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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
Contents
Contents
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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
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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
Testem-R is a standalone equipment appropriate for the electrical test of small wiring harnesses, clips
tables or assembly stations. Main features:
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
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USER MANUAL
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Engineering Department
3EETR TESTEM-R V2012
USB 2.0
RTC Included
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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
3. Installing
Installing the Testem-
estem-R
3.1. Testem-
Testem-R main parts
Hexadecimal
keypad
Display
Test Probe
socket
Serial Ports
COM1/COM2
115/230VAC
socket & switch
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USER MANUAL
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IM041 - 02/01/2012 1.0 Joan de Magriny
Engineering Department
3EETR TESTEM-R V2012
3.2. Input/output
Input/output connectors
Connector pin out:
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.
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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
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.
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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
4.1. Set-
Set-up
Before starting to program the harnesses, there are some important questions about Wintestem set-up
to consider:
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.
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Engineering Department
3EETR TESTEM-R V2012
A new process editor graphical environment has been created for Testem-R, located in Programming,
Extras, Testem-R, Process Editor.
General options:
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USER MANUAL
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Engineering Department
3EETR TESTEM-R V2012
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:
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:
INSERT HARNESS
Notes:
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Engineering Department
3EETR TESTEM-R V2012
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:
--------------------
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Engineering Department
3EETR TESTEM-R V2012
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)
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).
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.
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Engineering Department
3EETR TESTEM-R V2012
PIN MANAGEMENT
PROCESS CONTROL
GOTO: This instruction is used to jump to another line in the process (pointed by a
flag).
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3EETR TESTEM-R V2012
PRINT LABEL: Prints a label selecting the label filename and the printer port.
NOTE:
INPUT/OUTPUT
OUTPUT: This instruction is used to activate or deactivate one of the eight Testem-
R outputs.
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Engineering Department
3EETR TESTEM-R V2012
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.
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Engineering Department
3EETR TESTEM-R V2012
TEST CAPACITOR: This instruction is used to test capacitors between two test-
points, indicating the nominal value of the capacitor and the tolerance value.
SET LED: This instruction is used to light all the leds of the connectors that are
included in a harness.
COUNTERS
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3EETR TESTEM-R V2012
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.
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USER MANUAL
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Engineering Department
3EETR TESTEM-R V2012
4.3.3. Variables
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:
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).
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3EETR TESTEM-R V2012
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.
GENERAL OPTIONS
BUILD: Compile and generate the .tr file in the target folder.
BROWSE: This instruction is used to select the path of the .tr file created after
compilation.
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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.
To add a new reference to the current file, click the Add Reference icon. The following dialog box will
appear:
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.
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USER MANUAL
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Engineering Department
3EETR TESTEM-R V2012
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.
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USER MANUAL
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Engineering Department
3EETR TESTEM-R V2012
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.
01/01/12 08:00:55
1. TEST
2. MAINTENANCE
3. SET-UP
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.
Notice that it is not necessary to type a code. You can press Ok to continue.
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.
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3EETR TESTEM-R V2012
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.
Waiting scanner
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
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.
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3EETR TESTEM-R V2012
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
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
EXTRA CONNECTOR
Con_A
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
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3EETR TESTEM-R V2012
EXTRA DETECTION
Con_B
spacer
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]
SHORT 1.0e+02
Con_A Con_B
003 002
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.
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3EETR TESTEM-R V2012
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
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3EETR TESTEM-R V2012
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
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.
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3EETR TESTEM-R V2012
CAPACITOR TEST
1.00e-6 +/- 15%
Tested value:
1.24e-6
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.
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:
C/P: 03/54
< 0002/0003 >
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3EETR TESTEM-R V2012
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):
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).
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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.
0 1 2 3 4 5 6 7
O O O O O O O O
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.
0 1 2 3 4 5 6 7
O O O O O O O O
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.
Enter 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
If you have forgotten the password, after three bad attempts the next screen will be shown:
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-- PASSWORD RESET --
Testem-R code 961999
Emdep code
_
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
New password:
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).
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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.
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
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 |
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.
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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
Here the user can select how the operator will select the reference to be tested.
-- REF. SELECTION --
1. Manual selection
2. Scanner
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:
In the test menu, the scanned and the cut strings are shown:
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.
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-- RS-232 DISPLAY --
1. COM1
2. COM2
3. Disabled
Here the user can select how the operator will introduce his personal code (variable @USER).
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.
New password
***
5.3.6. Language
This option is used to select the language using the arrow keys.
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3EETR_MANUAL_EN_v2011.1.0.docx - EMDEP 2012
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
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.
This option is used to set the internal clock date and time.
-- TIME/DATE SETUP -
Enter Time:
_1:42
-- TIME/DATE SETUP -
Enter Date:
_2/12/11
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.
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3EETR_MANUAL_EN_v2011.1.0.docx - EMDEP 2012