CCT-100 Cable tester User’s Guide

CCT-100

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.

Identification:

CCT-100 Features

  1. Power Button
  2. Learn Button
  3. Power Connection (12V DC)
  4. Display
  5. Indicator light
  6. Connector board ports
  7. Connector board supports (6x)

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.

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.

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.
  • Plug in the power cord and turn on the CCT-100
    1. The Display will briefly flash “Calibrate” as the unit runs a self-diagnostic test.
    2. After calibration, the display will show either “READY” or “EMPTY”.  A “READY” display indicates a known good cable is stored in memory.  An “EMPTY” display indicates there is nothing stored in memory.
      1. The indicator light will be blue which means that the CCT-100 is not detecting continuity between any of its 52 test points.

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.

Theory

Cosam CCT-100 series testers work on a simple continuity principal.  Each of the 52 test points are sequentially powered with a 5 volt signal and the remaining 51 test points are scanned for a voltage reading.  All points higher than 3 volts are stored in memory.  Then, the next pin is powered and all other points with a voltage reading are identified.  The current point voltages are combined with the results of the previous points and after all 52 points have been evaluated, a geometric progression is used to obtain a unique value.  Because the number of combinations (251) or a sexdecillion is too large to practically view, the value is converted to hexadecimal and then sent to the display.

By the method above, the CCT-100 looks for continuity in both directions.  This is extremely valuable when testing cables with 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 will detect it, because pin 7 will not show pin 43 as a connect and 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, a cable for some reason had a capacitor inside of it, then the testing results would be erratic because the capacitor will store high voltage.  Personal injury via electric shock as well as damage to the CCT-100 may occur.

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 because they last longer.  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

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.

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 12VDC, center pin positive      5 mm x 2.1 mm and produces a minimum of 200mA.
  • Test Voltage: 5 VDC
  • Test Current: 15 mA Max
  • 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)
  • RoHS 2, China RoHS 2 and ECHA Reach (SVHC-173) Compliant

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.

Trouble Shooting:

Condition Possible Resolution
When unit is switched on, there is no power. 1)      The Power supply is defective.  Make sure there is 12VDC from the power supply.  Replace if necessary.

2)      There is an internal problem with the CCT-100.  Contact factory for repair or replacement

When unit is switched on, the indicator light is either red or green, but not Blue as it should be 1)      The CCT-100 is detecting a connected cable. Remove all test cables and connector boards and try again.  Inspect transition cables and connector boards for damage.

2)      Verify there is no debris on the CCT-100 connector ports.

The unit is displaying a different unique code for a known good cable. 1)      Swap the positions of the connector boards.  If this doesn’t work, then switch them back.

2)      Verify the same connector boards, and transition cables are identical to the originals.