MULTI-NETWORK CABLE TESTER KIT
MODEL TCT-255K
Assembly and Instruction Manual
Elenco Electronics, Inc.
Copyright © 2001 Elenco Electronics, Inc. 753089
INTRODUCTION
The TCT-255 Cable Tester is a convenient instrument
for testing different unshielded wiring schemed
communication cable with RJ-11 and RJ-45
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.
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
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.
GENERAL DISCUSSION
You can see a block diagram of the TCT-255 in Figure 1 below.
Cable Tester TCT-200 Terminator LD-100
STEP PULSES
POWER
SUPPLY
The TCT-255 Cable Tester has five basic blocks:
COUNTER SWITCHES
OSCILLATOR
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.
Figure 1
INPUT & OUTPUT
CONNECTORS
LED
INDICATOR
INPUT & OUTPUT
CONNECTORS
CIRCUIT
IDENTIFY
POLARITY
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-
IDENTIFYING RESISTOR VALUES
Use the following information as a guide in properly identifying the value of resistors.
BANDS
2 Multiplier Tolerance
1
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.
Multiplier
Note: The letter “R” may be used at times
to signify a decimal point; as in 3R3 = 3.3
The value is 10 x 1,000 = 10,000pF or .01mF 100V
For the No.01234589
Multiply By 1 10 100 1k 10k 100k .01 0.1
First Digit
Second Digit
Multiplier
103K
100
Tolerance
Maximum Working Voltage
The letter M indicates a tolerance of +20%
The letter K indicates a tolerance of +10%
The letter J indicates a tolerance of +5%
-2-
CONSTRUCTION
Introduction
Assembly of your TCT-255 Multi-Network Cable Tester Kit will prove to be an exciting project
and give you much satisfaction and personal achievement. If you have experience in soldering
and wiring techniques, then you should have no problem with the assembly of this kit. Care
must be given to identifying the proper components and in good soldering habits. Above all,
take your time and follow these easy step-by-step instructions. Remember, “An ounce of
prevention is worth a pound of cure”. Avoid making mistakes and no problems will occur.
Safety Procedures
• Wear eye protection when soldering.
•
Locate soldering iron in an area where you do not have to go around it or reach over it.
• Do not hold solder in your mouth. Solder contains lead and is a toxic substance. Wash your
hands thoroughly after handling solder.
• Be sure that there is adequate ventilation present.
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 and the board is turned to solder the
component leads on the foil side. Solder immediately unless the pad is adjacent to another
hole which will interfere with the placement of the other component. Cut excessive leads with
a diagonal cutter. Then, place a check mark in the box provided next to each step to indicate
that the step is completed. Be sure to save the extra leads for use as jumper wires if needed.
Foil Side
Mount Part
Bend Leads to Hold Part Solder and Cut Off Leads
Rx - 100W 5% 1/4W Resistor
(brown-black-brown-gold)
Soldering
The most important factor in assembling your 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. Many areas on the PC board are close together and care must be given not to form
solder shorts. Size and care of the tip will eliminate problems.
For a good soldering job, the areas being soldered must be heated sufficiently so that the
solder flows freely. Apply the solder simultaneously to the component lead and the component
pad on the PC board so that good solder flow will occur. Be sure that the lead extends through
the solder smoothly indicating a good solder joint. Use only rosin core solder of 63/37 or
60/40 alloy.
DO NOT USE ACID CORE SOLDER! Do not blob the solder over the lead because this can
result in a cold solder joint.
Soldering Iron
Heat Sinking
Electronic components such as transistors,
IC’s, 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
between the part and the solder joint.
Heat Sink (this can be ordered as part of Elenco’s Solder Ease
Kit Model SE-1).
Solder
PC Board
Heat Sensitive
Component (Diode)
Figure 6
-3-
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
A good solder connection should be bright, shiny,
smooth, and uniformly flowed over all surfaces.
Soldering a PC board
1. Solder all components
from the copper foil side
only. Push the soldering
iron tip against both the
lead and the circuit board
foil.
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.
Component Lead
Foil
Solder
Foil
Soldering Iron
Circuit Board
Soldering Iron
Types of Poor Soldering Connections
1. Insufficient heat - the
solder will not flow onto
the lead as shown.
2. Insufficient solder -
let the solder flow over
the connection until it is
covered. Use just
enough solder to cover
the connection.
3. Excessive solder -
could make
connections that you
did not intend to
between adjacent foil
areas or terminals.
Rosin
Soldering iron positioned
incorrectly.
Solder
Component Lead
Solder
Gap
3. Allow the solder to flow
around the connection.
Then, remove the solder
and the iron and let the
Solder
Foil
Soldering Iron
connection cool. The
solder should have flowed
smoothly and not lump
around the wire lead.
Here is what a good
4.
solder connection looks
like.
TROUBLESHOOTING
1. One of the most frequently occurring problems is poor
solder connections.
a) Tug slightly on all parts to make sure that they
are indeed soldered.
b) All solder connections should be shiny.
Resolder any that are not.
4. Solder bridges - occur
when solder runs
Soldering Iron
between circuit paths
and creates a short
circuit. This is usually
caused by using too
much solder. To correct
this, simply drag your
Foil
soldering iron across
the solder bridge as
shown.
c) Solder should flow into a smooth puddle rather
than a round ball. Resolder any connection that
has formed into a ball.
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.
Drag
-4-
SECTION A
Power Supply
PARTS LIST - SECTION A
RESISTORS
Qty. Symbol Description Color Code Part #
2 R12, R17 1kW 5% 1/4W brown-black-red-gold 141000
1 R16 5.6kW 5% 1/4W green-blue-red-gold 145600
1 R15 12kW 5% 1/4W brown-red-orange-gold 151200
1 R9 3.3MW 5% 1/4W orange-orange-green-gold 173300
CAPACITORS
Qty. Symbol Value Description Part #
1 C2 22mF Electrolytic Radial 272244
SEMICONDUCTORS
Qty. Symbol Value Description Part #
1 D17 1N4001 Silicon Diode 314001
1* 1N4736 Zener Diode 6.8V 1W 314736
1 D18 1N5235 Zener Diode 6.8V 0.5W 315235
2 Q2, Q3 2N3904 Transistor NPN 323904
1 Q1 2N3906 Transistor PNP 323906
1 D19 LED Red 350003
1 U4 40106 Integrated Circuit (IC) Hex Inverter 330106
MISCELLANEOUS
Qty. Symbol Description Part #
1 PC Board Tester TCT-200 517041
1 SW1 Switch Push Button DPDT 540203
1 Battery 9V 590009
1 Battery Snap 9V 590098
1 Spacer 624018
1 U4 Socket IC 14-pin 664014
1 Tubing #20 1/2” 890020
1 Solder 9ST4
* Packaged in a separate bag, used for testing only.
PARTS IDENTIFICATION
Resistor DiodesElectrolytic Transistor LED
Epoxy
Zener
Integrated Circuit (IC)
IC Socket 14-pin
Switch Push Button
Battery Snap
Spacer
PC Board (Tester)
Tubing
-5-
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.
R17 - 1kW 5% 1/4W Resistor
(brown-black-red-gold)
(see Figure A)
D19 - LED Red
Tubing
Spacer
(see Figure B)
R9 - 3.3MW 5% 1/4W Resistor
(orange-orange-green-gold)
(see Figure A)
Q2 - 2N3904 Transistor NPN
(see Figure C)
D17 - 1N4001 Diode (epoxy)
(see Figure D)
Q3 - 2N3904 Transistor NPN
(see Figure C)
U4 - 14-pin IC Socket
U4 - 40106 IC Hex Inverter
(see Figure E)
Figure A
Mount the resistor
flat against the PC
board as shown.
Figure D
Diodes have polarity. Mount the
diodes in the direction marked on
the PC board as shown.
SW1 - Push Button Switch
(see Figure F)
R16 - 5.6kW 5% 1/4W Resistor
(green-blue-red-gold)
(see Figure A)
C2 - 22mF Electrolytic
(see Figure G)
R15 - 12kW 5% 1/4W Resistor
(brown-red-orange-gold)
(see Figure A)
R12 - 1kW 5% 1/4W Resistor
(brown-black-red-gold)
(see Figure A)
D18 - 1N5235 Zener Diode 0.5W
(see Figure D)
Battery Snap
(see Figure H)
Q1 - 2N3906 Transistor PNP
(see Figure C)
Figure F
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
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
Tubing
Spacer
Figure C
Mount the
transistor to
the PC board
noting the flat
side.
Flat Side
1/8”
Polarity
Marking
Polarity
Marking
Epoxy
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
Notch
Marking
-6-
Figure G
Electrolytic capacitors have polarity. Be sure
to mount them with the negative (--) lead
(marked on the side) in the correct hole.
Polarity
Marking
(--) (+)
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
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.
TESTING
Figure 1
1. Connect the battery to the battery snap.
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
COM
V
+
9V
8
1
Figure 2
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.
4. Push the switch SW1 again. The meter should
indicate the same voltage as in step 2. If not:
a) Check that the battery snap is connected
with the the right polarity as shown in the
assembly instructions.
b) Check that the transistor Q1 is 2N3906 and
mounted with the emitter, base and collector
leads as shown in the assembly instructions.
c) Check that R9, R12 and C2 are the correct
values.
d) Check that D17, D18, C2, U4 and SW1 are
installed as shown in the assembly
instructions.
5. Bend the zener diode 1N4736 (6.8V 1W, located
in a separate bag) as shown in Figure 3.
0.5” - 0.6”
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:
a) Check that the transistors Q2 and Q3 are
2N3904 and mounted as shown in the
assembly instructions.
b) Check zener diode D18 and LED D19. Be
sure that they are installed as shown in the
assembly instructions.
c) Check that resistors R15, R16 and R17 are
the correct values.
Remove the battery from the battery snap and
the leads from the tester.
-7-
SECTION B
Oscillator
PARTS LIST - SECTION B
RESISTORS
Qty. Symbol Description Color Code Part #
1 R13 18kW 5% 1/4W brown-gray-orange-gold 151800
1 R14 100kW 5% 1/4W brown-black-yellow-gold 161000
CAPACITORS
Qty. Symbol Value Description Part #
1C3 1mF Electrolytic Radial 261047
SEMICONDUCTORS
Qty. Symbol Value Description Part #
1 U5 555 Integrated Circuit (IC) 555 Timer 330555
MISCELLANEOUS
Qty. Symbol Description Part #
1 U5 Socket IC 8-pin 664008
PARTS IDENTIFICATION
Resistor
Electrolytic IC Socket 8-pin
Integrated Circuit (IC)
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
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.
R13 - 18kW 5% 1/4W Resistor
(brown-gray-orange-gold)
(see Figure A)
R14 - 100kW 5% 1/4W Resistor
(brown-black-yellow-gold)
(see Figure A)
Notch
Notch
Marking
C3 - 1mF Electrolytic Radial
(see Figure G)
U5 - 8-pin IC Socket
U5 - 555 IC Timer
(see Figure I)
-8-
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.
TESTING
1. Connect the battery to the battery snap.
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
Figure 4
+
To Switches
14
1
a) Check U5 and C3 to be sure that they are
installed as shown in the assembly
instructions.
b) Check R13 and R14 are the correct values.
Remove the battery from the battery snap and
the leads from the tester.
V
COM
Figure 5
9V
-9-
SECTION C
Step Pulses with Counter
PARTS LIST - SECTION C
RESISTORS
Qty. Symbol Description Color Code Part #
1 R11 680kW 5% 1/4W blue-gray-yellow-gold 166800
1 R10 1.2MW 5% 1/4W brown-red-green-gold 171200
CAPACITORS
Qty. Symbol Value Description Part #
1 C1 .001mF Discap (102 or .001) 231035
SEMICONDUCTORS
Qty. Symbol Value Description Part #
1 U1 4017 Integrated Circuit (IC) Decade Counter 334017
MISCELLANEOUS
Qty. Symbol Description Part #
1 U1 Socket IC 16-pin 664016
PARTS IDENTIFICATION
Resistor
Capacitor IC Socket 16-pin
102
Integrated Circuit (IC)
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
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
Notch
Marking
U1 - 16-pin IC Socket
U1 - 4017 IC Decade Counter
(see Figure J)
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)
C1 - .001mF Discap
(102 or .001)
-10-
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.
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.
To Switches
}
Figure 6
TESTING
1. Connect the battery to the battery snap.
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.
3.
Push switch SW1 until the voltmeter indicates
9-10VDC.
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:
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.
VDC
V
Figure 7
COM
+
9V
16
1
-11-
SECTION D
Switches and LED Indicator
PARTS LIST - SECTION D
RESISTORS
Qty. Symbol Description Color Code Part #
8 R1-R8 200W 5% 1/4W red-black-brown-gold 132000
CAPACITORS
Qty. Symbol Value Description Part #
1 C4 470mF 16V Electrolytic Radial 284744
SEMICONDUCTORS
Qty. Symbol Value Description Part #
16 D1-D16 LED Red 350003
2 U2, U3 74HC4066 Integrated Circuit (IC) Quad Analog Switch 394066
MISCELLANEOUS
Qty. Symbol Description Part #
1 J2 F-Connector 590500
1 J1 Modular Jack RJ-45 621028
2 Spacer 624006
2 U2, U3 IC Socket 14-pin 664014
PARTS IDENTIFICATION
Resistor
F-Connector Modular Jack LED Spacer
Electrolytic IC Socket 14-pin
Integrated Circuit (IC)
-12-
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.
R6 - 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)
R1 - 200W 5% 1/4W Resistor
(red-black-brown-gold)
(see Figure A)
J2 - F-Connector
(see Figure K)
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)
J1 - Modular Jack RJ-45
(see Figure L)
R5 - 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)
U3 - 14-pin IC Socket
U3 - 74HC4066 IC
(see Figure E)
C4 - 470mF Electrolytic Radial
(see Figure G)
Figure K
Mount and solder the F-connector to the PC board in the
location shown. Note: The connector must be soldered
in straight.
Figure L
Mount and solder the modular jack to the PC board as
shown.
-13-
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
Mount the spacer to the PC board as shown.
Spacer
(see Figure M)
D1 - LED
D2 - LED
D3 - LED
D4 - LED
D5 - LED
D6 - LED
D7 - LED
D8 - LED
(see Figure N)
Figure N
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.
-14-
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).
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
B
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).
Connecting a cross-pinning cable, LED D4 will light
only during the discharging cycle (see Figure 9c).
Analog
Input/Output
ON/OFF Control
Figure 8
A
B
Output/Input
A
B
Analog
Charge
Discharge
Without Terminator
Figure 9a
TESTING
1. Connect the battery to the battery snap.
2. Push the switch SW1. Two vertical LEDs should
be blinking at a frequency of approximately 8Hz.
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.
c) Check the soldering on the modular jack and
F-connector.
Straight Cable
Figure 9b
From
Counter
Cross-Pinning Cable
Figure 9c
From Oscillator
{
Figure 10
-15-
SECTION E
Terminator
PARTS LIST - SECTION E
SEMICONDUCTORS
Qty Symbol Value Description Part #
4 D1-D4 1N4148 Diode 314148
MISCELLANEOUS
Qty Symbol Description Part #
1 PC Board Terminator LD-100 510005
1 J2 F-Connector 590500
1 J1 Modular Jack RJ-45 621028
PARTS IDENTIFICATION
F-Connector Modular Jack Diode 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)
J2 - F-Connector
Note: The connector must be
D4 - 1N4148 Diode
D3 - 1N4148 Diode
D2 - 1N4148 Diode
D1 - 1N4148 Diode
(see Figure D)
Note: R1 is not used.
soldered in straight.
(see Figure K)
IMPORTANT: Cut off the
excess leads after soldering the
F-Connector to the PC board.
-16-
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
SECTION F
Assemble Telecom Cables
PARTS LIST - SECTION F
MISCELLANEOUS
Qty. Symbol Description Part #
4 Plug RJ-45 621032
2’ Cable Flat 8 Wires 870984
PARTS IDENTIFICATION
8 Wire Flat Cable
Plug RJ-45
-17-
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 Electronics has modular crimping tools Models ST-500 and HT-568.
(BL) 1
(OR)2
(BK) 3
(R) 4
Straight Cable
Cross-Pinning Cable
(G) 5
(Y) 6
(BN) 7
(S) 8
(BL) 1
(OR)2
(BK) 3
(R) 4
(G) 5
(Y) 6
(BN) 7
(S) 8
Cut the 2’ telecom cable in half (see Figure 12).
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.
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
Note the orientation of the
RJ-45 plug for each cable.
Figure 12 Cutting Figure 13 Stripping
Figure 14
Figure 15 Crimping
-18-
SECTION G
Final Test and Assembly
PARTS LIST - SECTION G
MISCELLANEOUS
Qty. Symbol Description Part #
2 F to BNC Adapter 596020
1 Button Cap 622006
1 Case Top Tester 623114
1* Case Top Terminator 623115
1 Case Bottom Tester 623211
1* Case Bottom Terminator 623212
1 Cover Battery 623401
1 Velcro Hook and Loop Set 628002
2 Screw #4 5/16” AB Phillips Pan Head 642442
4 Screw 3 x 12mm Thread Cutting Phillips Flat Head 643104
1 Screw M3 x 10mm Machine Phillips Flat Head 643105
1* Screw 2.6 x 10mm Thread Cutting Phillips Flat Head 643107
1* Label Terminator 727050
1 Label Tester 727051
* Used for the assembly of the terminator.
PARTS IDENTIFICATION
Button Cap Case Top Terminator
Velcro Hook & Loop Set Screws (actual size) Label Tester Label Terminator
Hook
F to BNC
Adapter
#4 5/16” AB Phillips
Pan Head
Loop
Case Top Tester Case Bottom Tester
3 x 12mm Thread Cutting
Phillips Flat Head
M3 x 10mm Machine
Phillips Flat Head
2.6 x 10mm Thread
Cutting Phillips Flat Head
Case Bottom Terminator Cover Battery
-19-
SECTION G - FINAL TEST
Straight Cable
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.
2. Push switch SW1 until the two vertical LEDs D1
and D9 are blinking alternately and LED D16
should be blinking too.
Figure 16a
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.
Table 1
Two Vertical Straight Cable
# Blinking LEDs Single Blinking
LED on Top Row
1 D1 and D9 D16
2 D2 and D10 D15
3 D3 and D11 D14
4 D4 and D12 D13
5 D5 and D13 D12
6 D6 and D14 D11
7 D7 and D15 D10
8 D8 and D16 D9
Cross-Pinning Cable
1. Remove the straight cable and connect the
cross-pinning cable to the modular jacks on the
PC boards of the tester and terminator.
2. Push switch SW1 until the two vertical LEDs D1
and D9 are blinking alternately and LED D8
should be blinking too.
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.
Table 2
Two Vertical Cross-Pinning Cable
# Blinking LEDs Single Blinking
LED on Bottom Row
1 D1 and D9 D8
2 D2 and D10 D7
3 D3 and D11 D6
4 D4 and D12 D5
5 D5 and D13 D4
6 D6 and D14 D3
7 D7 and D15 D2
8 D8 and D16 D1
Short Test
1.
Push switch SW1 until the two vertical LEDs D4
and D12 are blinking alternately and LED D5 is
blinking too.
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.
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.
Figure 16b
The LED D13 should be blinking too. Remove the
jumper and LED D13 should turn off. If not, then:
Check the F-connector on the terminator PCB.
a)
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.
4. Remove the cable from the modular jacks on the
PC board and proceed to the final assembly.
-20-
SECTION G - FINAL ASSEMBLY OF TESTER
Push the button cap onto the switch as shown in Figure O.
Mount the PC board to the top case, as shown in
Figure P, with two #4 5/16” 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.
Wrap the wires from the battery snap around the
battery housing as shown in Figure Q.
Button Cap
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.
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.
3 x 12mm Screws
Bottom Case
PC Board
Figure O
#4 5/16” Screws
Figure Q
9V Battery
Battery Cover
Figure P Figure R
Top Case
-21-
FINAL ASSEMBLY OF TESTER (cont.)
Insert the M3 x 10mm machine phillips screw into
the battery cover hole, as shown in Figure S, and
tighten.
M3 Phillips
Screw
Figure S
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
Figure T
FINAL ASSEMBLY OF TERMINATOR
Before assembling, check that the excess leads
from the F-connector are cut off (see page 16).
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
Top Load Case
Load PC Board
Bottom Load Case
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.
Load Label
Figure U
Figure V
-22-
FINAL ASSEMBLY (cont.)
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
• Unshielded communication cable with RJ-11 and
RJ-45 connectors.
• Ethernet 10 Base-T, Token Ring, EIA/TIA-568A/B,
AT&T 258A, and USOC.
• 50 or 75W coaxial cable with F connectors.
• 50 or 75W coaxial cable with BNC connectors.
Must use F to BNC adapters.
Maximum testing length for all cable types is
1,000 feet.
ENVIRONMENTAL CONDITIONS
• Operating Conditions: 0OC - 45OC / 32OF - 113OF
70% RH max.
O
• Storage Conditions: -10
C - 50OC / 14OF - 122OF
80% RH max.
POWER
• Standard or alkaline 9V battery
• Low battery indicator (Lo Batt.)
• 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-
OPERATION INSTRUCTIONS
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.
Push the TEST (power) button and read the result.
2.
Good Pair: Two vertical and one single blinking
LEDs. The location of the single LED indicates a
straight or cross-pinning for the pair.
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
*
*
*
Good Pair (Cross-Pinning)
3 & 6 Wires
*
3. Push the TEST button again and read the result
for the next pair.
For testing coax cable, use the middle LEDs (boxed
4.
in as coax on the unit).
5.
If you do not push the button for 30 seconds, it will
automatically shut off.
= Blinking LED
For straight open wire #3
For Cross-Pinning
*
*
Open Pair
open wire #6
*
*
*
Short
Cross-Pinned cable
short wires 6 & 7
*
Configuration
for Testing
Communication
Cable
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
Figure 17
-24-
WIRING SCHEMES
Ethernet
EIA/TIA-568A EIA/TIA-568B
10Base-T
8-Position
USOC USOC
Token Ring
RJ-11 (4-Wire) Straight-Pinning RJ-11 (4-Wire) Cross-Pinning
1
(Y) 1
(G) 2
(R) 3
(BL) 4
NOTE: Cross-Pinning is for typical telephone use.
RJ-11 (6-Wire) Straight-Pinning RJ-11 (6-Wire) Cross-Pinning
(BL) 1
(Y) 2
(G) 3
(R) 4
(BK) 5
(W) 6
RJ-45 (8-Wire) Straight-Pinning RJ-45 (8-Wire) Cross-Pinning
(BL) 1
(OR)2
(BK) 3
(R) 4
(G) 5
(Y) 6
(BN) 7
(S) 8
(Y) 1
2
(G) 2
3
(R) 3
4
(BL) 4
1
(BL) 1
2
(Y) 2
3
(G) 3
4
(R) 4
5
(BK) 5
6
(W) 6
1
(BL) 1
2
(OR)2
3
(BK) 3
4
(R) 4
5
(G) 5
6
(Y) 6
7
(BN) 7
8
(S) 8
AT&T 258A
(Prs. 1,2 & 3)
1
2
3
4
1
2
3
4
5
6
1
2
3
4
5
6
7
8
-25-
MAINTENANCE
GENERAL MAINTENANCE
To clean, wipe the case with a damp cloth and
detergent (do not use abrasives or solvents).
When the Lo Batt. LED lights up, you need to
replace the battery. The terminator does not use
a battery.
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
3. Carefully remove the old battery and replace with
a new battery.
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.
5. Reinstall the battery cover and screw.
-26-
Elenco Electronics, Inc.
150 W. Carpenter Avenue
Wheeling, IL 60090
(847) 541-3800
www.elenco.com
e-mail: elenco@elenco.com
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