FACT : Cable / Wiring Harness Advanced Tester (64 - 512 / 128 - 1024 Points)
Futura's Advanced Continuity Tester is an economical, feature-rich, stand-alone wire harness tester offering up to 1024 test points. The powerful FACT Editor software application is used to create unique program files to successfully validate all electrical and electro-mechanical wire harness parameters.
- Continuity, Diode Checker
- Stand-alone system
- Precise testing results
- User role based access
- Built for rough industrial environments
- Tests up to 1024 test points
Introduction of FACT
Highlighted Features






Label print format is given here
FACT 512 | FACT 1024 |
---|---|
Brochure:Download Data:Download FAQ:Download Software:Download | Brochure:Download Data:Download FAQ:Download Software:Download |
Video Manuals
A1. FACT (Futura's Advanced Continuity Tester) Accessories Manual
A2. Introduction of FACT(Futura's Advanced Continuity Tester)
A3. Back Panel Information of FACT(Futura's Advanced Continuity Tester)
A4. Test Board Connection to FACT(Futura's Advanced Continuity Tester)
A5. Learning of Wiring Harness in FACT(Futura's Advanced Continuity Tester)
A6. Testing of Wiring Harness with FACT(Futura's Advanced Continuity Tester)
A7. Main Menu of FACT(Futura's Advanced Continuity Tester)
A8. Analyse menu of FACT(Futura's Advanced Continuity Tester)
B1. Setup menu of FACT(Futura's Advanced Continuity Tester)
B2. Setup menu of FACT(Futura's Advanced Continuity Tester)
B3. General setting menu in FACT(Futura's Advanced Continuity Tester)
B5. Create Authority and Assign Pen-drive for FACT
B6. Create new FCT file in FACT Editor.
B7. Transmit FCT file from PC to USB & USB to PC.
C1. Calibration of FACT(Futura's Advanced Continuity Tester)
C2. Connection of PHTM Board to FACT(Futura's Advanced Continuity Tester)
C3. Pokayoke Mode Information in FACT(Futura's Advanced Continuity Tester)
C4. Pokayoke,Fail Bin Setup in FACT(Futura's Advanced Continuity Tester)
C5. Demo of Pokayoke mode in FACT.
C6. Diode Checking Information using FACT(Futura's Advanced Continuity Tester)
C7. How to change Module in FACT(Futura's Advanced Continuity Tester)
DATA ENTRY/PROGRAMMING
- Program Creation
- Program Settings
- Learning
TESTING
- Continuity (Open, Short, Interchange, Extra Point)
- Diode (directional, polarity, open, short)
- Modes(Production, Sample Harness, Run Sample)
- Two stage testing
- Testing Methods(Circuit by circuit, all circuit)
- Error Display (Fault Type, IO Point, Fixture Number, Wire Name, Wire Colour, Fixture Image, Cutter Module timer, Sample harness timer)
OUTPUT
- PASS (Label Printing, Audio, Visual, Pass Counter, Relay output/s, Data logging, Signal for Connector Printing)
- FAIL ( Visual, Audio, Fail Bin, External Cutter Module activation signal, Locking, Relay output/s)
DATA LOGGING
- Basic data is logged in USB Storage for each PASS/FAIL event
DIGITAL I/O
- HACG as external accessory
BARCODE PRINTING
- Label Printing
- Barcode scanning for checking correct barcode print
- Barcode scanning for selection of program for testing
- Barcode scanning after harness pass for confirmation of selected program
- Resource Barcode (Confirmation of Child Part Assembly)
SYSTEM CHECKING
- Sample Harness
- Run Sample Mode
CALIBRATION
- Board Check
- Program Check
DIAGNOSTIC
- Self Test
- Internal Memory
- Buzzer
- Real-time Clock
- Serial Port
FACT 512 | FACT 1024 | |
---|---|---|
Test Point Capacity | 64, 128, 192, 256, 320, 384, 448 & 512 points | 128, 256, 384, 512, 640, 768, 896 & 1024 points |
Expandable in step of | 64 | 128 |
Components | Diodes: Check for proper orientation | Diodes: Check for proper orientation |
Diode Testing | Yes - Diode open: Diode missing or open from inside. Diode short: Diode short from inside or wire assembled instead of diode. | Yes - Diode open: Diode missing or open from inside. Diode short: Diode short from inside or wire assembled instead of diode. |
Test Voltage | Test voltage: 5 V DC. | Test voltage: 5 V DC. |
Test Current | Test current: In mill Amperes. | Test current: In mill Amperes. |
Test Speed | 1 seconds per 512 test points (continuity only) | 1 seconds per 512 test points (continuity only) 2-3 seconds for above 512 |
Display | 20*4 character LCD display with backlit | 20*4 character LCD display with backlit |
Audible Tones | Buzzer programmable, audio output on pass, fail, with tone and volume control | Buzzer programmable, audio output on pass, fail, with tone and volume control |
Program Storage | For 1K label data size—128 locations are available. For 2K label data size—96 locations are available. For 4K label data size—64 locations are available. For 8K label data size—32 locations are available. | For 1K label data size—80 locations are available. For 2K label data size—64 locations are available. For 4K label data size—48 locations are available. For 8K label data size—24 locations are available. |
Serial Ports | PC: Standard 2 RS232 serial ports. Serial port 1: For PC communication with Futura’s FACT editor only. Serial port 2: For serial printing, barcode scanner attachment. | PC: Standard 2 RS232 serial ports. Serial port 1: For PC communication with Futura’s FACT editor only. Serial port 2: For serial printing, barcode scanner attachment. |
Printer Port | 25 pin D for parallel port printer and 9 pin D for serial port printer | 25 pin D for parallel port printer and 9 pin D for serial port printer |
Test point interface | Output of each I/O card consist of 64 pin FRC connector with open wires which can be interfaced with 36 pin centronics dongle or 15-25-25 D type PCB or 64 pin PBT pcb. | Output of each I/O card consist of four 34 pin FRC connectors wirh open wires which can be interfaced with four 34 pin FRC cables terminating into 36 pin centronics or 37 pin D type or 32 pin PBT pcb. |
Input power | Supply Voltage: 12 V DC, 2A. (Input 230V AC +-10%) Power consumption: 5 Watts. Short circuit protected. | Supply Voltage: 12 V DC, 2A. (Input 230V AC +-10%) Power consumption: 5 Watts. Short circuit protected. |
Size (W x D x H) | 285 mm * 220 mm * 90 mm +- 2mm. | 285 mm * 220 mm * 90 mm +- 2mm. |
Weight | Approximately 5 Kgs. basic tester | Approximately 5 Kgs. basic tester |
Operating Parameters | Working temperature: 0 - 50 C. | Working temperature: 0 - 50 C. |
Warranty | Conditional for a period of 12 months only for new equipment/products | Conditional for a period of 12 months only for new equipment/products |
User Authentication | USB Pendrive (Soft Key) | USB Pendrive (Soft Key) |
Display Faults | Errors are displayed like open, short, location & extra points using point number | Errors are displayed like open, short, location & extra points using point number |
No of stages testing | 2 stage | 2 stage |
Relay output | Potential free Relay outputs 2 numbers, up to 230V AC, 5A load. 1 is configured as pass relay and relay 2 is configured as fail relay. | Potential free Relay outputs 2 numbers, up to 230V AC, 5A load. 1 is configured as pass relay and relay 2 is configured as fail relay. |
Barcode scanning | Yes | Yes |
Application | General Harness Checking as per points, Diode checking (Correct polarity and a faulty diode) | General Harness Checking as per points, Diode checking (Correct polarity and a faulty diode) |
- Run Futura FACT Editor Software which is given in CD or pen drive with tester.
- Connect Pendrive to Computer to which authority is to be given.
- Open FACT Editor.
- Click on setting – user setting – add.
- Type authority name, password & save it.
- Click on setting – Authority – burn database in pendrive.
- If USB device is found then click on Yes.
- Click on ok for further options.
- Click on setting – Authority – Assign Pen Drive Authority.
- If USB device is found then click on Yes.
- Select required authority and click on Assign.
- Now pendrive is assigned for given authority.
- Connect testing board to tester.
- Mount sample harness to be learnt on board.
- Switch ON the Tester.
- Select required Program No. & press enter.
- Select SETUP menu and press enter.
- Select FCT-DATA and press enter.
- Select LRN DATA and Press Enter.
- Points get learnt and number of points learnt will be displayed.
- Confirm if correct numbers of points are learnt.
- Tester will ask DELETE REMAINING FCT DATA?
- By pressing ESC key previous FCT data except harness data will remain.
- By pressing ENT key previous FCT data will delete.
- Go back to MAIN MENU and select TEST and press enter.
- Display will be REMOVE CABLE. Remove harness from board.
- Display will be PUT CABLE.
- Generate new FCT file from FACT editor software.
- Open generated FCT file from saved location.
- Fill up following information which is given in bold letters and save.
- This is basic information require for FCT file.
- To fill up (2 Stage data, BAR1, BAR2, CPLR data) refer manual.
<?xml version="1.0" encoding="UTF-8"?>
<!--FCT File Version = 1.1-->
<FACT_DATA>
<PGM_NO>001</PGM_NO>
<PGM_NAME>Sample</PGM_NAME>
<HRN_DATA>
<STAGE_1>
<![CDATA[
0004
0001 0002
0003 0004
]]>
</STAGE_1>
<STAGE_2>
<C![CDATA[
]]>
</STAGE_2>
</HRN_DATA>
<LABEL_DATA>
<C![CDATA[
Futura Apsol PVT.LTD.
Sample Harness
Tested OK
DATE:@1
TIME:@2
]]>
</LABEL_DATA>
<BAR1>XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX</BAR1>
<BAR2>XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX</BAR2>
<CPLR_DATA>
<![CDATA[
]]>
</CPLR_DATA>
<DETAILS>Sample Harness</DETAILS>
</FACT_DATA>
Capacity of FACT256 is maximum 256 points. If tester has less number of I/O cards than its maximum capacity, it can be increased by adding an I/O card in the next available slot or after 256 points same encloser Can connect to existing tester increase points.
- Check connection of serial cable, one end to PC and other end to tester.
- Replace serial cable.
- Check communication port number selected on PC software and it is connected and working. (COM port, com1 / com2 etc.)
- If problem persists
- Remove serial cable from back side of tester.
- Connect 9 pin ‘D’ serial dongle to tester which is given with tester.
- Select SETUP menu and press enter.
- Select DIAGNO menu and press enter.
- Select RS232 menu and press enter.
- If serial test is pass then problem is in PC side.
- If serial test is fail then open the tester.
- Check weather MAX232 IC is heating at the time of communication.
- If problem found in the IC then replace it.
- Send CPU PCB to Futura for repair.
- Instead of learning harness data in both stages transmit harness data file from P.C.
- Upgrade software to latest one
- Remove harness from mounting board.
- Select board check option on tester.
- Take board check for every point on board.
- There should be single point for every number.
- If some point is not showing any number then check cable.
- Check print label setting is On or Off for selected Program number.
- If yes, then connect another working printer with its working cable.
- If problem persists,
- Select SETUP menu and press enter.
- Select FCT-DATA menu and press enter.
- Select DEMO-LBL menu and press enter.
- If problem persists,
- Connect Dot Matrix printer to take test print.
- Select SETUP menu and press enter.
- Select DIAGNO menu and press enter.
- Select PARALLEL menu and press enter.
- If Test Print will come then tester is OK.
- If problem persists, open the tester.
- Replace IC 74HC244 or send CPU PCB to Futura for repair.
- It means that tester finds some points internally shorted even if harness is removed.
- Conduct self test after removing harness from the board. Tester will display shorted points. Check these points on the board.
- If problem persists, separate board from tester at board end and conduct self test. Check for shorted points from tester to board.
- If problem persists, remove cable from back side of the tester and conduct self test. Check for shorted points and replace appropriate I/O card.
- It means that tester dose not found any connection on board.
- Select BRD check option in main menu and check weather tester shows any points or not.
- If points are not shown (Display is BRD 0000) then check interface cable and Interface PCB connection.
- Remove FRC cable from back side of tester and conduct board check directly to points of I/O cards.
- If board check is coming properly then open the tester from bottom side. Also open Bezel (Black colour plate on which LCD is mounted). Then you can see FACT Mother Board PCB. On this PCB check JP1 connector (which is below 10 pin FRC connector) is shorted by short link or not. It must be shorted.
Program Creation
- Program Creation from FACT Editor software
- Self Learnt Data importing
Program Details
- Connections (IO Point)
- Label Program Import from previous files (Real time variables)
- Resource Barcodes
- Authority Management
- Two stage programming settings
- Shift Programming Settings (First Shift Timing, Second Shift Timing, Third Shift Timing)
Program Settings
- Common (Auto Mode, All Circuit Mode, Extra Point, Resource Barcode, Check Barcode, Label Printing, Run Sample Mode)
- Cutter Module (Cut for Open Error, Cut for Short error, Cut for location Interchange Error, Cut for Extra Point Error, Cutter module delay time)
- Sample Harness (Sample Harness delay time, Sample harness step error)
- Capacitor Delay (Starting Delay time, Capacitor Delay time)
- Shift Programming (Targeted Harnesses, Shift Time)
- Clear Count(Clear Pass Count, Clear Fail Count, Clear Cutter Count)
- Stage Circuit (Stage Circuit Action)
- Lot Quantity (Lot Quantity, Lot Counter, Import PRN File)
Continuity Testing
- Open
- Short
- Interchange
- Extra Point
Diode Testing
- Diode directional testing in the wiring harness can be tested.
- Diode to be programmed through software, learning is not available.
- Directional testing is done, i.e. diode polarity can be checked.
- Diode Open, Diode Short error types can be checked.
- Diode missing, Diode shorted from inside, Diode assembled in reverse direction can be identified.
Modes
- Production Mode
- Sample Harness Testing Mode
- Run Sample Mode
Two Stage Testing
- Two stages of harness can be programmed and tested.
- Testing is done stage by stage.
- Each stage can consist of continuity and diode.
- Data logging according to each stage.
Testing Methods (Settable for each stage seperately)
- Circuit by circuit
- All circuit
Error display
- Fault Type
- IO Point
- Cutter Module timer
- Sample harness timer
Pass
- Visual output
- Label printing with real time user defined data
- Audio output (User selectable)
- Relay output/s
- Pass counter
- Data Logging
Fail
- Audio output (User selectable)
- Visual output (Fault Type, IO Point, Cutter Module timer, Sample harness timer)
- Relay output/s
- Data Logging
- Cutter Module Activation Signal
- Critical harnesses where rework is not allowed after found faulty are cut using this mode.
- Activation/Deactivation of cutter for each error, is programmable.
- Individual error timing is programmable.
- After mounting harness if error arrives, down counter is started and operator have limited time to correct the error if not harness will be cut.
- Harness cutter can be designed as per user requirement and interfaced with tester
If mass storage device such as pen drive is connected continuously during testing of wiring harness, then at every pass or fail event, data will be logged in file FACTLOG1.TXT.
- Current program number
- Program name
- Date (DD/MM/YYYY)
- Time (HH:MM:SS)
- Pass count XXX
- Fail count XXX
- Serial number (no of digits will be set by label file)
- Result (PASS or FAIL)
Barcode Printing: Label Printing
- Provision for label sticker generation at harness pass is available.
- Programming through .prn file import in to the harness program.
- Can be connected to any label printer and programming is through .prn file.
- Variables such as date, time, serial number, shift, barcodes, operator codes, and many more are present in the label and can be customised in the future as per requirement.
Barcode Scanning
Barcode Scanning for checking correct barcode print
- Various barcodes are printed on the label during sticker generation.
- Rechecking these barcodes with respect to correct data is printed or not,
- Proper scanning, proper scanning can be done.
- Generating and checking unique barcode for particular harness can be done.
Barcode scanning for selection of program for testing.
- Program can be selected for testing through barcode scanning.
- Correct program selection and manual selection can be avoided.
- Barcode to be scanned for program selection is programmable.
Barcode Scanning after harness pass for confirmation of selected program
- Manual selection of program can be confirmed after testing through barcode. Programming is available through authority menu.
Resource Barcode (Confirmation of Child Part Assembly)
- Harness is a combination of various raw materials such as cable, sleeves, gromets, plastic tags, wrapping tape and many more.
- These materials can be acquired from various bins at the time of production.
- Each of these bins can have unique barcodes.
- These barcodes can be scanned before production for confirmation purpose for selection of correct material.
- Resource barcodes checked in both sequential and random modes.
- HACG can be connected as external accessory.
Sample Harness
- Used for daily set up or calibration activity.
- Faulty sample harnesses with different pre-determined errors such as OPEN, SHORT, LOCATION and EXTRA with defined points can be tested.
- Unlimited number of steps can be programmed.
- Each step is user programmable with time counter as per user need.
- Each step needs to be completed, for example if Step is OPEN Error i.e., OPEN 0002 and 0032
- Then after mounting faulty harness with OPEN 0002 and 0032 error, only, this step is passed.
- Data logging after each step is completed.
- If terminated in between or misused by operator or bypassed then tester will be locked and at next power on SUPERVISOR intervention it will be unlocked.
- Pass and fail count will not be incremented and no label is printed in sample mode.
Run Sample Mode
- During production mode running, if any sample is to be tested randomly for cross verification this mode is used.
- Harness PASS/FAIL declaration.
- No label print if harness pass.
- No relay is activated for PASS/FAIL.
- Counters such as pass, fail, cut, serial number, are not incremented.
- Data is logged at this event.
- As the tester compares data or connections of a standard harness with the connections of Harness under Test; calibration is not required.
- FACT does not measure any absolute quantity hence calibration is not required.
- To confirm functionality of the test system i.e. test equipment along with test rig, following procedure can be repeated after fixed period say 3 months or 6 months.
- Sample Harness testing facility for Master Sample.
- To check functionality of the equipment and the board, “check board” facility
Board Check
- Board check facility available through board check probe for board and IO diagnostics.
Diagnostic
- Self Test
- Self-test for IO points and cards is available.
- Internal Memory
- Buzzer
- Real-time clock
- Serial Port
Label Printing
- Design a label you need
- Contact printer supplier and get PRN File for required label
- Try printing the same PRN File through PC
- Modify PRN File to suit Futura testers and real time data / variable data (Link @ sheet here)
- Add PRN File to .FCT File
- Transfer FCT File to FACT
- Turn necessary printer setting ON
- Tester with label printer attached