others).
USER MANUAL
4.4. Data Manager
4.4.1. The Data Manager main

main screen
The File Manager, located in Programming -> Extras -> Testem-R -> Data Manager, is the part of
Testem-R software in charge of compiling and creating the file that contains all the information to be
compiled for one Testem-R.
Figure 9: Data Manager screen
GENERAL OPTIONS
LOAD: Open an existent File Generator file (.fg).
SAVE: Save the current .fg file.
BUILD: Compile and generate the .tr file in the target folder.
QUIT: Quit the Testem-R Data Manager.
BROWSE: This instruction is used to select the path of the .tr file created after
compilation.
ADD REFERENCE: This instruction is used to add a reference to the list.
USER MANUAL
REMOVE REFERENCE: This instruction is used to remove a reference from the list.
NOTES:
A .fg file contains a list of all the references that will be tested on a specific test-board.
It is recommended that a different WinTestem working folder is created for each test board,
with a file generator file for each, which will contain the references to be tested on that
board.
When a compilation succeeds, the .tr file is created. This is the file that will be uploaded to
the Testem-R through a USB stick. Testem-R does not support long file name, so long names
will be adapted by the Testem-R to the DOS format.
4.4.2. Adding new references
To add a new reference to the current file, click the Add Reference icon. The following dialog box will
appear:
Figure 10: Adding a new reference
Notice that a different test process can be selected for each reference. It can be useful to adapt to
special features of a harness (specific component to test, special label for one reference, etc.)
To assign an initial text to the static reference strings (see 3.3.Variables) click Static Reference
Strings button.
USER MANUAL
Figure 11: Static references
These strings can be used in the process (@RSTR0 to @RSTR7).
4.4.3. Compilation
Clicking build icon the compilation starts. If an error is detected the compilation will stop and will
show the error messages in the output text box. If it succeeds, then the .tr file will be created and
ready to be copied to the Testem-R using a USB pen drive.
Compilation notes:
At least one reference with a Test process instruction must be included, because the board
pins definition is taken from the compiled harness file.
The compiler will check that all the tested harnesses have the same board definition.
USER MANUAL
5. Control panel
When Testem-R is turned on the main menu appears. In this screen the user can choose one of three
submenus: test, maintenance and set-up.
Test: to start harness test.

Maintenance: system checking.
Set-Up: to change the equipment configuration.
01/01/12 08:00:55
1. TEST
2. MAINTENANCE
3. SET-UP
Figure 16: Main menu
5.1. Test Menu
5.1.1. Starting to test a reference
The Test menu is used to start a harness test. When test option is selected, an identification screen can
be shown depending on the configuration (see point IV.3. Set-up). There are two ways to enter the user
identifier: manual using the keypad, or using a scanner. This entered code will be stored in @USER
variable. This step can be also disabled in the set up menu.
The following is the screen shown in keypad mode:
------- TEST -------
Enter user id.

_
Figure 17: User Id.
Notice that it is not necessary to type a code. You can press Ok to continue.
------- TEST -------
Scan user id.
Figure 18: Scanning user barcode
After that, the operator must select which reference has to be tested. There are two different ways to
do it: using a scanner or selecting the reference with the keypad (manual selection). Both ways can be
configured in the set-up menu.
USER MANUAL
If scanner mode is selected, the system will wait until a barcode containing a valid reference
name is read. Then the test process will start automatically.
------- TEST -------
Waiting scanner
Figure 19: Scanning harness reference
In manual selection mode the reference to test is selected from a list using the left and right
arrow keys to choose the desired one. Pressing return key the process will start.
01/01/12 08:00:55
< 82141-05880 >
Figure 20: Manual selection
5.1.2. Electrical test details
There are three different test modes, selectable in the process instruction parameters:
Normal mode:
The test is passed only if a complete test without errors has happened. When an error
is solved, another test is started from the beginning.
Once OK:
One part is considered ok when it has been correct one time. After that, it will not be
checked. The parts that are still not ok are continuously scanned. It can be useful for
those tests when it is difficult to keep all elements inserted in the counterparts, like
clips test. It is only available for locks and detections.
Once OK sequential:
Equivalent to Once Ok mode, but only the current error is checked. It is useful to
force a fixed order in the test. It is only available for locks and detections.
USER MANUAL
There are four possible test steps, which are optional:
Hardware:
This test checks the correct isolation between free pins (not connected) and the rest of the rack
pins. It activates each free pin, checking that the other pins are not active. This is an example of
a hardware error, which means that an error appear (one active point) when activating
card/pin 1/6.
HARDWARE ERROR
C/P: 01/06
Figure 21: Hardware error
Locks:
This test checks the correct insertion of connectors in the counterparts. The system will ask for
those connectors that have at least one wire or detection programmed, and only if the lock pin
has been defined in the board edition. Two kinds of error can appear in this test step:
MISSING CONNECTOR
Con_A
Figure 22: Missing connector
EXTRA CONNECTOR
Con_A
Figure 23: Extra connector
Detections:
Detections test checks all the programmed detections, activating one of its test points, and
checking the others state. Two different error messages can appear, depending on the real and
the programmed state of a detection. The name of connector and detection is shown:
MISSING DETECTION
Con_A
spacer
Figure 24: Missing detection
USER MANUAL
EXTRA DETECTION
Con_B
spacer
Figure 25: Extra detection
Wires:
Wires test checks the programmed wiring of the harness. Short circuit and Open are the
possible errors.
OPEN 1.0e+02
Con_A Con_B
001 BK/WH/RD 002
[wire_name]
Figure 26: Open circuit
SHORT 1.0e+02
Con_A Con_B
003 002
Figure 27: Short circuit
Testem-R v2012 has the ability to perform analog test. The difference between the analog and
the standard (digital) test is the possibility to regulate the resistance threshold during the test,
in this case between 50 Ohms and 100 kOhms.. The resistance threshold is the value in ohms
for which the test equipment decides whether a single wire is good or bad in terms of
continuity parameters.
Using this feature, the electrical test of wires can be done in two steps:
Continuity test: moving the resistance threshold to a low level in ohms ensures that
after the test, the harness will not have any wire with a big resistance (a wire of
very bad quality).
Isolation test: moving the resistance threshold to a high level in ohms ensures that
after the test, the harness will not have any non programmed contact between
empty cavities, between wires or between empty cavities and wires.
During the electrical test, the used resistance threshold will be shown at the top-left part of the
display. See figure 26 and 27, where a 100 Ohm threshold is used.
See the table below for further details concerning Continuity and Isolation test steps.
USER MANUAL
Case Schema Desired Actual Test Test result

resistance resistance
2 wire ends Very low Very low Continuity Good continuity
Not very low Continuity Bad continuity
2 empty Very high Very high Isolation Good isolation
cavities Not very high Isolation Bad isolation
Empty cavity Very high Very high Isolation Good isolation
and wire end Not very high Isolation Bad isolation
2 ends of Very high Very high Isolation Good isolation
different Not very high Isolation Bad isolation
wires
5.1.3. In-
In-test maintenance options
Test Probe
During a test, when an error is shown on the display, the user can start a probe test pressing key 1.
This test will be finished pressing Esc key, then the previously displayed error will be shown to follow
with the normal test. See 2.1 Test Probe for further details.
Errors shifting
Sometimes it is useful for the operator to see more than one error to understand what is wrong in the
harness. There is an option to check the list of errors.
During hardware and wires test, other errors can be displayed pressing the down arrow key.
During locks and detections test, pressing up and down arrows the list of unsolved parts will
appear. Pressing Esc key the normal test will continue.
Process information
Pressing 2 during the electrical test, a screen with information about user and reference will appear.
Press Esc to return to the test.
01/01/12 08:00:55
Ref: 82141-05880
User: 123
Figure 28: Process information
5.1.4. Capacitor test
Normal and calibration modes
To test a capacitor, the calibration value is needed. To obtain this value:
USER MANUAL
1. Create a process with a Test capacitor instruction included in calibration mode.
Figure 29: Capacitor options for calibration
2. Run this process on the board with the harness and the capacitor correctly inserted on it.
3. A screen similar to the following one will be shown. The capacitor is continuously tested,
and the calibration value updated. Write down this value and then include it in the process
instruction, now in normal mode.
CAPACITOR TEST
calibration value:
1.8e03
PRESS A KEY TO ABORT
Figure 30: Capacitor test screen with calibration mode
Notice that, in Testem-R v2012, the calibration value has been rescaled so that normally will be close to
the real value of the capacitor in nF. So, a 100nF capacitor will normally get calibration values close to
100, while a 470uF capacitor will return approximately a calibration value of 470000.
Figure 31: Capacitor options after calibration
USER MANUAL
During a normal capacitor test, this information is shown:
CAPACITOR TEST
1.00e-6 +/- 15%
Tested value:
1.24e-6
Figure 32: Capacitor test screen
The capacitor is continuously tested until the value is in the specified range, or the test is cancelled
pressing Esc. The test result can be checked using If Test OK instruction.
5.2. Maintenance menu
5.2.1. Test probe
If a ground signal is applied on a test point using a probe, its description will appear on the screen.
Depending on the type of test point this screen shows:
Way type: card/pin, connector name and way number.
---- Probe Test ----

CT5-002
C/P: 01/20
0001/0003 >
Figure 33: Probe test way type pin
Detection type: card/pin, connector name and detection name

SPACER
C/P: 02/17
< 0003/0003
Figure 34: Probe test detection type pin
Free pin: card/pin.
C/P: 03/54
< 0002/0003 >
Figure 35: Probe test way-type pin
USER MANUAL
Special modes:
All test points Mode: Lock detections and leds could disturb the user during a probe test on a
test board with a harness inserted in its counterparts. So by default they are not shown in the
probe test. Press key 2 to see also the active pins which are defined as locks or leds (All test
points mode) and Esc to disable this special mode (return to Normal mode).
Wires Mode: If Probe Test is accessed during the electrical test (by pressing key 1), the user can
also check the wires related to the test point currently displayed, and also check either if they
are OK or not.
o Press key 1 another time to enter this mode.
o The list will include all the wires going to the test points that the tester should find as
active when it is activated.
o Notice that Testem-R will display the list of wires that should be connected to that test
point according to the harness being tested in that moment.
o This mode latches the state when the user presses key 1 and it does not refresh the
state of the wires (OK or not OK) until the user exits this mode and enters another
time.
o In Wires mode, the following information is shown (both screens are displayed
intermittently to show all the information):
--- Probe (Wires) --

BK/WH/RD (!)
[wire name]
< 0002/0003 >
Figure 36: Probe test wires mode (1)
--- Probe (Wires) --

Con_A Con_B
001 OK/NOK 002
< 0002/0003 >
Figure 37: Probe test wires mode (2)
In this mode the symbol (!) is always shown meaning that it may be not the current state of
the wires (it shows the state when this mode was accessed).
Important notes:
If more than one test-pin is activated, the user can navigate through a list using left and
right arrows.
The test probe screen shows a list of the last activated points. The user can leave the probe
disconnected to check the information on the screen. When the probe is not connected,
the symbol (!) will be shown meaning that there are not any active test points (the tester
shows a copy of the last test points that were activated).
This test is only available if the equipment has been previously programmed (board
information is set with WTT).
USER MANUAL
5.2.2. Inputs
This screen shows the state of the 8 inputs. If one of them is activated the white spot under the input
number becomes black.
------ INPUTS ------
0 1 2 3 4 5 6 7
O O O O O O O O
Figure 38: Inputs test
5.2.3. Outputs
In this screen the 8 output relays can be tested. To toggle a relay status, keys from 0 to 7 must be
pressed. When an output is activated, the white spot under the output number becomes black.
------ OUTPUTS -----
0 1 2 3 4 5 6 7
O O O O O O O O
Figure 39: Outputs test
5.3. Set-
et-up
In this version of firmware, there is the following new feature: to forbid the operator to access the set-
up menu, the system asks for a password.
------ SET-UP ------
Enter password
***
Figure 40: Set-up password
By default this password is empty, so by pressing enter the user will access to the set-up menu. If you
input a wrong password, the next screen will be shown:
Wrong password
Figure 41: Wrong password
If you have forgotten the password, after three bad attempts the next screen will be shown:
USER MANUAL
-- PASSWORD RESET --
Testem-R code 961999
Emdep code
_
Figure 42: Password recovery
In this case, send the Testem-R code to Emdep, and we will send a code to reset the password.
Through Set-up menu, the user can change the Testem-R basic settings and load new data. This part is
organized according to this map:
------ SET-UP ------ ---- TEST SET-UP --- ---- TEST DATA -----
1. Test set-up 1. Test data 1. View/Select file
2. User options 2. Ref. Select Mode 2. Copy from USB
3. Time/Date Set-Up 3. RS232 Display 3. Delete a file
-- REF. SELECTION --
1. Manual selection
2. Scanner
-- RS-232 DISPLAY --
1. COM1
2. COM2
3. Disabled
--- USER OPTIONS---- ----- USER ID ------

1. User Id. required 1. Disabled
2. Change password 2. Keypad
3. Select language 3. Scanner
----- PASSWORD -----
New password:
----- LANGUAGE -----

-- TIME/DATE SETUP -
< ENGLISH >
Enter Time:
:
Figure 43: Set-up menus
5.3.1. Test data
Test data can be managed using the "Test Data" menu. There are the following options:
1. View/Select file
With this option the configured working file will be shown, and the user will be allowed to select
another project file from the internal memory (1. Change).
USER MANUAL
--- WORKING FILE ---

PROJECT1.TR
1. Change
Esc. Exit
Figure 44a: Working file menu
If "Change" is selected, a file navigator will appear on the display. Press up/down in order to select the
desired file. If Ok is pressed, the file will be set as new working file. Press Esc to exit without changes.
>0:/PROJECT1.TR New working file: --- WORKING FILE ---

0:/PROJECT2.TR | 0:/PROJECT2.TR PROJECT2.TR
| 1. Change
Esc. Exit
Figure 44b: file navigator / new working file
2. Copy from USB
With this option the user can load a file from a USB pen drive. If no USB stick is detected, the following
message will be shown:
No USB drive
was detected
Figure 45: No USB drive detected
If a USB drive is connected, a file navigator will be shown. Notice that only ".TR" files located in the root
directory will be shown.
>PROJECT1.TR
PROJECT2.TR |
PROJECT3.TR |
PROJECT4.TR |
Figure 46a: TR files in the USB stick
If a file is selected by pressing "OK", that file will be automatically copied to the internal SD memory and
set as new working file.
File successfully New working file:

Copying file copied and set as 0:/PROJECT2.TR
new working file
Figure 46b: Copying from USB to internal memory
USER MANUAL
3. Delete a file
With this option the user can delete a project file from the internal SD memory. A file navigator will be
shown. If some file is selected by pressing OK, the system will ask for a confirmation:
>0:/PROJECT1.TR 0:/PROJECT1.TR
0:/PROJECT2.TR | File will be erased
| Are you sure?
Press OK / Esc
Figure 47: No USB drive detected
5.3.2. Reference selection

selection mode
Here the user can select how the operator will select the reference to be tested.
-- REF. SELECTION --
1. Manual selection
2. Scanner
Figure 48: Reference selection mode
When the first option is selected, the operator will see a list of references on the screen (see IV.1).
With the second option the operator must scan a barcode where the text is equal to a reference name.
When scanner is selected, the following options about the desired part of the barcode will be asked:
-- REF CUT STRING --

> FIRST 3
LENGTH 5
--XXXXX---------
Figure 49: Cut string (1)
In the test menu, the scanned and the cut strings are shown:
------- TEST -------

AAAREF01AAA
TESTING REFERENCE
REF01
Figure 50: Cut string (2)
5.3.3. RS-
RS-232 Display
This menu refers to the Serial Display (3EESD-01) that can be connected to the Testem-R through a serial
port.
USER MANUAL
-- RS-232 DISPLAY --
1. COM1
2. COM2
3. Disabled
Figure 51: RS-232 Display menu
5.3.4. User Id. required
Here the user can select how the operator will introduce his personal code (variable @USER).
------ USER ID -----

1. Disabled
2. Keypad
3. Scanner
Figure 52: User id. mode
Selecting the first option (Disable), when the operator enters the test menu, the system will show the
reference selection screen directly, and @USER variable will remain empty.
If the keypad option is selected, the operator must enter his code using the keypad of the Testem-R.
With the third option the operator must scan a barcode where the text is equal to a reference name.
5.3.5. Password
In this screen the user can change the password that will be asked to enter the set-up menu.
----- PASSWORD -----
New password
***
Figure 53: New password
The new password will be asked twice to avoid a possible mistake.
5.3.6. Language
This option is used to select the language using the arrow keys.
USER MANUAL
----- LANGUAGE -----
< ENGLISH >
Figure 54: Language selection
The pre-programmed languages in Testem-R are English, Spanish, French, Portuguese, Romanian, Polish
and Slovak, but other languages can be programmed. The default language is English.
5.3.7. Time/Date Set-

Set-Up
This option is used to set the internal clock date and time.
Enter Time:
_1:42
Figure 55: Time setup
Enter Date:
_2/12/11
Figure 56: Date setup
6. Firmware update
Upgrading the Testem-R firmware is fast and simple. The following steps must be followed:
1. Switch off the equipment, using the main switch located in the rear panel.
2. Press and keep pressed the "Esc" key, while you switch on the power.
3. Release the Esc key.
4. Insert the USB pen drive containing the firmware hex file renamed to "3EETR_FW.hex".
5. The firmware will be automatically overwritten and when finished, it will reboot and start
normally with the new version.
Do not remove the USB drive while updating.

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TESTEM-R

COMPACT STAND-ALONE HARNESS ANALYSER

Document history and versions

1. Overview and applications ................................................................................................................... 4

5.2. Maintenance menu ................................................................................................................... 29

1. Overview and applications

Analog test mode (programmable resistance threshold).

Power supply Voltage 88 ~ 264VAC, 47 ~ 63Hz

AC current 1.3A/115VAC 0.8A/230VAC

Electrical test Hardware self-test Yes

Connector locks test Yes

Detections test Yes

Open circuit test Yes

Short-circuit test Yes

Resistance threshold Programmable 50 - 100k ( 5%)

Diodes Polarity, Vf* (0-5V)

Resistors* 50 - 100k ( 5%)

Capacitors 10nF 1mF ( 5%)

Test modes Normal, Once OK, Once OK Sequential

Test points Test points 128 std version, up to 256

Test voltage/current 0 - 5V / 0 2.2mA

Counterpart Leds All test points can drive Leds

Led power supply voltage 5V

Connectivity Inputs 8 optocoupled inputs

Outputs 8 relay outputs

RS-232 for printers/scanners 2 ports

Parallel Printer port 1

Ethernet 10/100 Mbps

Operator interface Display Alphanumeric LCD 4x20

Acoustic signals Included buzzer

Buttons Numeric keypad

Languages English, Spanish, French, Portuguese, Romanian, Polish

Programming and variables Software Wintestem

Test process Programmable, full command set.

Variables Counters and string variables

Data transfer Standard USB pen drive

Internal memory 2GB (microSD)

Firmware upgrade Standard USB pen drive

* Supported by Hardware, not implemented in current firmware

Figure 1: Front view

Parallel printer port

Slots for test

Ground socket USB

Figure 3: I/O connector

Pin Description Pin Description

Table 1: I/O pinout

3.3. Serial ports

Default parameters: 9600 bauds/8 data bits/1 stop bit/No parity

3.4. Ethernet connection

3.5. Test board and counterparts

3.6. Installing the software

4. Programming with Wintestem

The number of test cards can be up to four (256 test points).

4.2. Harness compilation

Figure 7: Harness compilation

4.3. Process editor

4.3.1. Main screen

Figure 8: Process editor

NEW PROCESS: Create a new process.

LOAD PROCESS: Open a created process.

SAVE PROCESS: Save the current process.

PRINT PROCESS: Send the process to the default printer.

DELETE INSTRUCTION: Delete an instruction line.

QUIT: Quit the process editor.