Elenco | TCT255K | Owner Manual | Elenco TCT255K DataCom Tester Kit Owner Manual

Elenco TCT255K DataCom Tester Kit Owner Manual
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:16 AM Page 1
MULTI-NETWORK CABLE TESTER KIT
MODEL TCT-255K
Assembly and Instruction Manual
ELENCO
®
Copyright © 2016, 2001 by ELENCO® Electronics, Inc. All rights reserved.
REV-E
Revised 2016
No part of this book shall be reproduced by any means; electronic, photocopying, or otherwise without written permission from the publisher.
753089
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:16 AM Page 2
INTRODUCTION
The TCT-255 Cable Tester is a convenient
instrument for testing different unshielded wiring
schemed communication cable with RJ-11 and RJ45 connectors and coax cable. This tester can be
used for testing cables before and/or after they are
installed. The tester offers easy operation by having
to push only one button. Testing status is indicated
by multiple LEDs and an auto power-off function
maximizes battery life.
important, however, that good soldering practices
are used to prevent bad connections.
The actual assembly is broken into SEVEN
SECTIONS. After each assembly, you will be
instructed to make certain tests and measurements
to prove that each section is functioning properly.
The theory for each section, or stage, should be
read before the test is started. This will provide the
student with an understanding of what that stage
has been designed to accomplish, and how it
actually works. If a test fails to produce the proper
results, a troubleshooting guide is provided to help
you correct the problem. For testing you need to
have only a voltmeter for measuring DC and AC.
The unique design of the TCT-255 allows you to
place the parts over their corresponding symbol in
the schematic drawing on the surface of the PC
board during assembly. This technique maximizes
the learning process while keeping the chances of
an assembly error at a minimum. It is very
GENERAL DISCUSSION
You can see a block diagram of the TCT-255 in Figure 1 below.
STEP PULSES
Cable Tester TCT-200
COUNTER
POWER
SUPPLY
SWITCHES
INPUT & OUTPUT
CONNECTORS
OSCILLATOR
LED
INDICATOR
The TCT-255 Cable Tester has five basic blocks:
Figure 1
Terminator LD-100
INPUT & OUTPUT
CONNECTORS
CIRCUIT
IDENTIFY
POLARITY
1. Power Supply
It powers all of the circuits of the tester (not including the terminator). The power supply has a low battery
indicator (less than 7.5V) and a circuit to disconnect power 30 - 50 seconds after the last push on the
test switch.
2. Oscillator
Uses a 555 timer IC with two resistors and one capacitor. They control the free running frequency and
duty cycle.
3. Step Pulses with Counter
The outputs change by the positive pulses from the test button switch.
4. Switches and LED Indicator
It includes eight electronic switches for operating the indicators (16 LEDs).
5. Terminator
Connected to cable under test. Identifies the polarity signals.
-1-
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IDENTIFYING RESISTOR VALUES
Use the following information as a guide in properly identifying the value of resistors.
BAND 1
1st Digit
Color
Black
Brown
Red
Orange
Yellow
Green
Blue
Violet
Gray
White
Digit
0
1
2
3
4
5
6
7
8
9
BAND 2
2nd Digit
Color
Black
Brown
Red
Orange
Yellow
Green
Blue
Violet
Gray
White
Digit
0
1
2
3
4
5
6
7
8
9
Multiplier
Color
Black
Brown
Red
Orange
Yellow
Green
Blue
Silver
Gold
Resistance
Tolerance
Multiplier
1
10
100
1,000
10,000
100,000
1,000,000
0.01
0.1
Color
Silver
Gold
Brown
Red
Orange
Green
Blue
Violet
Tolerance
±10%
±5%
±1%
±2%
±3%
±0.5%
±0.25%
±0.1%
BANDS
Multiplier
2
1
Tolerance
IDENTIFYING CAPACITOR VALUES
Capacitors will be identified by their capacitance value in pF (picofarads), nF (nanofarads), or mF (microfarads).
Most capacitors will have their actual value printed on them. Some capacitors may have their value printed in
the following manner. The maximum operating voltage may also be printed on the capacitor.
If the capacitor is
connected with
incorrect polarity, it
may heat up and
either leak, or
cause the capacitor
to explode.
(+)
Axial
(–)
(+)
(–)
Polarity
marking
Radial
Means
Pico
nano
micro
milli
unit
kilo
mega
Multiply By
0
1
CERAMIC DISC
Second digit
101K
First digit
50V
1
10
2
First digit
Or
10-12
10-9
10-6
10-3
100
103
106
-2-
9
0.1
The value is 22 x 100 =
2,200pF or .0022mF, +5%, 100V
The value is 10 x 10 =
100pF, +10%, 50V
Multiply Unit By
.000000000001
.000000001
.000001
.001
1
1,000
1,000,000
8
MYLAR
Second digit
(may or may not appear
on the cap)
5
10k 100k .01
Multiplier
Tolerance*
The letter K indicates a tolerance of +10%
The letter J indicates a tolerance of +5%
1k
4
Tolerance*
Multiplier
* The letter M indicates a tolerance of +20%
3
100
Maximum working voltage
METRIC UNITS AND CONVERSIONS
Abbreviation
p
n
m
m
–
k
M
For the No.
100V
Warning:
Multiplier
2A222J
Electrolytic capacitors have a positive
and a negative electrode. The
negative lead is indicated on the
packaging by a stripe with minus
signs and possibly arrowheads. Also,
the negative lead of a radial
electrolytic is shorter than the positive
one.
Note: The letter “R” may be used at times
to signify a decimal point; as in 3R3 = 3.3
1. 1,000 pico units
= 1 nano unit
4. 1,000 milli units
= 1 unit
2. 1,000 nano units
= 1 micro unit
3. 1,000 micro units = 1 milli unit
5. 1,000 units
6. 1,000 kilo units
= 1 kilo unit
= 1 mega unit
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CONSTRUCTION
Introduction
The most important factor in assembling your TCT-255 Multi-Netwok Cable Tester Kit is good
soldering techniques. Using the proper soldering iron is of prime importance. A small pencil
type soldering iron of 25 - 40 watts is recommended. The tip of the iron must be kept clean
at all times and well tinned.
Solder
For many years leaded solder was the most common type of solder used by the electronics
industry, but it is now being replaced by lead-free solder for health reasons. This kit contains
lead-free solder, which contains 99.3% tin, 0.7% copper, and has a rosin-flux core.
Lead-free solder is different from lead solder: It has a higher melting point than lead solder, so
you need higher temperature for the solder to flow properly. Recommended tip temperature is
approximately 700OF; higher temperatures improve solder flow but accelerate tip decay. An
increase in soldering time may be required to achieve good results. Soldering iron tips wear
out faster since lead-free solders are more corrosive and the higher soldering temperatures
accelerate corrosion, so proper tip care is important. The solder joint finish will look slightly
duller with lead-free solders.
Use these procedures to increase the life of your soldering iron tip when using lead-free
solder:
● Keep the iron tinned at all times.
● Use the correct tip size for best heat transfer. The conical tip is the most commonly used.
● Turn off iron when not in use or reduce temperature setting when using a soldering station.
● Tips should be cleaned frequently to remove oxidation before it becomes impossible to remove.
Use Dry Tip Cleaner (Elenco® #SH-1025) or Tip Cleaner (Elenco® #TTC1). If you use a sponge
to clean your tip, then use distilled water (tap water has impurities that accelerate corrosion).
Safety Procedures
● Always wear safety glasses or safety goggles to protect your eyes when
working with tools or soldering iron, and during all phases of testing.
● Be sure there is adequate ventilation when soldering.
● Locate soldering iron in an area where you do not have to go around it or reach over it. Keep
it in a safe area away from the reach of children.
● Do not hold solder in your mouth. Solder is a toxic substance. Wash hands thoroughly
after handling solder.
Assemble Components
In all of the following assembly steps, the components must be installed on the top side of the
PC board unless otherwise indicated. The top legend shows where each component goes.
The leads pass through the corresponding holes in the board and are soldered on the foil side.
Use only rosin core solder.
DO NOT USE ACID CORE SOLDER!
Soldering Iron
Heat Sinking
Electronic components such as transistors,
ICs, and diodes can be damaged by the heat
during soldering. Heat sinking is a way of
reducing the heat on the components while
soldering. Dissipating the heat can be
achieved by using long nose pliers, an alligator
clip, or a special heat dissipating clip. The heat
sink should be held on the component lead
Heat Sink
between the part and the solder joint.
-3-
Solder
PC Board
Heat Sensitive
Component (Diode)
(this can be ordered as part of Elenco®’s Solder
Ease Kit Model SE-1).
Figure 6
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A poorly soldered joint can greatly affect small current flow in circuits and can cause equipment failure. You can damage
a PC board or a component with too much heat or cause a cold solder joint with insufficient heat. Sloppy soldering can
cause bridges between two adjacent foils preventing the circuit from functioning.
What Good Soldering Looks Like
Types of Poor Soldering Connections
A good solder connection should be bright, shiny, smooth, and uniformly
flowed over all surfaces.
1. Solder all components from the
copper foil side only. Push the
soldering iron tip against both the
lead and the circuit board foil.
Soldering Iron
Component Lead
1. Insufficient heat - the solder will
not flow onto the lead as shown.
Foil
Soldering iron positioned
incorrectly.
Circuit Board
2. Apply a small amount of solder to
the iron tip. This allows the heat
to leave the iron and onto the foil.
Immediately apply solder to the
opposite side of the connection,
away from the iron. Allow the
heated component and the circuit
foil to melt the solder.
3. Allow the solder to flow around
the connection. Then, remove the
solder and the iron and let the
connection cool. The solder
should have flowed smoothly and
not lump around the wire lead.
Solder
Soldering Iron
2. Insufficient solder - let the
solder flow over the connection
until it is covered.
Use just enough solder to cover
the connection.
Foil
Solder
Rosin
3. Excessive solder - could make
connections that you did not
intend to between adjacent foil
areas or terminals.
Soldering Iron
Foil
4. Solder bridges - occur when
solder runs between circuit paths
and creates a short circuit. This is
usually caused by using too
much solder.
To correct this, simply drag your
soldering iron across the solder
bridge as shown.
4. Here is what a good solder
connection looks like.
TROUBLESHOOTING
1. One of the most frequently occurring problems is poor
solder connections.
Solder
Component Lead
Gap
Solder
Soldering Iron
Foil
Drag
c) Solder should flow into a smooth puddle rather
than a round ball. Resolder any connection that
has formed into a ball.
a) Tug slightly on all parts to make sure that they
are indeed soldered.
d) Have any solder bridges formed? A solder
bridge may occur if you accidentally touch an
adjacent foil by using too much solder or by
dragging the soldering iron across adjacent foils.
Break the bridge with your soldering iron.
b) All solder connections should be shiny.
Resolder any that are not.
-4-
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PARTS LIST - SECTION A
SECTION A
Power Supply
RESISTORS
Qty.
r2
r1
r1
r1
Symbol
R12, R17
R16
R15
R9
Description
1kW 5% 1/4W
5.6kW 5% 1/4W
12kW 5% 1/4W
3.3MW 5% 1/4W
Color Code
brown-black-red-gold
green-blue-red-gold
brown-red-orange-gold
orange-orange-green-gold
Part #
141000
145600
151200
173300
Qty.
r1
Symbol
C2
Value
22mF
Description
Electrolytic radial
Part #
272244
Qty.
r1
r 1*
r1
r2
r1
r1
r1
Symbol
D17
Value
1N4001
1N4736
1N5235
2N3904
2N3906
Description
Silicon diode
Zener diode 6.8V 1W
Zener diode 6.8V 0.5W
Transistor NPN
Transistor PNP
LED red
Integrated circuit (IC) hex inverter
Part #
314001
314736
315235
323904
323906
350001
330106
Qty.
r1
r1
r1
r1
r1
r1
r1
r1
D18
Q2, Q3
Q1
D19
U4
Symbol
SW1
U4
40106
CAPACITORS
SEMICONDUCTORS
MISCELLANEOUS
Description
PC board tester TCT-200
Switch push button DPDT
Battery 9V
Battery snap 9V
Spacer
Socket IC 14-pin
Tubing #20 1/2”
Solder tube, lead-free
Part #
517041
540203
590009
590098
624018
664014
890020
9LF99
* Packaged in a separate bag, used for testing only.
Resistor
Electrolytic
PARTS IDENTIFICATION
Diodes
Transistor
LED
Epoxy
Zener
Integrated Circuit (IC) IC Socket 14-pin Switch Push Button
Battery Snap
Spacer
Tubing
-5-
PC Board (Tester)
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ASSEMBLE THE FOLLOWING COMPONENTS TO THE PC BOARD
In all of the following steps the components must be installed on the top legend side of the PC board. The
board is turned to solder the component leads on the foil side.
SW1 - Push Button Switch
(see Figure F)
R17 - 1kW 5% 1/4W Resistor
(brown-black-red-gold)
(see Figure A)
R16 - 5.6kW 5% 1/4W Resistor
(green-blue-red-gold)
(see Figure A)
D19 - LED Red
Tubing
Spacer
(see Figure B)
C2 - 22mF Electrolytic
(see Figure G)
R9 - 3.3MW 5% 1/4W Resistor
(orange-orange-green-gold)
(see Figure A)
R15 - 12kW 5% 1/4W Resistor
(brown-red-orange-gold)
(see Figure A)
Q2 - 2N3904 Transistor NPN
(see Figure C)
R12 - 1kW 5% 1/4W Resistor
(brown-black-red-gold)
(see Figure A)
D17 - 1N4001 Diode (epoxy)
(see Figure D)
D18 - 1N5235 Zener Diode 0.5W
(see Figure D)
Q3 - 2N3904 Transistor NPN
(see Figure C)
Battery Snap
(see Figure H)
U4 - 14-pin IC Socket
U4 - 40106 IC Hex Inverter
(see Figure E)
Figure A
Figure F
Figure D
Mount the resistor
flat against the PC
board as shown.
Diodes have polarity. Mount the
diodes in the direction marked on
the PC board as shown.
Figure B
Mount the LED with the tubing and
plastic spacer to the PC board as
shown. Note the flat side of the
LED and the PC board marking.
LED
Flat Side
Spacer
Tubing
Figure C
Mount
the
transistor to
the PC board
noting the flat
side.
Q1 - 2N3906 Transistor PNP
(see Figure C)
Polarity
Marking
IMPORTANT!!! Mount the push button
switch as shown. The circle MUST be
facing the other direction from the marking
“SW1” on the PC board.
Circle
Epoxy
Polarity
Marking
Zener
Figure E
Insert the IC socket into the PC board with the
notch in the direction shown on the top
legend. Solder the IC socket into place.
Insert the IC into the socket with the notch in
the same direction as the notch on the socket.
Notch
Flat Side
Notch
Marking
1/8”
-6-
Figure G
Electrolytic capacitors have polarity. Be sure
to mount them with the negative (–) lead
(marked on the side) in the correct hole.
Warning:
Polarity Marking
If the capacitor is connected
with incorrect polarity, it may
heat up and either leak, or
cause the capacitor to
explode.
Figure H
Mount the battery
snap as shown.
The black (–) lead
goes to –B and
the red (+) lead
goes to +B.
Red Lead
(–)
(+)
Black Lead
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SECTION A - POWER SUPPLY
When the SW1 (test button) is pushed, capacitor C2
(see schematic diagram, Figure 1) is charged to the
battery voltage. Transistor Q1 turns on and all of the
circuits in the tester are powered. If you don’t push
SW1, capacitor C2 begins discharging. When the
voltage on C2 is less than 0.7V, transistor Q1 and
the power turn off after 30-50 seconds.
When the voltage of the battery is less than 7.5V,
transistors Q2 and Q3 turn on and LED D19 (Low
Battery) lights. The diode D17 protects the tester
from wrong polarity input voltage.
Figure 1
TESTING
c) Check that R9, R12 and C2 are the
correct values.
r 1. Connect the battery to the battery snap.
r 2. Set the voltmeter to read 20VDC and connect
the COM lead to the negative (–) side of the
battery and the V lead to the positive (+) side
of the battery as shown in Figure 2. The meter
should indicate 9-10VDC. Push switch SW1.
VDC
d) Check that D17, D18, C2, U4 and SW1
are installed as shown in the assembly
instructions.
r 5. Bend the zener diode 1N4736 (6.8V 1W,
located in a separate bag) as shown in Figure 3.
0.5” - 0.6”
+
V COM
9V
Figure 3
Push the switch SW1 again and short the
battery by the zener diode for 1-2 seconds (the
side with the band should be touching the “+”
terminal of the battery, see Figure 2). LED D19
(Lo Batt.) should be lit. Remove the zener diode
and the LED should turn off. If not:
8
1
Figure 2
a) Check that the transistors Q2 and Q3
are 2N3904 and mounted as shown in
the assembly instructions.
r 3. Remove the V lead from the positive (+) side
of the battery and move to pad of pin 4 of IC
U5. The meter should indicate the same
voltage, but after 30-50 seconds, the voltage
should drop to 0V.
b) Check zener diode D18 and LED D19.
Be sure that they are installed as shown
in the assembly instructions.
r 4. Push the switch SW1 again. The meter should
indicate the same voltage as in step 2. If not:
c) Check that resistors R15, R16 and R17
are the correct values.
a) Check that the battery snap is connected
with the the right polarity as shown in the
assembly instructions.
Remove the battery from the battery snap and
the leads from the tester.
b) Check that the transistor Q1 is 2N3906
and mounted with the emitter, base and
collector leads as shown in the assembly
instructions.
-7-
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PARTS LIST - SECTION B
SECTION B
Oscillator
RESISTORS
Qty.
r1
r1
Symbol
R13
R14
Description
18kW 5% 1/4W
100kW 5% 1/4W
Color Code
brown-gray-orange-gold
brown-black-yellow-gold
Part #
151800
161000
Qty.
r1
Symbol
C3
Value
1mF
Description
Electrolytic radial
Part #
261047
Qty.
r1
Symbol
U5
Value
555
Description
Integrated circuit (IC) 555 timer
Part #
330555
Qty.
r1
Symbol
U5
Description
Socket IC 8-pin
Resistor
CAPACITORS
SEMICONDUCTORS
MISCELLANEOUS
PARTS IDENTIFICATION
Electrolytic
Integrated Circuit (IC)
Part #
664008
IC Socket 8-pin
ASSEMBLE THE FOLLOWING COMPONENTS TO THE PC BOARD
In all of the following steps the components must be installed on the top legend side of the PC board. The
board is turned to solder the component leads on the foil side.
Figure I
R13 - 18kW 5% 1/4W Resistor
(brown-gray-orange-gold)
(see Figure A)
Insert the IC socket into the PC board with the
notch in the direction shown on the top
legend. Solder the IC socket into place.
Insert the IC into the socket with the notch in
the same direction as the notch on the socket.
R14 - 100kW 5% 1/4W Resistor
(brown-black-yellow-gold)
(see Figure A)
C3 - 1mF Electrolytic Radial
(see Figure G)
Notch
U5 - 8-pin IC Socket
U5 - 555 IC Timer
(see Figure I)
Notch
Marking
-8-
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SECTION B - OSCILLATOR
The oscillator section consists of a 555 timing
circuit, resistors R13, R14, and capacitor C3. The
555 IC is configured as an astable or free-running
oscillator. The values of the resistor R14 and
capacitor C3 set the output frequency at 8Hz. The
IC will produce a continuous 8Hz square wave from
pin 3 as long as it is powered.
To Switches
Figure 4
TESTING
r 1. Connect the battery to the battery snap.
r 2. Set the voltmeter to read 20VAC and connect
the COM lead to the negative (–) side of the
battery and the V lead to pad of pin 8 of IC U3
as shown in Figure 5. The meter should
indicate 0V. Push switch SW1. The meter
should indicate 3-5VAC.
If not:
VAC
V COM
a) Check U5 and C3 to be sure that they
are installed as shown in the assembly
instructions.
Figure 5
b) Check R13 and R14 are the correct
values.
Remove the battery from the battery snap and
the leads from the tester.
-9-
+
14
1
9V
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PARTS LIST - SECTION C
SECTION C
Step Pulses with Counter
RESISTORS
Qty.
r1
r1
Symbol
R11
R10
Description
680kW 5% 1/4W
1.2MW 5% 1/4W
Color Code
blue-gray-yellow-gold
brown-red-green-gold
Part #
166800
171200
Qty.
r1
Symbol
C1
Value
.001mF
Description
Discap (102 or 0.001)
Part #
231035
Qty.
r1
Symbol
U1
Value
4017
Description
Integrated circuit (IC) decade counter
Part #
334017
Qty.
r1
Symbol
U1
Description
Socket IC 16-pin
Resistor
CAPACITORS
SEMICONDUCTORS
MISCELLANEOUS
PARTS IDENTIFICATION
Capacitor
102
Integrated Circuit (IC)
Part #
664016
IC Socket 16-pin
ASSEMBLE THE FOLLOWING COMPONENTS TO THE PC BOARD
In all of the following steps the components must be installed on the top legend side of the PC board. The
board is turned to solder the component leads on the foil side.
Figure J
U1 - 16-pin IC Socket
U1 - 4017 IC Decade Counter
(see Figure J)
Insert the IC socket into the PC board with the
notch in the direction shown on the top
legend. Solder the IC socket into place.
Insert the IC into the socket with the notch in
the same direction as the notch on the socket.
R10 - 1.2MW 5% 1/4W Resistor
(brown-red-green-gold)
(see Figure A)
R11 - 680kW 5% 1/4W Resistor
(blue-gray-yellow-gold)
(see Figure A)
Notch
Notch
Marking
C1 - .001mF Discap
(102 or .001)
-10-
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SECTION C - STEP PULSES WITH COUNTER
In this section, a 4017 counter IC and a 40106
inverter IC are used to control eight electronic
switches. A short positive pulse must be generated
and applied to the clock input of the 4017 IC
whenever switch SW1 is depressed. This is done by
wiring three inverters in series. When switch SW1 is
depressed, the voltage at pin 1 of the 40106 is
pulled to ground. This low condition is then inverted
three times to produce a positive pulse to the CLK
pin of the 4017.
}
To Switches
Figure 6
The 4017 IC is a five-stage Johnson decade
counter. The IC has 10 outputs, but only one output
will be driven high at any given time, the other nine
will be low. For each pulse at the clock (CLK) input,
the output will move one position. In this design,
only eight outputs are used, the ninth output is wired
to the reset (RST) pin. When the reset pin goes
high, it sets the Q0 output high again. The clock
enable (ENA) pin is tied to ground, so every clock
pulse will move the output.
TESTING
r 1. Connect the battery to the battery snap.
r 2. Set the voltmeter to read 20VDC and connect
the COM lead to the negative (–) side of the
battery and the V lead to pin 3 of IC U1 as
shown in Figure 7.
VDC
r 3. Push switch SW1 until the voltmeter
indicates 9-10VDC.
+
16
1
r 4. Move the V lead of the voltmeter to pin 2. The
voltmeter should indicate 0V. Push SW1
again. The voltmeter should indicate 8-9VDC.
In the same manner, test the outputs of the
counter (pins 4, 7, 10, 1, 5, and 6).
If the test results are not satisfactory, then:
V COM
Figure 7
a) Check U1. Be sure that it is installed as
shown in the assembly instructions.
Remove the battery from the battery snap and
the leads from the tester.
-11-
9V
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:16 AM Page 13
PARTS LIST - SECTION D
SECTION D
Switches and LED Indicator
RESISTORS
Qty.
r8
Symbol
R1-R8
Description
200W 5% 1/4W
Color Code
red-black-brown-gold
Part #
132000
Qty.
r1
Symbol
C4
Value
470mF 16V
Description
Electrolytic radial
Part #
284744
Description
LED red
Integrated circuit (IC) quad analog switch
Part #
350001
394066
CAPACITORS
SEMICONDUCTORS
Qty. Symbol
r 16 D1-D16
r 2 U2, U3
Value
Qty.
r1
r1
r2
r2
Description
F-connector
Modular jack RJ-45
Spacer
IC socket 14-pin
Symbol
J2
J1
U2, U3
74HC4066
Resistor
F-Connector
MISCELLANEOUS
PARTS IDENTIFICATION
Electrolytic
Integrated Circuit (IC)
Modular Jack
LED
-12-
Part #
590500
621028
624006
664014
IC Socket 14-pin
Spacer
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:16 AM Page 14
ASSEMBLE THE FOLLOWING COMPONENTS TO THE PC BOARD
In all of the following steps the components must be installed on the top legend side of the PC board. The
board is turned to solder the component leads on the foil side.
J1 - Modular Jack RJ-45
(see Figure L)
R6 - 200W 5% 1/4W Resistor
(red-black-brown-gold)
(see Figure A)
R5 - 200W 5% 1/4W Resistor
(red-black-brown-gold)
(see Figure A)
R3 - 200W 5% 1/4W Resistor
(red-black-brown-gold)
(see Figure A)
R8 - 200W 5% 1/4W Resistor
(red-black-brown-gold)
(see Figure A)
R1 - 200W 5% 1/4W Resistor
(red-black-brown-gold)
(see Figure A)
U3 - 14-pin IC Socket
U3 - 74HC4066 IC
(see Figure E)
J2 - F-Connector
(see Figure K)
C4 - 470mF Electrolytic Radial
(see Figure G)
R4 - 200W 5% 1/4W Resistor
(red-black-brown-gold)
(see Figure A)
R2 - 200W 5% 1/4W Resistor
(red-black-brown-gold)
(see Figure A)
R7 - 200W 5% 1/4W Resistor
(red-black-brown-gold)
(see Figure A)
U2 - 14-pin IC Socket
U2 - 74HC4066 IC
(see Figure E)
Figure K
Figure L
Mount and solder the F-connector to the PC board in the
location shown. Note: The connector must be soldered
in straight.
Mount and solder the modular jack to the PC board as
shown.
-13-
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:17 AM Page 15
ASSEMBLE THE FOLLOWING COMPONENTS TO THE PC BOARD (cont.)
Spacer
(see Figure M)
D9 - LED
D10 - LED
D11 - LED
D12 - LED
D13 - LED
D14 - LED
D15 - LED
D16 - LED
(see Figure N)
Figure M
Figure N
Mount the spacer to the PC board as shown.
Mount the LEDs onto the spacer as shown. Note the flat
side of the LED in relation to the marking on the PC
board. Solder and cut off the excess leads.
Spacer
(see Figure M)
D1
D2
D3
D4
D5
D6
D7
D8
-
LED
LED
LED
LED
LED
LED
LED
LED
(see Figure N)
-14-
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:17 AM Page 16
SECTION D - SWITCHES AND LED INDICATOR
In this section, two quad analog switches
(74HC4066) and 16 LEDs are used to indicate
which pins are being tested and the type of cable.
Figure 8 shows the logic diagram for each switch.
Each switch contains an input, output and a control
pin. The inputs are connected to the oscillator
section and the outputs to two LEDs and connector.
The control pins connect to the outputs of the 4017
IC (see Figure 10).
Connecting a cross-pinning cable, LED D4 will light
only during the discharging cycle (see Figure 9c).
When switch A is closed, capacitor C charges and
discharges at the oscillator frequency. This causes
LEDs D1 and D2 to blink at the same rate (see
Figure 9a).
A
A
B
B
Charge
Without Terminator
Figure 9a
Discharge
TESTING
{
Connecting a straight cable, LED D3 will light only
during the charging cycle. The diode in the
terminator only allows the current flow in one
direction (see Figure 9b).
Straight Cable
Figure 9b
r 1. Connect the battery to the battery snap.
Analog
Input/Output
Analog
Output/Input
ON/OFF Control
Figure 8
A
B
Cross-Pinning Cable
Figure 9c
From Oscillator
r 2. Push the switch SW1. Two vertical LEDs
should be blinking at a frequency of
approximately 8Hz.
r 3. Test the other pairs of LEDs by pushing switch
SW1. For every step, there should be only two
vertical blinking LEDs. If not, then:
a) Check U2, U3, C4 and diodes D1-D16.
Be sure that they are installed as shown
in the assembly instructions.
b) Check that the resistors R1-R8 installed
are the correct values.
From
Counter
c) Check the soldering on the modular jack
and F-connector.
-15-
Figure 10
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:17 AM Page 17
PARTS LIST - SECTION E
SECTION E
Terminator
SEMICONDUCTORS
Qty
r4
Symbol
D1-D4
Value
1N4148
Qty
r1
r1
r1
Symbol
Description
PC board terminator LD-100
F-connector
Modular jack RJ-45
J2
J1
F-Connector
Description
Diode
Part #
314148
MISCELLANEOUS
PARTS IDENTIFICATION
Modular Jack
Diode
Part #
510005
590500
621028
PC Board
ASSEMBLE THE FOLLOWING COMPONENTS TO THE PC BOARD
In all of the following steps the components must be installed on the top legend side of the PC board. The
board is turned to solder the component leads on the foil side.
Modular Jack (RJ-45)
(see Figure L)
D4
D3
D2
D1
-
J2 - F-Connector
Note: The connector must be
soldered in straight.
(see Figure K)
1N4148 Diode
1N4148 Diode
1N4148 Diode
1N4148 Diode
(see Figure D)
IMPORTANT: Cut off the excess
leads after soldering the FConnector to the PC board.
Note: R1 is not used.
-16-
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:17 AM Page 18
SECTION E - TERMINATOR
The terminator uses four diodes to identify the
polarity of the input signals. The diodes are placed
in series with wires 1-8, 2-7, 3-6, and 4-5 (see
Figure 11).
Figure 11
PARTS LIST - SECTION F
Qty.
r4
r 2’
Symbol
SECTION F
Assemble Telecom Cables
Description
Plug RJ-45
Cable flat 8 wires
MISCELLANEOUS
PARTS IDENTIFICATION
8 Wire Flat Cable
-17-
Part #
621032
870984
Plug RJ-45
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:17 AM Page 19
ASSEMBLE THE TELECOM CABLES
For testing and troubleshooting the tester, you need to assemble straight and cross-pinning cables.
For cutting, stripping, and crimping, use a standard tool for RJ-45 plugs (flat cable).
ELENCO® has modular crimping tools Models ST-500 and HT-568.
Straight Cable
(BL) 1
(OR)2
(BK) 3
(R) 4
(G) 5
(Y) 6
(BN) 7
(S) 8
1
2
3
4
5
6
7
8
Cross-Pinning Cable
(BL) 1
(OR)2
(BK) 3
(R) 4
(G) 5
(Y) 6
(BN) 7
(S) 8
1
2
3
4
5
6
7
8
r Cut the 2’ telecom cable in half (see Figure 12).
Note the orientation of the
RJ-45 plug for each cable.
r Using the instructions for your tool, make two
cables (straight and cross-pinning) as shown in
Figures 13 - 15. Make sure that you make a
clean cut on the cable.
Figure 12 Cutting
Figure 13 Stripping
Figure 14
Figure 15 Crimping
-18-
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:17 AM Page 20
PARTS LIST - SECTION G
Qty.
r2
r1
r1
r 1*
r1
r 1*
r1
r1
r2
r4
r1
r 1*
r 1*
r1
Symbol
SECTION G
Final Test and Assembly
MISCELLANEOUS
Description
F to BNC adapter
Button cap
Case top tester
Case top terminator
Case bottom tester
Case bottom terminator
Cover battery
Velcro hook and loop set
Screw 2.6 x 8mm thread cutting phillips pan head
Screw 3 x 12mm thread cutting phillips flat head
Screw M3 x 10mm machine phillips flat head
Screw 2.6 x 10mm thread cutting phillips flat head
Label terminator
Label tester
Part #
596020
622006
623114
623115
623211
623212
623401
628002
642109
643104
643105
643107
727050
727051
* Used for the assembly of the terminator.
Button Cap
F to BNC
Adapter
Velcro Hook & Loop Set
Hook
Loop
PARTS IDENTIFICATION
Case Top Terminator
Case Bottom Terminator
Cover Battery
Screws (actual size)
Label Tester
Label Terminator
2.6 x 8mm Thread
Cutting Phillips Pan Head
M3 x 10mm Machine
Phillips Flat Head
3 x 12mm Thread Cutting
Phillips Flat Head
Case Top Tester
2.6 x 10mm Thread
Cutting Phillips Flat Head
-19-
Case Bottom Tester
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:17 AM Page 21
SECTION G - FINAL TEST
Straight Cable
Cross-Pinning Cable
r 1. Connect one end of the straight cable to the
modular jack on the PC board of the terminator
and the second end to the PC board of the
cable tester as shown in Figure 16a.
r 2. Push switch SW1 until the two vertical LEDs
D1 and D9 are blinking alternately and LED
D16 should be blinking too.
r 1. Remove the straight cable and connect the
cross-pinning cable to the modular jacks on
the PC boards of the tester and terminator.
r 2. Push switch SW1 until the two vertical LEDs
D1 and D9 are blinking alternately and LED
D8 should be blinking too.
r 3. Check the other LEDs by pressing switch SW1
and referring to Table 2 below. The single LED
should always be on the bottom row. If not, then:
a) Check the cable using the master tester.
b) Check diodes D1-D4 on the PC board of
the terminator. Be sure that the diodes
are installed as shown in Figure D in the
assembly instructions.
#
1
2
3
4
5
6
7
8
Figure 16a
r 3. Check the other LEDs by pressing switch SW1
and referring to Table 1 below. The single
blinking LED should always be on the top row.
#
1
2
3
4
5
6
7
8
Table 1
Two Vertical
Blinking LEDs
D1 and D9
D2 and D10
D3 and D11
D4 and D12
D5 and D13
D6 and D14
D7 and D15
D8 and D16
Straight Cable
Single Blinking
LED on Top Row
D1 and D9
D2 and D10
D3 and D11
D4 and D12
D5 and D13
D6 and D14
D7 and D15
D8 and D16
Cross-Pinning Cable
Single Blinking
LED on Bottom Row
D8
D7
D6
D5
D4
D3
D2
D1
r 1. Push switch SW1 until the two vertical LEDs
D4 and D12 are blinking alternately and LED
D5 is blinking too.
r 2. Using a short piece of wire or a discarded lead from
one of the components, short the F-connector on
the terminator PC board as shown in Figure 16b.
If the LEDs are not functioning properly, then:
a) Check the cable using a master tester.
Figure 16b
b) Check the ICs U2, U3 and LEDs D1-D16
on the PC board of the tester. They
should be mounted as shown in the
assembly instructions.
c) Check that resistors R1-R8 on the PC board
of the tester are the correct values (200W).
d) Check diodes D1-D4 on the PC board of
the terminator. Be sure that the diodes
are installed as shown in Figure D in the
assembly instructions.
Two Vertical
Blinking LEDs
Short Test
D16
D15
D14
D13
D12
D11
D10
D9
Table 2
-20-
The LED D13 should be blinking too. Remove the
jumper and LED D13 should turn off. If not, then:
a) Check the F-connector on the terminator PCB.
r 3. Short the F-connector on the tester PC board. The
LED D13 should be blinking again. If not, then:
a) Check the F-connector on the terminator PCB.
r 4. Remove the cable from the modular jacks on
the PC board and proceed to the final
assembly.
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:17 AM Page 22
SECTION G - FINAL ASSEMBLY OF TESTER
r Mount the bottom case to the front case, as
shown in Figure Q, using four 3 x 12mm flat
phillips screws. Be sure that the battery snap is
through the battery compartment hole as shown.
r Push the button cap onto the switch as shown in Figure O.
r Mount the PC board to the top case, as shown in
Figure P, with two 2.6 x 8mm phillips screws.
Note: The button cap should be centered in the
top case hole. Make sure that the Lo Batt LED
goes through the hole in the case.
r Connect the 9V battery to the battery snap and
place it into the case. Slide the battery cover onto
the case as shown in Figure R.
r Wrap the wires from the battery snap around the
battery housing as shown in Figure Q.
Button Cap
3 x 12mm Screws
Bottom Case
Figure O
2.6 x 8mm Screws
PC Board
Figure Q
9V Battery
Battery Cover
Figure P
Top Case
-21-
Figure R
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:17 AM Page 23
FINAL ASSEMBLY OF TESTER (cont.)
r Insert the M3 x 10mm machine phillips screw into
the battery cover hole, as shown in Figure S, and
tighten.
r Peel the backing off of the label and stick it onto
the front case as shown in Figure T. Use the hole
in the middle to line up the label. Note: Be very
careful when applying this label. The adhesive is
very sticky and when the label is on, it’s on!
Label
M3 Phillips
Screw
Figure S
Figure T
FINAL ASSEMBLY OF TERMINATOR
r Before assembling, check that the excess leads
from the F-connector are cut off (see page 16).
r Peel the backing off of the terminator label and
carefully place it onto the unit as shown in Figure V.
Note: Be sure that the terminator has been
tested and is in working order before you apply
the label.
r Assemble the terminator as shown in Figure U.
Insert the 2.6 x 10mm flat phillips screw and
tighten down.
2.6 x 10mm Flat
Phillips Screw
Load Label
Top Load Case
Load PC Board
Bottom Load Case
Figure U
-22-
Figure V
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:17 AM Page 24
FINAL ASSEMBLY (cont.)
r Peel off the two backings, and attach the two
velcro pieces onto the terminator and the tester
in the location shown in Figure W.
Velcro Pieces
Figure W
SPECIFICATIONS
CATEGORY OF CABLE
ENVIRONMENTAL CONDITIONS
● Ethernet 10 Base-T, Token Ring, EIA/TIA-568A/B,
AT&T 258A, and USOC.
● Storage Conditions: −10OC - 50OC / 14OF - 122OF
80% RH max.
● 50 or 75W coaxial cable with BNC connectors.
Must use F to BNC adapters.
● Standard or alkaline 9V battery
● Unshielded communication cable with RJ-11 and
RJ-45 connectors.
● Operating Conditions: 0OC - 45OC / 32OF - 113OF
70% RH max.
● 50 or 75W coaxial cable with F connectors.
POWER
● Low battery indicator (Lo Batt.)
Maximum testing length for all cable types is
1,000 feet.
● Auto power-off function (30 s)
MULTIPLE FUNCTIONS
● Testing cables before or after their installation.
● Mapping Function (to test individual wire pairs or
coaxial cables).
● Cable identification (straight or cross-pinning).
● Pair identification (straight or cross-pinning).
● Open/short wiring test.
-23-
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:17 AM Page 25
OPERATION INSTRUCTIONS
3. Push the TEST button again and read the result
for the next pair.
1. Connect one end of the cable to be tested to the
terminator and the other end to the cable tester
as shown in Figure 17.
4. For testing coax cable, use the middle LEDs (boxed
in as coax on the unit).
2. Push the TEST (power) button and read the result.
Good Pair: Two vertical and one single blinking
LEDs. The location of the single LED indicates
a straight or cross-pinning for the pair.
5. If you do not push the button for 30 seconds, it will
automatically shut off.
Open Pair: Only two vertical LEDs blinking.
Short: Four or more LEDs are blinking (two or
more wires are shorted).
*
*
*
Good Pair (Straight)
3 & 6 Wires
*
*
* = Blinking LED
*
*
*
Good Pair (Cross-Pinning)
3 & 6 Wires
Open Pair
For straight open wire #3
For Cross-Pinning
open wire #6
CAUTION
DO NOT test cable connected to electric power. To avoid electric
shock, disconnect the power to the cable under test. Connection to
an active power cable can result in injury or even death.
Configuration
for Testing
Coaxial Cable
Configuration
for Testing
Communication
Cable
Figure 17
-24-
*
*
**
Short
Cross-Pinned cable
short wires 6 & 7
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:17 AM Page 26
WIRING SCHEMES
Ethernet
10Base-T
EIA/TIA-568A
EIA/TIA-568B
AT&T 258A
8-Position
Token Ring
USOC
USOC
(Prs. 1,2 & 3)
(Y)
(G)
(R)
(BL)
1
2
3
4
RJ-11 (4-Wire) Straight-Pinning
1
2
3
4
(Y)
(G)
(R)
(BL)
1
2
3
4
NOTE: Cross-Pinning is for typical telephone use.
(BL) 1
(Y) 2
(G) 3
(R) 4
(BK) 5
(W) 6
(BL) 1
(OR)2
(BK) 3
(R) 4
(G) 5
(Y) 6
(BN) 7
(S) 8
RJ-11 (6-Wire) Straight-Pinning
RJ-45 (8-Wire) Straight-Pinning
1
2
3
4
5
6
(BL) 1
(Y) 2
(G) 3
(R) 4
(BK) 5
(W) 6
1
2
3
4
5
6
7
8
(BL) 1
(OR)2
(BK) 3
(R) 4
(G) 5
(Y) 6
(BN) 7
(S) 8
-25-
RJ-11 (4-Wire) Cross-Pinning
RJ-11 (6-Wire) Cross-Pinning
RJ-45 (8-Wire) Cross-Pinning
1
2
3
4
1
2
3
4
5
6
1
2
3
4
5
6
7
8
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:17 AM Page 27
MAINTENANCE
GENERAL MAINTENANCE
3. Carefully remove the old battery and replace with
a new battery.
To clean, wipe the case with a damp cloth and
detergent (do not use abrasives or solvents).
4. Reinsert the battery into the case, dressing the
battery leads so that they will not be pinched
between the case and the battery cover.
When the Lo Batt. LED lights up, you need to
replace the battery. The terminator does not use
a battery.
5. Reinstall the battery cover and screw.
BATTERY REPLACEMENT
The tester is powered by a single standard or
alkaline 9V battery. Use the following procedure to
replace the battery.
1. Disconnect the cables from the tester.
2. Using a phillips screwdriver, remove the battery
cover screw and open the battery cover.
SCHEMATIC DIAGRAM
-26-
TCT-255K_REV-E_031016.qxp_TCT-255K.qxd 3/10/16 11:17 AM Page 28
ELENCO®
150 Carpenter Avenue
Wheeling, IL 60090
(847) 541-3800
www.elenco.com
email: elenco@elenco.com
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