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Continuity Testing

A continuity test verifies that an electrical connection exists between two specific points. This is the most common test used for wire harnesses, cables, component verification, and voltage measurements. The analyzer performs a continuity test by applying either a constant current or a low-voltage stimulus between two addresses. A test passes when the measured resistance is below the programmed limit.

When Should You Use a Continuity Test?

Use a continuity test to:

  • Verify wire-to-wire connections
  • Detect open circuits
  • Confirm component connections
  • Validate wiring before insulation or Hipot testing


Two-Wire Continuity Test

A standard two-wire continuity test measures resistance between two points using one output address and one input address. This is the most commonly used continuity test in NETS.




Example Test Setup

Example:

  • Connector J1 Pin A is connected to Output Address 0
  • Connector J2 Pin A is connected to Input Address 100

The required test instructions are:

X0
C100

Where:

  • X0 connects Address 0 to the output.
  • C100 connects Address 100 to the input.

The analyzer then performs the programmed continuity measurement.




Reverse Test Script

NETS executes the reverse continuity test using the same parameter statement with the addresses reversed.

This is useful when diagnosing switching path issues.


Four-Wire (Kelvin) Continuity Testing

For applications requiring greater measurement accuracy, NETS supports Four-Wire (Kelvin) continuity testing.

When Kelvin mode is enabled:

  • Odd addresses become Sense
  • Even addresses become Power

This method minimizes measurement error caused by lead resistance.




Enabling Kelvin Mode

Before running a Four-Wire test, execute:

ENB, KEL

Then perform the continuity test using the same X and C commands as a standard two-wire test.

Example:

ENB,KEL
X0
C100

Kelvin mode can be enabled only when needed and turned off afterward. Adapter cables must also support Kelvin testing.




 Best Practices

  • Use Two-Wire continuity testing for most wire harness applications.
  • Use Four-Wire (Kelvin) testing when higher resistance accuracy is required.
  • Verify the correct addresses before running the test.
  • Reverse the test direction when troubleshooting possible switching path issues.
  • Ensure adapter cables are compatible before enabling Kelvin mode.

 


Troubleshooting Tips

Test Fails in One Direction Only

Possible causes:

  • Switching relay issue
  • Input relay fault
  • Output relay fault

Try performing the reverse continuity test to help isolate the problem.


Unexpected Resistance Reading

Possible causes:

  • Incorrect test limits
  • Poor adapter connection
  • Damaged wiring
  • Lead resistance (consider using Kelvin mode)