Auto Grip Pull Tester PT-1500 Auto Grip Pull Tester Operation Manual Order No. 63801-9100 Description Operation Maintenance Doc No: TM-638019100 Revision: B Release Date: 08-10-09 Revision Date: 10-01-09 UNCONTROLLED COPY Page 1 of 15 Auto Grip Pull Tester WARNING NEVER OPERATE, SERVICE, INSTALL, OR ADJUST THIS PULL TESTER WITHOUT PROPER INSTRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE INSTRUCTIONS IN THIS MANUAL. NEVER REGARDLESS OF WHETHER THE DISPLAY MODULE (FORCE GAUGE) IS ON OR OFF, DO NOT EXCEED THE CAPACITY OF THE DISPLAY MODULE. AT 230 LBF (105 kgf), THE DISPLAY WILL FLASH. NEVER EXCEED THE MAXIMUM CAPACITY OF 440 LBF (200 kgf), OR THE LOAD CELL WILL BE DAMAGED. AVOID SHOCK LOAD. WARNING! FAILURE TO ALLOW FOR SUFFICIENT OVERLOAD CAPACITY IN THE LOAD, STRUCTURE AND MOUNTING ELEMENTS, MAY RESULT IN PROPERTY DAMAGE, SERIOUS INJURY, AND EVEN DEATH. CAUTION When mounting display module, after recalibration or repair, use M4 mounting screws with a maximum insertion depth of 5mm into the display module. Only use mounting hardware supplied. CAUTION Hand tighten wire terminal grip only. Do not use tools. CAUTION Do not remove the warranty seal or disassemble the display module. Disassembly will void the warranty. CAUTION Molex crimp specifications are valid only when used with Molex terminals, terminators and tooling. CAUTION Specifications subject to change without notice. CAUTION Always wear safety glasses. WORK SAFELY AT ALL TIMES For Service, Contact Your Local Molex Sales Office Molex Application Tooling Group 2200 Wellington Court Lisle, Illinois 60532, USA Tel: 630-969-4550 Fax: 630-505-0049 Doc No: TM-638019100 Revision: B Release Date: 08-10-09 Revision Date: 10-01-09 UNCONTROLLED COPY Page 2 of 15 Auto Grip Pull Tester Table of Contents SECTION 1 General Description 2 Setup and Operation 3 Maintenance Doc No: TM-638019100 Revision: B Release Date: 08-10-09 Revision Date: 10-01-09 UNCONTROLLED COPY Page 3 of 15 Auto Grip Pull Tester Section 1 General Description 1.1 Description 1.2 Features 1.3 Technical Specifications 1.4 Delivery Check 1.5 Tools Doc No: TM-638019100 Revision: B Release Date: 08-10-09 Revision Date: 10-01-09 UNCONTROLLED COPY Page 4 of 15 Auto Grip Pull Tester General Description 1.1. Description The PT-1500 Auto Grip Pull Tester, order no. 63801-9100, is a manual, lever-operated digital pull tester for checking pull strength of crimped terminals. The tester is designed to automatically grip the wire as the hand lever is pulled down. The unit is complete with display module, two multi-terminal grips, pull tester frame, and an AC adapter/charger for the display module. It has a 3-point, NIST certification. Principal Mechanical Parts of the Auto Grip Pull Tester See Figure 1-1 1. 2. 3. 4. 63801-9100 63801-9101 63801-9102 63801-9103 63801-9105 5. 63801-9104 4 PT-1500 Pull Tester assembly Multi-terminal grip Clamp type terminal grip A.C. adapter / charger, 120 VAC A.C. adapter / charger, 230 VAC Display module 3 1.2. Features 5 Single-stroke, ergonomic pull-down motion Automatically grips sample wire as lever is pulled 1 Grips wire diameters up to 0.23" (8-30 AWG) Lbf, kgf, and Newton units are push-button selectable Digimatic and analog outputs Display module is easily removed for recalibration or repair Runs on internal rechargeable batteries or AC adapter (120 or 230 VAC) NIST Calibration Certificate included Figure 1-1 2 1.3. Technical Specification Dimensions See Figure 1-2 Width: Depth: Height: 475.0 to 5.45.0mm (18.70 to 21.45") (Depending on the handle position) 150.00mm (5.90") 400.0mm (15.74") Weight 10.88kg Doc No: TM-638019100 Revision: B (24 lbs) Release Date: 08-10-09 Revision Date: 10-01-09 UNCONTROLLED COPY Page 5 of 15 Auto Grip Pull Tester Figure 1-2 63801-9100 Range (Resolution) ± 0.2% F.S. ± 1 LSD Capacity (Resolution) Pound-force Kilogram-force Newtons 63801-9100 220.0 (0.1 lbf) 100.0 (0.1 kgf) 1000 (1 N) Model 1.4. Delivery Check Carefully remove the assembly from its shipping container and determine that the following items are included in the package. Description Quantity 63801-9100 Pull Tester assembly 1 63801-9102 Clamp type terminal grip 1 63801-9103 A.C. Adapter / charger (120 VAC) or 1 63801-9105 A.C. Adapter / charger (230 VAC) 1 TM-638019100 Operation Manual 1 1.5. Tools The following tools are recommended for set up and maintaining the tester: Open end wrench, 10mm Hex wrench, 5mm Doc No: TM-638019100 Revision: B Release Date: 08-10-09 Revision Date: 10-01-09 UNCONTROLLED COPY Page 6 of 15 Auto Grip Pull Tester Section 2 Set-Up and Operation 2.1 Display Module Operation 2.2 LCD Display 2.3 Installation 2.4 General Operation 2.5 Removing the Display Module 2.6 Settings and Functions Doc No: TM-638019100 Revision: B Release Date: 08-10-09 Revision Date: 10-01-09 UNCONTROLLED COPY Page 7 of 15 Auto Grip Pull Tester Read the following instructions before attempting to operate the Auto Grip Pull Tester. 2.1. Display Module Operation See Figure 2-1. Display To set the measurement units to pound-force (lbf), kilogram-force (kgf), or Newtons (N), follow the steps below: 1. Turn off the display module. 2. Then set the display units by pressing and holding the ZERO button until the desired measuring unit is displayed. 3. Press the ON/OFF button. 4. Then press the ZERO button to cycle the units. 5. Push the SEND button to select. 6. The newly selected units will stay as the default. MEASURING SHAFT DISPLAY ON / OFF BUTTON On / Off Button Power ON, capacity is displayed. After 10 minutes, unit powers down if no key is pressed. ZERO BUTTON SEND BUTTON Peak Button Press to activate the Peak mode. PEAK BUTTON Send Button Transmits display value. Zero Button Tares weight of attachment and resets peak value. CHARGER PORT RS-232 PORT Measuring Shaft Attach any of the included standard attachments or optional special attachments to measure tension. Figure 2-1 Charger Port Recharge the internal NiMH battery or connect directly to an AC power supply by using one of the included AC charger / adapters, appropriate for your local electrical requirements. (See Figure 1.1). RS-232 Port For data transmission to the external device. 2.2 LCD Display See figure 2-2. Compression Icon Indicates the compression measurement. Doc No: TM-638019100 Revision: B Release Date: 08-10-09 Revision Date: 10-01-09 UNCONTROLLED COPY Page 8 of 15 Auto Grip Pull Tester Tension Icon Indicates the tension measurement, (used for crimp pulls). Unit Indicator Displays selected measuring unit. Display pound-force (lbf), kilogram-force (kgf) or Newtons (N). Battery Icon Flashes when gauge needs to be recharged. TENSION ICON COMPRESSION ICON NEGATIVE SIGN GO/NO GO Indicator -- Under low set point Between low and high set point Over high set point Negative Sign Will displayed when measuring tension. Peak Icon Will displays continuously when peak mode is active. PEAK ICON GO / NO GO INDICATOR UNITS INDICATOR BATTERY ICON Figure 2-2 2.3 Installation (See Figure 2-3) 1. Place the Auto grip Pull Tester securely on a stable work surface. 2. To adjust clearance between the two wire gripping fixtures if necessary, loosen the cap screw on the displaymodule mounting bracket. Adjust the position and the re-tighten the cap screw. DISPLAY MODULE 3. To remove the grip, use a 10mm open-end wrench HEX NUT to hold the hex nut while turning the grip counterAC ADAPTER GRIP clockwise (CW). Installation is the reverse of removal but do not over tighten the grip on the display module. 4. Connect the appropriate AC adapter (120 or 230 VAC included) to the display module and plug it into an AC outlet or use the internal rechargeable CAP SCREW battery. Figure 2-3 2.4 General Operation (See figure 2-4) 5mm HEX WRENCH 1. Press the ON/OFF button to turn on the display module on, press the PEAK button to enter the peak measuring mode. 2. If using the ring wire terminal grip, turn the turret to select an appropriate aperture and bring the hand lever forward. See Figure A. 3. Insert the sample so that the wire terminal is held in place by the grip. If necessary, press the ZERO button to reset. See Figure B. Doc No: TM-638019100 Revision: B Release Date: 08-10-09 Revision Date: 10-01-09 UNCONTROLLED COPY Page 9 of 15 Auto Grip Pull Tester 4. Thread the wire between the gripper and the cylinder which is attached to the end of the hand lever. See Figure C. 5. Slowly pull the hand lever back to automatically grip the wire and pull off the terminal. See Figure D. NOTE: Pull the lever slowly and steadily to insure consistent readings. 6. Read the result from the display module and press the ZERO button to reset for the next test. Figure B Figure A Figure 2-4 Figure C Figure D 2.5 Removing the Display Module (See Figure 2-5) The display module can be easily removed for recalibration or repair. To do this: 1. Loosen the cap screw on the display module mounting bracket and slide the mounting bracket off the base. Remove the (4) M4 Phillips screws from the back of the mounting plate. 2. Remove the display module. Doc No: TM-638019100 Revision: B Release Date: 08-10-09 Revision Date: 10-01-09 MOUNTING PLATE CAP SCREW 5mm HEX WRENCH Figure 2-5 UNCONTROLLED COPY Page 10 of 15 Auto Grip Pull Tester 2.6 Settings and Functions RS-232C Bi-directional Interface Functions (See Chart below) Connect the gauge to an external data receiving device, with the optional RS-232C cable (Order No. 638019151). See Optional Cables and Software below. All gauge functions can be duplicated from a remote location by using the RS-232C interface. All commands must be sent in uppercase ASCII character format followed by [Enter]. Signal level: RS-232C, 8 data bits, 1 stop bit, and no parity bit. Baud rate: 19200 bps. RS-232C Interface Functions (Upper case ASCII format) Function Response* Select “kgf/gf” units Select “N” units Select “lbf/ozf” units Select peak mode R [Enter] executed E [Enter] error* Select real time mode Tare Display Turn off power Set high/low set points(4 digit) HHHH=High, LLLL=Low EHHHHLLLL [Enter]** Read high/low set points set point values (4 digit) HHHH=High, LLLL=Low Transmit display data [value][units][mode][Enter] *E [Enter] response if the command is not accepted. **Ignore decimal point for high low set points Command K [Enter] N [Enter] O [Enter] P [Enter] T [Enter] Z [Enter] Q [Enter] EHHHHLLLL [Enter]** E [Enter]** D [Enter] Optional Cables and Software To capture and analyze the peak data from the force gauge. A running log of all the data is displayed along with a chart. Calculate max/min, average, and standard deviation. Order No. 63901-9150 Description Software, Data Acquisition. 63801-9151 RS-232C cable (10', 9 pin female) 63801-9152 RS-232C to USB Adapter Type Recharging NI-MH Battery 1. To maximize the life of the battery, power is shut off after 10 minutes of non-use. Automatic shut off is bypassed when used with the AC adapter/charger. 2. Battery icon will flash when the gauge needs to be recharged. 3. Turn off power. Only use one of the AC adapter / chargers provided, 63801-9103 for 120VAC, 638019105 for 230VAC. Plug into the correct AC output. It takes 10 hours to charge fully. 4. When the gauge is turned off, make sure the AC adapter/charger is disconnected to avoid overcharging. Doc No: TM-638019100 Revision: B Release Date: 08-10-09 Revision Date: 10-01-09 UNCONTROLLED COPY Page 11 of 15 Auto Grip Pull Tester Section 3 Maintenance 3.1 Cleaning 3.2 Calibration Doc No: TM-638019100 Revision: B Release Date: 08-10-09 Revision Date: 10-01-09 UNCONTROLLED COPY Page 12 of 15 Auto Grip Pull Tester 3.1 Cleaning CAUTION: Always disconnect power supply before all maintenance The Auto Grip Pull Tester maintenance will increase instrument life and produce a consistent, crimp strength measurement capability. The following procedure should be followed at the end of each operation. 1. Always disconnect the power supply from this tool when not in use. 2. For efficient operation, the Auto Grip Pull Tester should be cleaned daily. Use a soft bristle brush to remove debris from critical areas such as the terminal grip and clamp. 3.2. Calibration The display module should be calibrated on a regular schedule (usually annually). Molex does not offer a Calibration service for the display module. A local calibration service should be used. Doc No: TM-638019100 Revision: B Release Date: 08-10-09 Revision Date: 10-01-09 UNCONTROLLED COPY Page 13 of 15 Auto Grip Pull Tester For more information use the Quality Crimping Handbook And Industrial Crimping Handbook There is no charge for these books, they can be found on the Molex Website (www.molex.com) or contact you local Molex sales engineer Doc No: TM-638019100 Revision: B Release Date: 08-10-09 Revision Date: 10-01-09 UNCONTROLLED COPY Page 14 of 15 Auto Grip Pull Tester 2 YEAR WARRANTY (RESTRICTIONS APPLY) Molex warrants its products to the original purchaser to be free from defects in workmanship and material under normal use and proper maintenance for two years (one year for adapters, attachments, batteries, and cables) from original purchase. This warranty shall not be effective if the product has been subject to overload, shock load, misuse, negligence, accident, or repairs attempted by others than Molex. During the warranty period, we will, at our option, either repair or replace defective products. Please call our customer service department for a return authorization number and return the defective product to us with freight prepaid. The foregoing warranty constitutes the SOLE AND EXCLUSIVE WARRANTY, and we hereby disclaim all other warranties, express, statutory or implied, applicable to the products and/or software, including but not limited to all implied warranties of merchantability, fitness, non-infringement, results, accuracy, security and freedom from computer virus. In no event shall Molex be liable for any incidental, consequential or punitive damages in connection with the use of its products and/or software. CAUTION: To prevent injury, wear eye protection when using this tool. http://www.molex.com Doc No: TM-638019100 Revision: B Release Date: 08-10-09 Revision Date: 10-01-09 UNCONTROLLED COPY Page 15 of 15