Operating Manual

Cable tester CT45

Identification no.: 2432471

Version, date, author: Version 1.4 11.2017 SHL

Document type: Translation

 Operating Manual

Imprint
© Copyright 2017 TSK Prüfsysteme GmbH. All rights reserved.

Manufacturer and contact person

TSK Prüfsysteme GmbH
Strengelrott 4
32457 Porta Westfalica
Germany
Tel: + 49 (0)571 – 7958 – 0
Fax: + 49 (0)571 – 7958 – 106
E-mail: [email protected]

Internet
Visit our website:
www.t-s-k.de

Contacts
www.t-s-k.de/en/locationscontacts/

In case of question, please contact our After Sales

Service.
Tel: +49 571 7958 300
E-mail: [email protected]

Thank you for purchasing a TSK cable tester.

Page | 2
 Operating Manual

General document information:

Document name
[Path] EN_Operation_Manual_CT45_V1.4.docx

History:
Date Name Version Type Comments
24.03.2016 UMG 0.7 Creation
13.04.2017 SHL 1.0 Change Information for the conversion kit incorporated
31.05.2017 SHL 1.1 Change Network setup on the computer
19.07.2017 SHL 1.2 Change Serial number label of measurement unit added
08.11.2017 SHL 1.3 Change Supplement in the technical data
17.11.2017 SHL 1.4 Change Notice for calibration added
--- --- ---
--- --- ---

Page | 3
 Operating Manual

Contents

1. NOTES ABOUT THIS DOCUMENTATION ........................................................................................................ 6

1.1 About this manual ................................................................................................................................. 6
1.2 Photos, figures and screenshots......................................................................................................... 6
1.3 Copyright ............................................................................................................................................... 6
1.4 Document presentation ........................................................................................................................ 7

2. IMPORTANT STATEMENT ........................................................................................................................... 7

2.1 Qualification of personnel .................................................................................................................... 7
2.2 Intended use .......................................................................................................................................... 7
2.3 Warranty................................................................................................................................................. 7

3. SAFETY INFORMATION.............................................................................................................................. 8
3.1 Cable testers.......................................................................................................................................... 8
3.2 Risk assessment ................................................................................................................................... 8
3.3 FMEA (failure mode and effects analysis) .......................................................................................... 8

4. CABLE TESTER CT45 .............................................................................................................................. 9

4.1 Description ............................................................................................................................................ 9
4.1.1 System requirements ........................................................................................................................................ 10
4.1.2 Connection tester CT45 (Art. No.: 2432471) – Interfaces and label ................................................................. 10
4.1.3 PIN allocation of the DIO interface .................................................................................................................... 11
4.1.4 PIN allocation of the power adapter .................................................................................................................. 11
4.1.5 Status display .................................................................................................................................................... 12
4.1.6 Network connection .......................................................................................................................................... 12
4.1.7 Bus connection ‘’Test point cards’’ .................................................................................................................... 13
4.1.8 Label of serial number of the used measurement unit ...................................................................................... 13
4.1.9 Type plate ......................................................................................................................................................... 14
4.2 Electrical connections and components .......................................................................................... 15
4.3 Block diagram test system with CT45 with standard TSK TP cards .............................................. 15
4.4 Master (Art. No.: 277224) .................................................................................................................... 16
4.5 Link topology....................................................................................................................................... 17
4.5.1 Link topology with a CT45 in the test system with test point cards (128 TPs) .................................................. 17
4.5.2 Link topology with a CT45 in the test system with test point cards (64 TPs) .................................................... 17
4.5.3 Link topology with two CT45 in the test system ................................................................................................ 18

5. DESCRIPTION OF THE SOFTWARE INTEGRATION ........................................................................................ 19

5.1 Settings of the network card on the computer ................................................................................. 19
5.2 Network setup on the computer ........................................................................................................ 20
5.3 CT45 set-up in the CS WIN nx software ............................................................................................ 21
5.4 Access to CT45 information via web browser .................................................................................. 29
5.4.1 Overview ........................................................................................................................................................... 29
5.4.2 Explanation of the interface display .................................................................................................................. 29
5.4.3 Explanation of the menu points ......................................................................................................................... 30
5.4.3.1Menu point “Start page” ........................................................................................................................................................ 30
5.4.3.2Menu point “,Network settings” ............................................................................................................................................. 31
5.5 CT35 / CT45 Service Tool nx .............................................................................................................. 32

6. CTXX PROFESSIONAL SERVICE TOOL ..................................................................................................... 34

Page | 4
 Operating Manual

7. CONVERSION KIT CT35 ==> CT45 (ART. NO. 2439154) ......................................................................... 38

7.1 Prerequisites ....................................................................................................................................... 38
7.2 Checking for completeness ............................................................................................................... 39
7.3 Upgrading the software ...................................................................................................................... 39
7.4 Upgrading the hardware ..................................................................................................................... 40
7.4.1 Procedure (Installation Instructions Part 1) ....................................................................................................... 40
7.4.2 Power adapter (Art. No. 2460986) .................................................................................................................... 42
7.4.3 Connection of the power adapter – (Implementation Instructions Part 2) ......................................................... 42
7.5 Using the “Detect.exe” program ........................................................................................................ 44
7.6 Changes to the CS WIN nx software ................................................................................................. 46

8. TECHNICAL DATA................................................................................................................................... 53

9. SOURCES OF ERRORS AND REMEDY ........................................................................................................ 54

10. SPARE PARTS ..................................................................................................................................... 55

APPENDIX A (CERTIFICATE OF INCORPORATION) ......................................................................................... 56

Page | 5
 Operating Manual

1. Notes about this documentation

1.1 About this manual

This documentation forms part of the cable tester. Therefore, keep the documentation for the entire service
life of the cable t ester.

Prior to commissioning, the operating manual must be carefully read. Only if its content
is fully understood, work with the cable tester may commence.
We strive to ensure that the content of this manual is always up to date. However, please let us know if you
find any discrepancies between the manual and the cable tester. If you have any further questions or
comments, do not hesitate to contact us.

1.2 Photos, figures and screenshots

Illustrations in the form of photos, figures and screenshots should always reflect the current product status.
However, ongoing innovations and improvements may mean that the illustrations in this manual may not
precisely match the product. This does not affect operation, functionality or safety.

1.3 Copyright
© Copyright 2017 – TSK Prüfsysteme GmbH according to DIN ISO 16016
In case of further developments and other improvements, we reserve the right to make changes to the
technical data and function sequences contained in the descriptions and figures of this manual. This
manual is copyright protected. We reserve all rights regarding the translation, reprint and reproduction of
the manual in whole or in part.
This manual must not be reproduced in whole or in part in any form (photocopy, microfilm or any other
process) or processed or forwarded using electronic systems, including for training purposes, without the
prior written consent of the publisher.
If you have any suggestions you would like to make for improving this operating manual, please contact
TSK Prüfsysteme GmbH.
All of the product and brand names mentioned in this manual are the property of the respective
manufacturer.
CS WIN® is a registered trademark of TSK Prüfsysteme GmbH.

Page | 6
 Operating Manual

1.4 Document presentation

All safety information in the operating manuals have the same structure.
Safety information are comprised of:
 a pictogram indicating the hazard type,
 a signal word indicating the severity of the hazard and/or a note that accurately describes the hazard.
Symbol Text Font conversion

Caution Arial Narrow, bold

Specific instructions Arial Narrow, bold

Warning, danger, ... Arial Narrow, bold

Information, Note, ... Arial Narrow, italic

2. Important statement

2.1 Qualification of personnel

Only persons who have been previously trained by qualified experts are allowed to work with the cable
tester.

2.2 Intended use

The cable tester forms integral part of the test environment.

Any inappropriate use invalidates the warranty!

Modifications to the cable tester are not permissible!

Detailed description about the use can be found under ,4. Cable tester CT45’.

2.3 Warranty
TSK grants a 12-month warranty from the date of delivery.
Damage due to improper handling or caused by the use of incorrect spare parts and assemblies (third-party
manufacturer) are excluded from the warranty.

Software updates must be performed by qualified staff after consultation with TSK.

Any changes implemented on your own may destroy the tester!

This shall void the warranty!

Page | 7
 Operating Manual

3. Safety information
Current standards and directives must be complied with when carrying out work on electrical systems and
electrical devices.

TSK Prüfsysteme GmbH accepts no liability for damage or injuries caused by improper
handing or by modifications to the cable tester.

3.1 Cable testers

The cable tester is operated with a low-voltage supply of 5 V / 5 A.

Works regarding maintenance, extension or repair must only be performed by trained

expert personnel!
Remove the power adapter.
 Before conducting repairs or service operations
 Before installing any extensions or accessories
Please pay attention to these instructions, so that no electrical shock can occur at any
time.

3.2 Risk assessment

The risk assessment for the cable tester was prepared.

You can access the risk assessment upon request at all times.

3.3 FMEA (failure mode and effects analysis)

A failure mode and effects analysis was carried out for the cable tester CT45.

You can access the FMEA upon request at any time.

Page | 8
Operating Manual

4. Cable tester CT45

4.1 Description
The cable tester CT45 is designed for the use and
installation in TSK test systems.
The CT45 is accessed via the Ethernet interface of a
computer which uses the CS WIN nx test software. In the
test system, the computer with the CS WIN nx test
software assumes all control functions of the test
devices, the test procedures and the saving of the results
for evaluation.
The CT45 provides the measuring technology in the test
environment to realize precise requirements, typically in
the field of cable set testing.
The CT45 manages and controls up to 8,192 test points.
With the double linkage built with another CT45, 16,384
test points are possible.
The CT45 is mechanically realized as a 19’’ plug-in
module/ 1 U.

The following (test) features are realized with the CT45:

 Continuity and short-circuit test with selectable
threshold
 Detection of the presence of mechanical
components
 Test of resistances, (Z) diodes and capacitors
 Detection and actuation of test adapter LEDs for
position and error detection
 PIN number search function
 8 freely programmable SPS-compatible inputs
and outputs each
 Position test with length measuring pin
 Supports attenuation measurement of optical
fiber conductors
 Supports B+, leak test and color recognition
Furthermore, the CT45 supports:
 New types of test point cards/measurements: HV
and 4-pin for the test with high voltage (HV) and
the high-precision measurement of very low
resistances within a HV system.

Page | 9
 Operating Manual

4.1.1 System requirements

The computer and CS WIN nx test software must exhibit the following characteristics for the integration of
the CT45 in a test system:

 Minimum requirements for the PC

 CPU, e.g. Intel G3xxx or better
 Min. 4 GB RAM (8 GB is recommended)
 1 GB free hard disk storage
 1x free Ethernet port required
 Requirements for the CS WIN nx
 CS WIN nx version 5.6.13.12
 From CS WIN nx version 5.9.9.5

Use of the CT45 with an older CS WIN software version is possible but requires special testing
and approval in the individual customer system.

TSK Service will gladly support you in such case.

4.1.2 Connection tester CT45 (Art. No.: 2432471) – Interfaces and label
 Serial number label of the
measurement unit
 Connection to the computer
 (Ethernet)
 Power
 Plug-in power pack
 State
Communication display
 DIO interface
 Connected to master board
with DIO cable
 Test card bus
 Test point cards

The connection cables to be used are depending on the test system. Please learn from the
operating manual of the test system which cables are appropriate.

Page | 10
 Operating Manual

4.1.3 PIN allocation of the DIO interface

 PIN Signal
1- DO0 (digital output 1)
2- DO1 (digital output 2)
 3- DO2 (digital output 3)
4- DO3 (digital output 4)
5- DO4 (digital output 5)
6- DO5 (digital output 6)
7- DO6 (digital output 7)
8- DO7 (digital output 8)
9- +24 V EXT (+24 V output)
10 - +24 V EXT (+24 V output)
11 - DI0 (digital input 1)
12 - DI1 (digital input 2)
13 - DI2 (digital input 3)
14 - DI3 (digital input 4)
15 - DI4 (digital input 5)
16 - DI5 (digital input 6)
17 - DI6 (digital input 7)
18 - DI7 (digital input 8)
19 - GND EXT
20 - GND EXT
21 - 24 V EXTIN (24 V feed)
22 - 24 V EXTIO (24 V feed)
23 - PINPROBE
24 - FORCE+E
25 - AGND
26 - (not connected)

4.1.4 PIN allocation of the power adapter

1- +5 V
2- GND
3- PE

Page | 11
Operating Manual

4.1.5 Status display

 LED (red) lights up: CT45 tester is

not initialized.
(turns itself off when CT45 is
recognized by the CS WIN nx test
software)
 LED (greens) lights up: Operating
voltage OK

4.1.6 Network connection

 RJ 45 Ethernet connection for the
communication with the PC.

Connection via Ethernet switch

possible.

Required network cable min. CAT5.

Page | 12
Operating Manual

4.1.7 Bus connection ‘’Test point cards’’

 Connection of the CT45 TP card bus via
 25-pin sub D-connection.

The CT45 bus cable must be

connected to the master of the
test system.
Please also see section 4.5

4.1.8 Label of serial number of the used measurement unit

 Serial number of used measurement unit
as 1D barcode und readable text.

Serial number of the used

measurement unit is not equal as
the serial number of the complete
tester.
Please also see section 4.1.9.

Page | 13
 Operating Manual

4.1.9 Type plate

The type plate is at the bottom of the CT45, as well as a sticker with information about the next test date.
Those are described in the following. In addition, there is a recommendation for the calibration interval.

Additional information about the CT45 can be found in the web browser (see section 5.4‘).

 Tester type –S/N

(Serial number: CT45 - XXXXX)
 Material number
xxxxx (Article number: 2432471)
 Date of Product.
dd.mm.yyyy (Date of manufacture in the form of
Day/Month/Year)
 Main Voltage
(Operating voltage: 5 V DC)
 Power consumpt.
(Power consumption: 25 W)

Recommendation: The CT45 should be

checked and calibrated every 24 months by the
TSK.

Page | 14
 Operating Manual

4.2 Electrical connections and components

4.3 Block diagram test system with CT45 with standard TSK TP cards

Test Test Test

adapt adapt adapt …
er er er

10.1

1.2 Master 2.1 2.1

Computer Test point card
CT45 Art. No. 2409424 3.6 / 3.10 Art. No. 8.1 8.1 …
incl. CS WIN nx Art. No. 277957
277224
6.2 9.2 9.2

4.1 2.3 / 2.7

23
0
VA
C
Power pack plug-in module Voltage
Art. No. 2437430 (600 W) 5.1 distribution 3.4
Test Test Test
or 2436465 (1100 W) Art. No. 219331 adapt adapt adapt …
Voltage input 230 VAC 11.1
er er er

Slave 2.1
8.1 Test point card
7.3 Art. No. 8.1 …
Art. No. 277957
219325
9.2 9.2

7.3 2.3
/ /
3.4
7.1 2.7
0

Key of the cables:

Description No. Art. No. Length Description No. Art. No. Length
Buc cable CT (daisy chain) 1.1 266485 1500 mm Power supply cable  slave 7.1 228548 600 mm
1.2* 268018 3000 mm 7.2 228549 1300 mm
Buc cable TPC (daisy chain) 2.1* 209842 100 mm 7.3* 236962 1400 mm
2.2 209843 200 mm 7.4 219535 1600 mm
2.3* 209612 530 mm 7.5 219534 1900 mm
2.4 209613 730 mm 7.6 224152 2100 mm
2.5 209614 930 mm 7.7 219536 2350 mm
2.6 209615 1130 mm 7.8 219537 2400 mm
2.7* 216115 1700 mm 7.9 219538 2450 mm
2.8 209634 1900 mm 7.10* 236963 3000 mm
2.9 223860 2000 mm 7.11 219540 3300 mm
2.10 216116 2100 mm 7.12 219539 3550 mm
2.11 209635 2200 mm Power supply cable 8.1* 219253 80 mm
TPC 1
2.12 223861 2500 mm Power supply cable 9.1 2434431 80 mm
Connection cable DIO 3.1 2314908 330 mm TPC 2 9.2* 210441 120 mm
CT45 3.2 209636 800 mm 9.3 2434459 150 mm
3.3 228544 1650 mm 9.4 209621 250 mm
3.4* 209637 2100 mm 9.5 2434460 250 mm
3.5 287112 2450 mm 9.6 209622 550 mm
3.6* 283289 2600 mm 9.7 209623 750 mm
3.7 273390 5500 mm 9.8 209624 950 mm
Power supply cable CT45 4.1 2411090 3000 mm 9.9 209625 1150 mm
Power supply cable Power 5.1* 289445 3600 mm Network cable 10.1* 108125 1000 mm
board
Power supply cable  6.1 228546 600 mm NT supply 11.1* 2444939 5000 mm
master 6.2* 228547 1400 mm
6.3 224151 1700 mm 3.8 209648 400 mm
6.4 219531 1900 mm Connection cable DIO 3.9 287113 2450 mm
6.5 236961 2600 mm CT35 3.10* 209611 3000 mm
6.6 219533 3050 mm
6.7 219532 3250 mm
* default length

Page | 15
 Operating Manual

4.4 Master (Art. No.: 277224)

The master assumes the control of the digital inputs and outputs and the special functions of the test
adapters, such as hot stamping, airbag and optical fiber measurement. Furthermore, the DC/DC converter
for the LED bus is located on the board. The communication between the tester and test point cards is also
routed via the master board.

The CT45 is connected with the X1 connection of the master and X18 with the link bus of the CT45.
X1 I/O bus input (of DIO CT45 tester)

X16
X2
X7 X9
X8 X10 X2 I/O bus output (to the next I/O adapter)
X6 X11
X18 DC/DC converter microfuse 2A

X19
X5 X12
X3 X4 X3 Gauger (test adapter Ver.2)
X4 Solenoid valve levels (Ver.4)
X5 Hot stamping test adapter
X17 X23 X14
X15
X20
X13

X1
X6 3-button operating test adapter

X7/X8 Airbag test adapter 1

Status of the LEDs X9/X10 Airbag test adapter 1
D1: Short-circuit between TP and GND
X11/X12 Spacer impact test adapter 1
D2: OK
D3: Short-circuit between TP and +24 V X13/X15 24 V supply TP cards, 4-pin
X16 5 V/9 V supply TP cards, 3-pin
X17 Input supply of the voltage distribution
board
X18 Input test point link bus
1: You can connect a max. of 2 spacer X19 Output test point link bus
impact or airbag test adapters or 1 spacer impact
or airbag test adapter each to each of the I/O X20 24 V supply TP cards, 4-pin
boards. P1 Short UB
P2 Short GND
PIN Output pin terminal

Page | 16
 Operating Manual

4.5 Link topology

4.5.1 Link topology with a CT45 in the test system with test point cards (128 TPs)
Link building with master, test point cards and slaves corresponds to the following topology.
CT45  Master  TPK 1  TPK 2  TPK 3  TPK 4  TPK 5

Slave  TPK 10  TPK 9  TPK 8  TPK 7  TPK 6  Slave

TPK 11  …

After a master or slave board, up to max. 5 test point cards are possible!

In a link of a cable tester, max. 64 cards (8192 test points) can be connected!

4.5.2 Link topology with a CT45 in the test system with test point cards (64 TPs)
Link building with master, test point cards and slaves corresponds to the following topology.
CT45  Master  TPK 1  TPK 2  TPK 3  TPK 4  TPK 5

TPK 11  TPK 10  TPK 9  TPK 8  Slave  TPK 7  TPK 6

TPK 12  TPK 13  TPK 14  Slave  TPK 15  …

After a master or slave board, up to max. 7 test point cards are possible!

In a link of a cable tester, max. 28 cards (1792 test points) can be connected!

Page | 17
 Operating Manual

4.5.3 Link topology with two CT45 in the test system

Double linkage building with two CT45 cable testers is required if more than 64 test point cards (128 TPs)
are used in the test system.
Both cable testers are connected to the PC via an Ethernet switch.
CT45(1)  Master  TPK 1  TPK 2  TPK 3  TPK 4  TPK 5

…  TPK 6  Slave
Kopplungskabel 
(Art.-Nr. 2315975) 
…  TPK 70  Slave

CT45(2)  Master  TPK 65  TPK 66  TPK 67  TPK 68  TPK 69

An extension of the test system is required for more than 48 test point cards (Art. No.
2314216)!

The use of 2007 master (Art. No. 277224) and older master boards is not permitted in a
test system!

The use of 2007 master (Art. No. 277224) and older master boards is not permitted in a
test system!

If, for example, a CT35 with double linkage building is to be replaced with the CT45 cable tester,
the double linkage building must be realized with two CT45.

Page | 18
 Operating Manual

5. Description of the software integration

5.1 Settings of the network card on the computer

The computer must have an independent network card for the communication with the CT45. The
connection is via a crossover cable.

The following configurations have to be made on the network card:

 IP address: 198.168.1.1
 Subnet mask: 255.255.255.0

Page | 19
 Operating Manual

5.2 Network setup on the computer

The following other settings have to be made
 Modifications / checking of properties in
the network setup
(Transmission rate and mode)
 Auto Negotiation / automatic

Page | 20
Operating Manual

5.3 CT45 set-up in the CS WIN nx software

Description of TSK Studio
TSK Studio is loaded as soon as the system
is launched. This screen shows all programs
you are authorized for.

Explanation of the buttons:

CS WIN

Logging Monitor

Graphical Label Editor

CT35 Service Tool

QDV

Exit

Page | 21
Operating Manual

Login
Enter your user name and the appropriate
password. Press the button to confirm
your entries.

Operator rights
 Testing only:
Name:
Password:

 Administrator:
Name:
Password:

Screen keyboard
Press the button to open the CS
WIN numeric keyboard.

Further information about the user

management can be found in the
CS WIN nx instructions.

Page | 22
Operating Manual

Preparation
 Acknowledge the current test
environment / ,Default Table’ with
,Ignore’.

 Confirm that no current project exists.

 End the search process with .

Page | 23
Operating Manual

Description of the CS WIN interface

The CS WIN is starting after you have
pressed the ' ' button in 'TSK Studio'.

Optionally, you can allow the

automatic start of CS WIN via the
Windows Autostart function.

Explanation of the buttons:

Start [F5]

Log off [F3]

Select project [F2]

Edit Mode [F4]

End [F8]

Help [F1]

Page | 24
Operating Manual

Starting the CS WIN

 Select 'Edit Mode'.

Opening the CS WIN

 Change to 'Expert Mode'.

Opening a database
 Activate / Open the editor selection via
'DB Manager'.

Page | 25
Operating Manual

Creating new tester configurations

 Change to 'Tester Configuration'

 Press 'New' to create a new tester.

 Select 'Untitled1' with a right mouse click.

 Press 'Add' to create a new tester/driver.

 Select the CT45 driver via the drop-down

menu.

 Confirm with 'OK'.

Page | 26
Operating Manual

The preset 'CT45 Advanced

Properties' must be maintained.
 Confirm with 'OK'.

Broadcast Address = address of the

network in which the user (CT45) is
located.

 Press 'CT45(Inst1)' with a right mouse

click.

 Select 'Detect'.

 Save the created tester by pressing

'Save'.

You will be asked for a name. Freely

assign it, i.e. “CT45 tester”

Figure similar

Page | 27
Operating Manual

New tester is created

The new test configuration is now

created.

Page | 28
 Operating Manual

5.4 Access to CT45 information via web browser

5.4.1 Overview
The CT45 can be accessed with a web browser (e.g. Internet Explorer). Here you can find specific
information about the used CT45 and can change the network address/IP address.

Before accessing the CT45 via the web browser it must be installed via the CS WIN nx!
(see section 5. )

The preset default IP address during installation is 192.168.1.210.

5.4.2 Explanation of the interface display

 Contact data: TSK Prüfsysteme GmbH
 Tester designation
 Page header of the selected menu point
 Page content of the selected menu point

Page | 29
 Operating Manual

5.4.3 Explanation of the menu points

 Start page
Start page with general information.
 Network settings
Changing the network settings of the
tester

5.4.3.1 Menu point “Start page”

 General and individual system
information
Version numbers:
o CT35 protocol: x.x.x.x
o CT45 protocol: x.x.x.x
o Firmware: x.x.x.x
o Website: x.x.x
o Bootloader: x.x
 ID: 0xxxxxxxxxxxxxxxxxxxxxxxxx
 Number of available test points

Page | 30
 Operating Manual

5.4.3.2 Menu point “,Network settings”

The mask shows the default

values, not the current tester
values!

 IP Address [default value:

192.168.1.210]
Entry of the new 'P address'
 NetMask [default value: 255.255.255.0]
Entry of the new 'NetMask'
 Gateway [default value: 0.0.0.0]
Entry of the new 'Gateway'
 Change network settings
Update of the values in the system

Changing the IP address requires

an update in the web browser
under the new IP address!

The authorized IP address range

is from 192.168.1.210 to
192.168.1.219!

Page | 31
 Operating Manual

5.5 CT35 / CT45 Service Tool nx

The CT35/CT45 Service Tool is incorporated in the TSK Studio software, which also contains the CS WIN.
Within these service tools tests for the hardware diagnosis can be performed. In case of an error you will
receive precise instructions for troubleshooting.
For hardware diagnosis, perform the following steps:
 Start the CT35 / CT45 Service Tool nx.

 Select the tests to be performed.

 Confirm the selection with .

Page | 32
Operating Manual

 The selected tests are being performed.

Should operator instructions appear
during the tests, they need to be
followed and acknowledged with .
 At the end of the test a result message
will follow and where applicable an
instruction for the service case on the
system.
Use to return to the starting
interface.

Figures similar.

Page | 33
 Operating Manual

6. CTxx Professional Service Tool

To perform tests manually (e.g. for servicing purposes or for manual testing), the “CTxx Professional
Service Tool” is available. It is automatically installed with the CS WIN nx.
You can start the CTxx Professional Service Tool via the Windows start menu.

The CTxx Professional Service Test tool must only be used by expert personnel!

If the following window appears, please proceed with the connection as follows:

 Press 'Search'

 Select the 'Tester Type' CT45

 Confirm with 'OK'

Page | 34
Operating Manual

 Apply the default settings with 'OK'

Broadcast Address = address of the

network in which the user (CT45) is
located.

 If several connected testers are found,

please select the desired tester.
 Confirm with 'OK'.

In the following, the CTxx Professional Service Tool user interface is described.

Page | 35
Operating Manual

2 3 4 5

6 7

10

11

Connected Tester Information: information about the connected and selected tester
1 Search: Search button to search for a tester
IP Address: IP address of the active tester (default value: 192.168.1.210)
Firmware version: Display of the tester firmware version
Number of TPs: Display of the available test points

Set IP Address: The IP address must only be changed in the web browser!
TP Tests: Tests for checking the individual test points
2 Resistor: The contact resistance of the individual test points is tested.
Threshold: Specification of the OK threshold (measured value < Threshold = OK)
3 Isolation: The insulation resistance of the test points against GND is measured.
Per Asic: Should errors occur during the test, measurements with regard to Asics of the test point
cards can be performed. Thus, possible disturbance variables are eliminated.

Page | 36
Operating Manual

4 High On/Low Off: “High Side” of all test points is switched. “Low Side” of all test points is open.
High Off/Low On: “High Side” of all test points is open. “Low Side” of all test points is switched.
Threshold, Ohms: Assessment threshold in Ohm
5 All: Performance of all TP tests
Wait Time, ms: Settling time after switching of the test points in milliseconds
General Tests: Testing the digital inputs and outputs
6 Bus Diagnostic: A specified 8-bit pattern is set.
LED Voltage On: Activation of the module's LED voltage
7 DOs: The following digital outputs can be set via the check boxes – DO1, DO2 (Module Voltage,
reserved), DO3 (Repair Plain Up, reserved), DO4, DO5, DO6, DO7, DO8
8 DIs: The following digital inputs are shown (green = off, red = on) – DI1, DI2 (TP Short, reserved),
DI3 (Start, reserved), DI4 (Release, reserved), DI5 (Repair, reserved), DI6, DI7, DI8
Manual Tests: Performance of manual tests
9 Set TPs
High Side TP: Information of the test points of the High Side.
Low Side TP: Information of the test points of the Low Side.
Update TPs: Setting of the High and Low Side.
11
10 Measure
Resistor: Manual resistance measurement for the set test points
Result: Display of the measured resistance value
Capacitor: Manual capacitance measurement for the set test points
Expected Capacitance: Display of the expected capacity value to define the appropriate charging
time for the measurement.
Result: Display of the measure capacity value
Status: Display and saving of the measurement results
11 Status: Display of the measurement results in the status field
Save Results: Saving of the measurement results
Close: Closes the Service Tool

The reports must be interpreted independently, as the results are influenced by connected
pushback or optical fiber modules, for example.
The current module template is consulted for the evaluation of results in the 'CT35/CT45 Service
Tool nx' (see section '5.5 CT35 / CT45 Service Tool nx'). Hereby the software takes care of the
interpretation.

Page | 37
 Operating Manual

7. Conversion kit CT35 ==> CT45 (Art. No. 2439154)

Test systems with a CT35 as a connection tester can be upgraded to a CT45 connection tester by means
of a conversion kit (see section 7.2).
The following instructions explain the conversion.

7.1 Prerequisites
For the use of the CT45 connection tester in an existing test system, the following prerequisites must be
met:

 Only test point cards from version 4.x are installed in the test system.
 The 2007 master is exclusively used as the master.
 All repeaters in the system must be removed.
 With more than 48 test point cards in the link an additional power supply is required (Art. No. 2314216).
 Please do not use a CT45 connection tester with a CT35 connection tester in double linkage building.

In order to use new features such as the faster test speed, the CS WIN test software version 5.6.13.12 or
5.9.9.5 or higher must be used.

If you use the CT45 exclusively as hardware exchange for the CT35 and you have not
installed a current CS WIN nx, please send an email to [email protected]
and request the “Detect.exe” program.

The “Detect.exe” program may only be started once the hardware conversion is complete
(see section '7.5 - Using the “Detect.exe” program').

One-time administrator rights are required for the installation. Please inform your IT.

TSK offers service support to fully integrate the CT45 and to utilize the full functionality after a
hardware exchange. Ask for a customized offer.

Page | 38
 Operating Manual

7.2 Checking for completeness

Check the conversion kit for completeness.
 CT 45 connection tester, 19‘‘
(Art. No. 2432471)
 DIO cable 2.6 m (Art. No.
283289)
 Ferrite core (Art. No. 113239)
 CT45 power supply adapter with
fuse (Art. No. 2460986)
 Documentation

7.3 Upgrading the software

 Copy and save the database or databases on your computer.
 Check your system with the help of the CT35/CT45 Service Tools for functional test point cards (see
section 5.5).
 If desired, install the current version of CS WIN.

From CS WIN nx version 5.6.13.12, 5.9.9.5 or higher the features of the CT45 are supported.
Older software statuses can be continued to use under certain conditions. Special testing and
approval in the individual customer system are required, though.

TSK Service will gladly support you in this.

If no new CS WIN nx version is installed, it is necessary to run the “Detect.exe” program

with administrator rights. Here you specify the correct network settings for the CT45.

The “Detect.exe” program may only be started once the hardware upgrade is complete
(see section '7.5 - Using the “Detect.exe” program').

Page | 39
 Operating Manual

7.4 Upgrading the hardware

7.4.1 Procedure (Installation Instructions Part 1)

Connection works must be carried in de-energized condition!

After performing the steps from section “7.3 Upgrading the software”, the hardware must be converted.
The following steps must be performed.
1. Shut down your PC.
2. Shut down the test system.
3. Disconnect all connections to the CT35.
4. Remove the CT35 from the test system.
Remove also the power supply cable of the CT35 and the DIO cable to the master.
5. Install the CT45 in that position.
6. Connect the test point bus cable and the network cable with the CT45 (see next figure).
7. Connect the power supply cable (Art. No. 2449915) with the CT45 (see figure)

8.
Figure: CT45 with connection markings for the test point bus cable and network cable as well
as the input for the power supply

8. Connect the other end of the power supply cable with the 5 V plug of the test system's power pack (see
figure).

The supply voltage of the CT45 is +5 V (not 24 V)! Use of a wrong power supply can
destroy the tester!

Page | 40
Operating Manual

Examples

5 V connection CT45

Plug-in power pack (new), rear view - TS1500, Test bench power pack, rear view - (TS1400,
TS1600, TS1700 TS1500-08, TS4000/4100 lines, aluminum
frame)

If you use a test bench power pack or an older plug-in power pack, make sure to use the
power adapter which is included in the conversion kit (Art. No. 2460986).

For the use of two CT45 (double linkage) without a second power pack, also connect the
voltage input of the CT45 with the system's power pack. Additionally, use the separately
available power supply cable for double linkage (Art. No. 2439153).

If two power packs are available make sure to use them so that each tester/link has its
own power supply.

Page | 41
Operating Manual

7.4.2 Power adapter (Art. No. 2460986)

 Power plug for table power supply
 Fuse (5 A)
 PE plug for power pack
 5 V power plug for CT45 power supply
 Power plug for the power pack side

7.4.3 Connection of the power adapter – (Implementation Instructions Part 2)

a) Disconnect the connection of the system b) Connect the power adapter (Art. No. 2449915)
voltage from the power pack. with the power pack.

c) Connect the power adapter (Art. No. 2449915) d) Connect the live end of the power adapter with
with the power pack. the table end.

e) Plug the PE in the power pack. f) Plug in the 5 V plug of the CT45 in the power
adapter.

Page | 42
 Operating Manual

9. Connect the DIO cable (Art. No. 283289) with the master in the test system.
10. Attach the supplied ferrite core to the test point bus cable near the CT45 (see figure).

The hardware conversion is thereby complete.

Page | 43
 Operating Manual

7.5 Using the “Detect.exe” program

The “Detect.exe” program reserves the IP address range in the Windows operating system for the use of a
CT45.

The following addresses are intended:

192.168.1.210, 192.168.1.211, 192.168.1.212, 192.168.1.213,192.168.1.214, 192.168.1.215,
192.168.1.216, 192.168.1.217, 192.168.1.218, 192.168.1.219

The “Detect.exe” program is used only once, or after re-installation or upgrade of the
operating system (Windows 7 to Windows 10). Also with the exchange of a network card.

Proceed as follows.

 Ensure that the CT45 is connected and

switched on.

The green LED lights up.

 Run the “Detect.exe” program with a

right click as administrator.

Page | 44
Operating Manual

Run notification and End

 After successful execution the following
screen appears.

Should errors occur during the

procedure, please contact the TSK
Service.

 Press any button to end the program.

Checking the address range

 Open a run dialog via the

Windows + R key.
 Enter 'cmd'.
 Confirm with OK.

Display of the computer network setup

The display depends on the number

of network cards and connected
devices. Scroll down to the network
card entry for your TSK tester.

You can now see 10 address entries

(192.168.1.210 … 192.168.1.219) of
the type 'static'.

The entries are retained even after a

restart of the computer.

Page | 45
 Operating Manual

7.6 Changes to the CS WIN nx software

The installed test software environment can be used after the hardware exchange of the tester and
completion of the works on the test system hardware (see previous steps).
For a smooth transition several settings have to be made in the CS WIN nx which are described below.

The works must be carried out by authorized and trained personnel only.

The screens of the CS WIN nx software are based on the English language setting of the
software. All screens are to be understood “Representation may deviate from the original”.

Preparatory steps

Carry out the steps in section 5.3

including opening the database!

Log in as administrator to do so!

Creating a new test configuration

 Press 'Tools'. A selection menu appears.

 Select 'Setup' in the menu.

Page | 46
Operating Manual

 Under 'Generals > Table name' delete

the current “table” with 'Erase'.

 Confirm with 'OK'.

 Change to 'Tester Configuration'.

 Press 'New' to create a new tester.

 Press 'Untitled1' with a right mouse click.

 Press 'Add' to create a new tester/driver.

Page | 47
Operating Manual

 Select the CT45 driver via the drop-down

menu.

 Confirm with 'OK'.

 The preset 'CT45 Advanced Properties'

must be maintained. Confirm with 'OK'.

Broadcast Address = address of the

network in which the user (CT45) is located.

 Press 'CT45(Inst1)' with a right mouse

click.

 Press 'Detect'.

 Save the created tester and press 'Save'.

You will be asked for a name. Assign

an unambiguous name without
spaces.

Page | 48
Operating Manual

In the following it is explained which modifications you have to perform to integrate the
new tester into the existing test environment (software) to retain the known functionality.

Integration into the existing test

environment

 Press the right mouse button to open the

Properties of the test point card
database.

 Open the Properties of the test point card

database by pressing the left mouse
button on the entry.

 Rename the 'Name' to exactly match the

name in the previous tester!

Pay attention to the exact spelling!

Here Link 1 became Link1.

A different example: CT45 Instance 1

becomes CT35 Instance 1

With double linkage, please repeat the

respective renaming in the same
manner for the second instance.
 Confirm with 'OK'

 Save the 'Tester Configuration' with

'Save'.

 Close the 'Tester Configuration' with 'X'.

Page | 49
Operating Manual

Allocation of the 'Module Template'

 Select the 'Module Templates' category.

 Open the module template that is

supposed to work with the new CT45
tester with a double click.

 Press the right mouse button in the

opened template to display the menu.

 Select the item 'Properties' with the left

mouse button.

 Open the 'Tester configuration'.

Page | 50
Operating Manual

 Select the above created tester.

 Confirm with 'OK'.

 Confirm the new 'Tester configuration'

with 'OK'.

 Save the new Module Template with

'Save'.

 Close the Module Template with 'X'.

Page | 51
Operating Manual

 With the right mouse button define the

Module Template as default table in the
database.

Completion of the upgrade

 At this point the upgrade is complete.

 Everything is functioning as usual.

Upgrade
complete!

Page | 52
Operating Manual

8. Technical data
Technical data
 Management and actuation of up to 8,192 test points (with a second CT45 up to 16,384 TPs).
 Continuity and short-circuit test with selectable threshold
 Detection of the presence of mechanical components
 Test of resistances, (Z) diodes and capacitors
 Detection and actuation of test adapter LEDs for position and error detection
 PIN number search function
 8 freely programmable SPS-compatible inputs and outputs each
 Position test with length measuring pin
 Supports attenuation measurement of optical fiber conductors
 Supports B+, leak test and color recognition
 Supports new test point card types and measurement types: HV and 4-pin

with the HV option max. 96 TPs.

Maximum limit values:
Power supply: 4.5 V – 6 V; max. 2 % ripple
SPS voltage: max. 50 V
Storage temperature: -10 to +60 °C
Operating temperature: 10 to 40 °C
Air humidity: 40 % to 75 % non-condensing
Operating altitude: max. 2000 m above sea level
Rated data:
Power supply: 5 V-5.5 V / 5 A
Rated output: max. 25 W
Test current: up to 122.5 mA ± 1 %, min. ± 10 uA
Test voltage: up to 15 V ± 1 %, min. ± 20 mV
Continuity test: 20 Ω to 10 kΩ ±2%
Short-circuit test: 10 kΩ to 1 MΩ ±5%
Resistance measurement: 5 Ω to 100 kΩ ± 1 %, min. ± 2 Ω
100 kΩ to 10 MΩ ±5%
Capacitor measurement: 10 nF to 100 uF ± 5 %, min. ± 10 nF

The measurement is performed with a

typical frequency of fMess = 20 Hz.
Deviations to the data sheet specification of the
capacitor may occur due to different frequency.
This must be considered.
Position measurement: 5 mm travel ± 0.1 mm
Diodes test: Silicon, Germanium, Z diodes up to 11 V
Voltage IO bus: 12 V or 24 V
Digital control outputs: 350 mA (per output); max. 500 mA
Dimensions:
Width: 217 mm (without brackets)
482.6 mm (19‘‘, with brackets)
Height: 37.6 mm
Depth: 156 mm
Weight: 1.48 kg (with brackets)

Page | 53
Operating Manual

9. Sources of errors and remedy

Malfunction Cause Remedy
Cable tester does not work  Power supply is interrupted (green  Check power supply wiring up
LED is off) to the cable tester (replace
where necessary)
 Check all power packs for
proper function (replace where
necessary)
Communication with the  Network connection is faulty  Check network connection
computer cannot be
established
 Check network configuration in
the computer

 The network cable does not fulfill the  Replace the network cable
minimum requirement of CAT5
standard
Test point card cannot be  Test point card is faulty  Check the test point card for
recognized proper function. Use the
Service Tool for this. (Note: the
test point card must only be
replaced by qualified expert
personnel.)
 Faulty connection to the test point card  Check the connection cables

Page | 54
Operating Manual

10. Spare parts

Part number Designation Quantity Unit

2432471 Cable Tester CT45, 19’’ 1 PCS

108125 CAT 5 crossover patch cable (1 m) 1 PCS

106461 CAT 5 crossover patch cable (20 m) 1 PCS

209636 Connection cable TS1500 MasterSlave 26-pin 0.8 m 1 PCS

209637 Connection cable TS1500 MasterSlave 26-pin 2.1 m 1 PCS

266485 Bus cable (ext. CT45 master) 1 PCS

2411090 Power supply cable CT45 1 PCS

Please refer to section '4.3 - Block diagram test system with CT45 with standard TSK TP cards'
for replacement cables (default length) for operating a test system with CT45 and standard TSK
TP cards.

Page | 55
Operating Manual

Appendix A (Certificate of Incorporation)

Page | 56
Operating Manual

Page | 57