CCT-100 User’s Guide

The CCT-100 is a very simple and intuitive cable verification device.  The system works by memorizing the connections of a known good cable and then comparing those connections to a single or group of test cables.

User’s Guide Identification:

1. Power Button
2. Learn Button
3. Power Connection (5 V DC)
4. Display
5. Indicator light
6. Connector board ports
7. Connector board supports (6x)

User’s Guide Features:

• Capable: 52 Testpoints (Cables up to 26 wires) Detects Opens, Shorts, Miss-wires, Bad connections and Diode polarity.
• Versatile: Many standard connector boards available as well as a build-your-own option for specialized connectors.
• Compact: 75” x 3.5” x 2.0” (197mm  x89mm x 51mm)
• Rugged: Made from 18 gauge cold rolled steel
• Fast: Tests at speeds up to thirty times per second.
• Intuitive: Easy to read status updates shown on the clear and bright OLED display along with Simple Pass/Fail indication by both green/red LED and dual tone audio buzzer.

User’s Guide Quick Start

• PREPARE: Install Connector Boards and/or interface cables and make sure no cables are connected to the unit.
• POWER-UP: Plug in the power cord and turn on the CCT-100.  The cable tester will perform a self-diagnostic check, and the display will show either  “READY”  or  “Empty”.  The indicator light will be bluel.

WARNING!  Do not test connected cables.  Cables connected to a power supply or power storing device may cause personal injury due to shock electric shock and will damage the CCT-100 and void the warrantee.

• LEARN: Attach a “known good cable” to the connectors on the connector boards.
  1. A green indicator light means that the current cable matches the last cable stored in memory.  The display will show a unique cable code.
  2. A red indicator light means that the current cable does not match the last cable stored in memory.  To store the currently connected cable in memory, press and release the “Learn” button.  The indicator light will then turn green and a unique cable code will appear in the display.
  3. {Optional} To test this type of cable again at a future date, record the unique code. At a future date, a “known good cable” will not be necessary.  Simply compare the unique code of the current cable with the one that you have recorded.  Cables that have the same unique code are electrically identical.
• TEST: Remove the known good cable and connect a test cable
  1. A green light indicates a good test cable because it electrically matches the known good cable.
  2. A red light indicates a bad test cable because it electrically does not match the known good cable.
• REPEAT: Repeat Test for all other test cables.

꙳ How to establish a “known good cable” – There are several ways to establish a known good cable.  The easiest way is to use a cable that is working in the application.  When that is not possible or practical, test the cable with a multi-meter or continuity measuring device.

User’s Guide Detailed Operation Instructions:

• Install connector boards (if Required)
  1. Align the boards directly over the connectors and push straight down allowing the three alignment posts to pass thru the board. The ball shaped tops of the alignment posts hold the connector boards in place without any additional hardware.
• Remove all cables from the cable tester during Power-up. This allows the unit to run a diagnostic check and fully calibrate itself.  (If your model does not have a battery, then plug in the power cord)

• Turn on the CCT-100
  1. The Display will briefly flash Cosam followed by a software revision number as the unit runs a self-diagnostic test.
  2. if the self-diagnostic test passes, the display will show “READY” if there is a cable stored in memory or “EMPTY” if there is not.   The indicator light will be blue l meaning the CCT-100 is not detecting continuity between any of its 52 test points
  3. If the self-diagnostic test fails (The above does not happen), then there is an internal problem and the CCT-100 must be returned for service.

NOTE:   The CCT-100 keeps the last cable stored in its memory even when powered down. 

WARNING!  Do not test connected cables.  Cables connected to a power supply may cause personal injury due to shock and will damage the CCT-100 and void the warrantee. 

• Attach a known good cable
  1. The indicator light will be either red or green and there is a repeating audible beep. The beep tone coincides with the indicator light color allowing both audio and visual cable verification.
  2. A red indicator light means that the current cable does not match the last cable stored in memory.  To overwrite the memory with the connections of the current cable, press and release the “Learn” Button.  (This copies the cables connections into memory)  The Indicator light will then change to green and the audible tone will change as well.
  3. A green indicator light means that the current cable matches the last cable stored in memory.  The display will show a unique cable code.

 NOTE:  At this point, you may wish to write down the Cable Code shown on the display for later reference.  In the future this type of cable will not require a known good cable.  The cable can be verified by comparing the display of the current cable with the cable code written in the log.  If the cable codes match, then you have a known good cable and can store the value into memory by pressing the learn button.

 Disconnect the known good cable and connect a test cable to the cable tester

• 1. A green light indicates a good test cable because it electrically matches the known good cable.  The unique code in the display is identical to that of the known good cable.
  2. A red light indicates a bad test cable because it electrically does not match the known good cable.
• Continue testing all other test cables.

User’s GuideTheory

Cosam CCT-100 series testers work by reading continuity.  Each of the 52 test points are sequentially powered with a 5 volt test signal and the remaining 51 test points are scanned for a voltage reading.  All points that have a reading are stored in memory.  Then, the next pin is powered and all other points are scanned and stored in a separate memory location.  After all 52 points have been powered and scanned, a geometric progression is used to combine all connections into a unique value.  The number of possible combinations that these 52 pins can be connected is 2⁵¹ or a sexdecillion.  To reduce the number of digits required, the value is converted to hexadecimal code and then sent to the display.  This process occurs approximately thirty times per second.

By using the method above, the CCT-100 looks for continuity in both directions.  This is extremely valuable if the cable being tested has a diode or an LED embedded in it.   Because diodes only allow current to flow in one direction, if they are installed backwards the entire circuit changes.  For example, a cable to be tested has an LED installed between pin 7 and pin 43 with the anode connected to pin 7.  When the CCT-100 evaluates the cable it will determine that there is continuity from pin 7 to pin 43, but will not see continuity in the reverse direction (pin 43 to pin 7).  If the LED were installed backwards, the CCT-100 would detect it, fail the cable and display a different unique code.

Due to the fact that the CCT-100 works by measuring small voltages, it is very important that the cables being tested do not have any energy storing components in them.  For example, if a cable for some reason had a capacitor inside of it, then the testing results would be erratic and if the capacitor was charged with a high voltage, then personal injury via electric shock as well as damage to the CCT-100 may occur.

User’s Guide Connector boards vs. Interface cables

Connector boards provide the fastest and most trouble free testing.   They are faster than interface cables because they only require one hand to install or eject. They are more reliable and they last longer because there are no wires to bend or twist.  Interface cables, on the other hand, are much less expensive and will work with almost any type of cable connector.  If you can’t find a connector board for your application, then there are a couple of options.

1. You can purchase a Build-your-Own connector board along with the mating connector to your cable.
2. You can purchase an interface cable along with the mating connector to your cable

User’s Guide How to make your own Interface cables

Making your own interface cables is a fast and simple process.  You will need to purchase the mating connectors for the cables you will be testing as well as a cable to connect to the CCT-100.

User’s Guide Specifications:

• Input Voltage: The Power supply shipped with the CCT-100 is a standard 120/240VAC Class 2 US style plug.  The connector is a 5 VDC, center pin positive      5 mm x 2.1 mm and produces a minimum of 200mA.  Do not use a power supply with more than 5 VDC on the battery powered model or damage will occur.
• Test Voltage: 5 VDC
• Test Current: 15 mA Max
• Maximum detectable Resistance: 50kΩ (± 10%)
• Temperature Range: -20°C to 60°C   (-4 F to 140°F)
• Size: 75” x 3.5” x 1.5” (197mm  x89mm x 38mm)

User’s Guide Maintenance

Tester Maintenance:   The CCT tester requires no maintenance.  Clean the outside surfaces with a mild cleaner.  Use a vacuum to remove accumulated debris on the connector board ports.

Connector Board Maintenance:  The contacts must be clean, because dirty contacts will produce intermittent connections.  After thousands of repeated insertion cycles the gold plating on the connectors will begin to wear off.  The depleted gold surfaces cause higher connection resistances which will eventually lead to replacing the connector board.

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User’s Guide Trouble Shooting: