IOT123 - IDC CABLE TESTER (6 WIRE)

In developing the ICOS10 ASSIMILATE SENSOR HUB, I needed to verify the cables I was creating. The verification was to check continuity between the sockets and isolation between the wires. The design I came up with used DIP switches to change between continuity and isolation tests. As I expect to have a different board for each tests (the DIP Switches aren't built for constant use), the two circuits can be hard-wired without the need for DIP Switches,

The same design principles can be applied to larger (wire number) connectors as well.

Step 1: Materials and Tools

1. 4cm x 6cm Uninersal PCB (1)
2. Hookup wire (~10)
3. 0.5mm Tinned Wire (~4)
4. 1K Resistors (6)
5. 6 Pin Shrouded IDC Male Header (2)
6. 6 bit DIP Switch (1)
7. Micro USB Breakout (1)
8. Blue LEDS (6)
9. SPDT Side PCB Switch (1)
10. Solder and Iron (1)

Step 2: Assembly

1. Add the 5P/2 off 1P male header to the Micro USB Breakout with the plastic collar on the opposite side as the socket.
2. On the top of the PCB, insert SPDT switch (1), USB Breakout (2), DIP Switch (3) and solder off on bottom.
3. On the bottom, use tinned wire to connect RED1 through RED7 and solder off.
4. On the top, insert the 1K resistors as shown and put light solder on the insertion through-holes.
5. On the top of the PCB, insert Shrouded IDC Male Headers (4,5) and solder off on bottom.
6. On the top of the PCB, insert LEDs (6-11) and solder off on bottom.
7. On the bottom, trace a tinned wire from BLACK1 to BLACK3 and solder off.
8. On the bottom, trace a tinned wire from BLACK4 through to BLACK9 and solder off on each LED.
9. On the bottom, trace a black wire from BLACK2 to BLACK4 and solder off.
10. On the bottom, trace the Resistor leads from SILVER5 to SILVER6, and solder off.
11. On the bottom, trace the Resistor leads from SILVER3 to SILVER4, and solder off.
12. On the bottom, trace the Resistor leads from SILVER1 to SILVER2, and solder off.
13. On the bottom, trace the Resistor leads from SILVER7 to SILVER8, and solder off.
14. On the bottom, trace the Resistor leads from SILVER9 to SILVER10, and solder off.
15. On the bottom, trace the Resistor leads from SILVER11 to SILVER12, and solder off.
16. On the bottom, trace a red wire from RED8 to RED9, and solder off.
17. On the bottom, trace a red wire from RED10 to RED11, and solder off
18. On the bottom, trace a red wire from RED12 to RED13, and solder off.
19. On the bottom, trace a red wire from RED14 to RED15, and solder off.
20. On the bottom, trace a red wire from RED16 to RED17, and solder off.
21. On the bottom, trace a red wire from RED18 to RED19, and solder off.

Step 3: Next Steps

Plug the IDC Sockets to be tested into the 2 Headers.

Power up with 5V Micro USB.

Turn SPDT on.

For continuity testing, leave all DIP Switches on, and all LEDS should glow.

For isolation testing, alternate off and on, and alternate LEDS should glow.

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