Cooper Instruments TX1000 Installation Manual

TX-Series

Digital Tension Meter

User’s Guide

www.cooperinstruments.com

PH: 540-349-4746 ▪ FAX: [phone]

CONTENTS

1.0 SAFETY ...............................................................................................................................1

2.0 CHARGING INSTRUMENT BATTERIES ............................................................................1

3.0 OPERATION: QUICK START..............................................................................................1

4.0 ADDITIONAL TECHNICAL INFORMATION........................................................................2

5.0 FEATURES ..........................................................................................................................4

6.0 AVAILABLE OPTIONS FOR ALL INSTRUMENTS.............................................................4

7.0 SPECIFICATIONS................................................................................................................5

8.0 CUSTOM CALIBRATIONS ..................................................................................................5

9.0 FLOW CHART......................................................................................................................7

10.0 WARRANTY REPAIR POLICY ..........................................................................................8

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1.0 SAFETY

WARNING: When using cordless, electronic instruments, always follow basic safety precautions to reduce the risk

of fire, electric shock and personal injury.

READ AND SAVE ALL INSTRUCTIONS FOR FUTURE USE. Before use, ensure all users read and understand
this manual, as well as any labels packaged with or attached to the instrument.

1. KNOW YOUR INSTRUMENT. Read this manual carefully to learn your tension meter’s applications and
limitations, as well as the potential hazards associated with this type of instrument.

2. AVOID DANGEROUS ENVIRONMENTS. Do not use your instrument in the presence of explosive
atmospheres (gaseous fumes, dust or flammable materials). Do not submerge your instrument in liquids.

3. USE THE RIGHT TOOL OR INSTRUMENT. Do not use this instrument to do a job for which it is not
recommended.

4. CHECK FOR DAMAGED PARTS. Inspect instrument before use. Check for any binding of moving parts,
improper mountings, broken parts and any other condition that may affect operation. Do not use a damaged
instrument. Tag damaged instrument “DO NOT USE” until repaired. For repair, send instruments directly to
Cooper Instruments.

5. GUARD AGAINST ELECTRIC SHOCK.

6. MAINTAIN INSTRUMENT CAREFULLY. Keep handles dry, clean and free from oil and grease. Do not

lubricate. All roller bearings are sealed.

7. DO NOT USE INSTRUMENT IF it has received a sharp blow, been dropped of damaged in any way. Do not
dissemble. Incorrect reassembly may result in the risk of electric shock, fire or exposure to battery fluids. If
instrument is damaged return it to Cooper Instruments for repair.

8. STANDARD POWER SUPPLY IS RATED FOR 120 VOLT AC ONLY and must be plugged into an appropriate
receptacle. For input voltages between 100-240V, use power supply P/N: TX-15-PS-240.

9. DO NOT USE INSTRUMENT WHEN TEMPERATURE is below 40˚ F (5˚ C) or above 105˚ F (40˚ C). Charging
in direct sunlight or near a heat source will not produce a full charge and may permanently damage battery
pack.

10. STORE INSTRUMENT AND CHARGER in a cool, dry place. Do not store where temperatures may exceed
120˚ F (50˚ C) for storage times less than one month. The storage temperature should not exceed 35˚ C for
storage times of more than one year. Never let LCD display or battery pack assembly freeze.

11. WARNING: Only use battery pack assemblies provided by Cooper with your meter. Other types of batteries
may explode, causing personal injury and damage.

2.0 CHARGING INSTRUMENT BATTERIES

1. Connect power supply cable to instrument.

2. Plug the power supply into a 120V AC outlet (For input voltages between 100-240V use power supply P/N: TX­15-PS-240).

3. Full charge of battery assembly takes approx. 8 hours.

4. Battery pack assembly cannot be overcharged, however instrument will remain on while plugged into power
supply.

5. Full charged battery assemblies will operate approx. 9 hours +/- 20% depending upon usage.

6. Battery charge level is indicated in the upper right hand corner of display.

3.0 OPERATION: QUICK START

1. TURN UNIT ON by pressing ON button. Main display will indicate: Tension (in grams, Newtons, cN or lbs),
Material (with description of calibration selected), and Min and Max values.

2. MOVE BETWEEN SCREENS by pressing either the UP or DOWN arrows. To make or enter a selection,
depress the ENTER key. To exit a setting, depress the ESCAPE key.

3. ZERO THE INSTRUMENT before taking readings by pressing the key marked ZERO. When zeroing the unit

hold the instrument in the attitude in which it will be used, with no load or speed applied to the instrument.

4. READING OF TENSION. Variations in materials and diameters affect tension readings. It is essential to select
the correct material and size (whether it be AWG wires, Filaments, or Custom Materials) from the calibration

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menu before use, or values may be incorrect. For Textile use, either approximate your material diameter form
the filament selection or (preferably) use a custom calibration made directly to your material.

5. SELECT MATERIAL. From the Main Display (first screen seen when unit is turned on) use the UP or DOWN
keys until SELECT MATERIAL is displayed. Press ENTER. Next select your material from: Wire, Filaments or
Custom. After you’ve entered this selection you can now select your material size (diameter) in Inches, mm or
AWG (for wires). Remember to ENTER your selection.

6. SELECTING TENSION UNITS IN LBS, NEWTONS OR GRAMS. Depress the UP or DOWN keys until
TENSION UNITS is displayed. Press ENTER. Next, select from: Grams, Newtons, LBS or cN (for Model TX-
125 only) and ENTER selection.

7. ENGAGE INSTRUMENT TO TENSIONED MATERIAL. For best accuracy, hold the instrument in the attitude

the measurement will be taken in and depress ZERO. Then engage the tensioned material by separating the
rollers (squeeze the trigger assemble) and inserting onto your material. Once material is in line with the three
rollers slowly release the trigger until it makes a full stop. Then note your reading.

4.0 ADDITIONAL TECHNICAL INFORMATION.

1. INDICATING SPEED (optional feature). From main display press the UP arrow once. Your display will now

show either feet per minute or meters per minute with both high and low values recorded.

2. LENGTH OF PART RUN (optional feature). From the main display press the UP arrow twice. Your display will
now indicate length or material run in either feet or meters.

3. CHANGING LENGTH OR SPEED UNITS (optional feature). From the main display depress either UP or
DOWN keys until the screen indicates: SETUP. Press Enter. Next use the UP and DOWN keys until Length
Units is displayed. Press ENTER and make your selection from either Feet or Meters. Enter selection.

4. DATA LOGGING (optional feature). From the Main display, use the UP or DOWN keys until Data Logging is

displayed. Press ENTER. Next, select Logging Rate and select Hz rate which your data will be collected in
(choices are from 1Hz to 100Hz). Next, select Duration and select the time period the data will be collected
over by using the UP or DOWN keys. Finally select Begin Logging when you are ready to collect your data.
Note: You can stop collecting data at any time by simply depressing ESC (escape.) Collected data will remain
in memory, regardless if instrument in turned off, and will only be overwritten once new data is collected. To
view collected data select View Data Log and press ENTER. Logged Data can also be uploaded to your
computer via the RS-232, serial port. Refer to sec. 4.16, Uploading logged data, for specific instructions.

5. SPEEDING UP OR SLOWING DOWN DISPLAY LCD REFRESH RATES – DAMPENING ADJUSTMENT.

To help control oscillating tension display values the user can either speed up or slow down the rate at which
tension values refresh on the display. Using the UP or DOWN keys select SETUP and press ENTER. Next
select Dampening and after entering this selection, choose the refresh rate from: 1Hz, 2Hz or 5Hz. Remember
to ENTER your selections.

6. AUDIO. Turn on or off Audio beep (with key inputs) by selecting: SETUP, then select Audio, and finally either
select ON or OFF.

7. BACKLIGHTING INTENSITY. Increase or decrease Backlighting intensity by selecting: SETUP, then
BACKLIGHT, and finally intensity level.

8. DISPLAY CONTRAST. Increase or decrease LCD display contrast by selecting: SETUP, then select
CONTRAST and finally manipulate contrast using the UP or DOWN keys. Remember to ENTER your new

setting.

9. VERSION. Instrument model number along with software version information can be viewed under SETUP and
then Version.

10. CUSTOM CALIBRATIONS. Calibrations are password-protected to prevent unintended changes and can only
be performed on Custom Calibration selections. All other calibrations under Wire and Filament selections can
only be reset by the manufacturer. See Section 7 for step-by-step instructions to perform this 5 point, dead
weight calibration, or contact Cooper Instruments for assistance. NOTE: if you simply want to verify your
instrument’s accuracy, refer to Checking Accuracy in the Custom Calibration section.

11. CUSTOM CALIBRATION NAMES. Custom Calibrations (listed as Custom 0-9) can be renamed so that the
Main Display indicates your name for the calibration instead of Custom 1,2, etc. From the Main Display use the

UP and DOWN keys until SETUP is selected. Press ENTER. Using the UP and DOWN arrows select Custom
Names. Press ENTER. Next, using the UP and DOWN arrows select calibration number, or previous name

you wish to rename (selection are 1-7). Press ENTER. Using the UP and DOWN arrows select the calibration
number, or previous name you wish to rename. Using the UP and DOWN keys select the number, letter or
character for the beginning of your new name. Press ENTER. Follow the same procedure for each sequential

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letter or space of your new description. Continue pressing ENTER until all spaces in the description have
entered values. Once your new name has been entered you will be returned to the SETUP screen. To select
your new calibration follow the procedures outlined in Section 3.5.

12. CALIBRATION OF SPEED (optional features). From the Main Display press the UP and DOWN keys until you
reach SETUP. Press ENTER. Using the UP and DOWN keys select CALIBRATE LENGTH. Press ENTER.
Next calibrate the speed function as follows: Using a precise 20 foot length of your material (20.0’), thread one
end through the instrument’s three rollers and slowly pull exactly 20.0’ through the instrument. (While you are
pulling your 20’ length the instrument will count pulses on the display) Once you have finished pulling the 20’
length, press ENTER. Your instrument speed calibration is now complete.

13. MONITORING TENSION OR SPEED THROUGH THE ANALOG OUTPUT (optional feature). Output values
are: 0-5 VDC or 4-20 mA. Connect Analog Output Cable to receptacle located on the bottom side of
instrument. Connect output cable leads to the analog input of your measurement or control device. The RED
lead is Voltage +, the WHITE lead is mA and the BLACK lead is ground. From the main display use the UP
and DOWN arrows until you reach SETUP. Press ENTER. Next using the UP and DOWN keys until you reach
SETUP. Press ENTER. Next using the UP and DOWN arrows select ANALOG OUTPUT. Press ENTER.
Using the UP and DOWN arrows select from: ANALOG SPEED CURRENT, ANALOG SPEED VOLTAGE,

ANALOG TENSION CURRENT OR ANALOG TENSION VOLTAGE. Once correct selection is made press
ENTER.

14. CALIBRATION OF ANALOG OUTPUT. From Main Display press the UP and DOWN keys until you reach
SETUP. Press ENTER. Press the UP and DOWN keys until you reach CALIBRATE ANALOG. Press
ENTER. Using the UP and DOWN keys adjust display to show the value at which the instrument reads
maximum current or voltage. Press ENTER.

15. SERIAL DATA COLLECTION (RS-232 Option). Instruments outfitted with the optional RS-232 feature

(designated with a -E or –D in the part number) support serial communications as follows:
a) The Baud rate is 9600 with no parity bit, 8 data bits and 1 stop bit (9600 N81).
b) Serial communications will work with most PC’s with a cable up to 15 feet long.
c) Setting the dampening rate on the instrument to “1HZ + Serial “, “2Hz + Serial” or “5Hz + Serial” will cause

the instrument to output the tension values at a rate of once, twice or five time per second, respectively.
The dampening rate can be set by going to the SETUP menu, selecting DAMPENING, adjusting the value
of the dampening rate with the UP and DOWN button and then pressing the ENTER button.

d) The units output serially will be the same units that are selected in the “Tension Units” menu. The currently

selected tension units are also displayed on the main tension screen.

e) Perform the following steps in order to log serial data from the instrument using Hyper Terminal on a PC

and put it into a Microsoft Excel spreadsheet:
i. Ensure that the dampening rate is set to “1HZ + Serial “, “2Hz + Serial” or “5Hz + Serial”.
ii. Connect the serial cable from the instrument to a serial port on your PC.
iii. Go to the Windows start menu and choose Programs>Accessories>Communications>Hyper Terminal.
iv. In the Connection description dialog box that pops up, type in a name for the new connection (any

name will work) and press the OK button.

v. In the Connect To dialog box that pops up next, go to the drop down menu labeled “Connect Using:”

and select the serial port you connected the cable to in step 2. It is most likely that you are connected
to COM1.

vi. In the COMx Properties dialog box that pops up next, set the “Bits per second:” to 9600, the “Data bits:

to 8, the “Parity” to None, the “Stop bits:” to 1 and the “Flow Control;” to None.
vii. Click the Apply button and then click the OK button.
viii. You should now see tension values appearing in the Hyper Terminal window.
ix. To download the data log data: Go to: Transfer>Capture Text…and enter the name of the file that you

wish to save the data to.
x. Next, click anywhere inside the Hyper Terminal window and then press “d” on your keyboard. The data

should download from the instrument to the file that you chose.
xi. When you are finished collecting data, close Hyper Terminal.
xii. To save the data in Microsoft Excel format, use Microsoft Excel to open the file you saved the data log

to and save it as an Excel file.

16. UPLOADING LOGGED DATA (Optional feature) via RS-232, SERIAL COMMUNICATIONS.
a) Refer to the previous section, Serial Data Collection (RS-232 option) and configure communication

protocols as outlined. Note: step c has no effect on transferring stored data and can be adjusted to any
setting.

b) To retrieve or upload logged data from the instrument, send a lower case d.

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c) Collected data will remain in memory, regardless if instrument is turned off, until overwritten with new data.

5.0 FEATURES

• Large, easy to read backlit, graphic display with adjustable backlighting and contrast.

• Display shows tension, name of calibration selected, running line minimum and maximum tension values, and

battery charge level.

• Select tension values to display in Grams, lb, Newtons, or cN.

• Instruments come with calibrations for numerous wire and filament sizes.

• Up to 10 additional custom calibrations may be programmed into instrument. (All calibrations password

protected.)

• Choose your calibration by first highlighting and selecting the material (either wires, filaments, custom), the

units of measurement (inches, mm. AWG wire sizes, or custom). Lastly, select the material size or gauge
number and push “Enter”. The instrument automatically adjusts to the calibration you’ve selected with a full­scale accuracy of +/- 1%. (Full-scale accuracy for custom sizes is material specific.)

• Selectable LCD refresh rates allow for stable digital readings.

• Re-chargeable NIMH batteries and power supply provided. Approximately 0 hours of operation per battery

charge. Automatic shut-off after 10 minutes of non-use.

• Instruments may be operated continuously while connected to power supply.

• Numerous application-specific models available.

• All instruments factory-calibrated and ready for use. Calibration certificate included. All calibration values

traceable to National Standards.

• All models typically available in 3-5 business days.

Model Range Resolution

TX 125 0-125 Grams 0.1 to 1 Grams
TX 1000 10-1000 Grams 1 to 5 Grams
TX 5000 50-5000 Grams 5 to 10 Grams

TX-5EDM 50-5000 Grams – For use on EDM wires.

Note: For tapes, webs and custom materials please provide thickness, width, or diameter with order.

6.0 AVAILABLE OPTIONS FOR ALL INSTRUMENTS

Note: Add option designator to the end of the Model Number. (For example a Model TX-1000-S denotes a standard
TX 1000 with the optional Speed and Length function included.)

R Custom Roller Option. Choose from numerous sizes of cylindrical, flanged, or U-shaped rollers. Note: For

tapes, webs and custom materials, please provide thickness, width, or diameter with order.

S Speed and length Option. Indicate Real-time speed in FPM or MPM. Maximum measurable speed is

9,999 FPM or 9,999 meter per minute; however, line speeds in excess of 2,000 FPM are generally unsafe
for hand-held applications. Read length of part run in feet or meters. Maximum length measuring up to
9,999 meters or feet.

A Analog Output Option. For both speed and tension values. 0-5 VDC or 4-20 mA with software definable

ending sequences. Provided with 10’ cable. Data is outputted at a rate of 40Hz.

E RS-232 Serial Output Option. Provided with 10’ cable to interface with your receiving device. Select data

sampling rate from 1, 2, or 5 Hz.

D Data Logging Option. Capture and play back data within a user-defined time window. Select the time

window, then select the sampling rate (adjustable from 1-100 Hz). After capturing the data, review the
data on the instrument’s display or upload it using the 10’ serial interface cable.

Instruments can be configured with any or all of these options.

Additional options for all meters

• Input real-time serial data into any Windows® applicaton using the optional software WinWedge Pro for
Windows®

• Euro Plug. P/N: TX-15-PS-240

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• Magnetic or rigid mounting bracket. P/N: TX-350

7.0 SPECIFICATIONS

• Approximate weight .75 lbs (14 oz.), depending upon configuration.

• (5) Rechargeable NIMH battery assembly and power supply provided. (For input voltages between 100-240

V, use power supply P/N TX-15-PS-240)

• Durable, lightweight carrying case with foam inserts.

• CE certification complying with heavy industrial, immunity standards.

8.0 CUSTOM CALIBRATIONS

Note 1: CHECKING ACCURACY. If you simply want to verify the accuracy of your instrument, simulate a tension

load on your material by suspending known weights to a sample length of the same material and then verify these
values with the instrument. If, for example, a 100-gram weight is freely suspended from your material, your tension
will 100 grams and your instrument should indicate 100 grams. To correctly obtain readings, first zero your instru­ment in the attitude it will be used and then engage the three instrument contact rollers onto the tensioned material.
Never hang weights from only the center roller, as this will overload the instrument and cause damage. Check
several tension values to determine full-scale accuracy.

Note 2: The TX series of Tension Meters allows field calibration changes for Custom Materials. All other calibra­tions can only be reset at the factory. This feature is incorporated into the instrument programming to prevent
inadvertent calibration changes and to provide “due diligence” in assuring unauthorized calibration changes.

Note 3: The Custom Calibration feature is password protected. In order for an end user to perform a Custom
Calibration a series of key inputs are required.

Note 4: When calibrating instruments use gram weight values only. For optimum accuracy use certified weights

traceable to National Standards.

Performing a 5-Point Multilinearization Calibration

Step 1: From Main Display press UP or DOWN arrows until you reach SETUP. Press ENTER. Use the UP and
DOWN arrows until you reach CALIBRATE TENSION. Press ENTER. Next, press the UP arrow once and then

press ENTER. You will now be able to select a description or number that you wish to recalibrate. Select the
calibration number or name you wish to calibrate and then press ENTER.

Step 2: Next you will be prompted ENTER WEIGHT 1. Using the UP and DOWN arrows select a minimum tension
value (do not use zero). Press ENTER. Select increasing weight values for WEIGHT 2 THROUGH 4 (number 4
being the maximum weight value). At each weight number select your weight value using the UP and DOWN
arrows. ENTER each selection. Next you will calibrate the instrument to the weight values you just selected. (To

simulate tension loads for calibration, take a sample length of your material and suspend it from above. Next hang
weights from your material in the weight values you previously selected in “enter weights 1 through 4”.) Your

instrument will now prompt you PLACE WEIGHT 0. With zero tension applied to the instrument press ENTER.
Next you will be prompted PLACE WEIGHT 1. Suspend the exact weight value from your material that you
previously selected. Engage instrument to the tensioned material and then press ENTER. Next suspend weight
value 2 from your material, engage the instrument to your tensioned material and press ENTER. Repeat procedure
for steps 3 and 4. Once you have entered the value for WEIGHT 4 you have finished the calibration and will be
returned to the Main Display. Your main display will now indicate the description of the calibration you’ve just
entered. This indicates you have now selected the calibration you just performed. To change calibration, use the
UP or DOWN arrows until you reach SELECT MATERIAL. Follow procedures outlined in Sec 3.5.

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COPPER WIRE DIAMETERS

CONVERSION TABLE

Diameters Diameters
(nominal) (nominal)

AWG Millimeters inches AWG Millimeters inches

25.0 0.455 0.01790 37.5 0.107 0.00421

25.5 0.429 0.01688 38.0 0.102 0.00396

26.0 0.404 0.01590 38.5 0.094 0.00370

26.5 0.381 0.01499 39.0 0.089 0.00353

27.0 0.361 0.01420 39.5 0.084 0.00330

27.5 0.340 0.01339 40.0 0.079 0.00314

28.0 0.320 0.01260 40.5 0.076 0.00299

28.5 0.302 0.01188 41.0 0.071 0.00280

29.0 0.287 0.01129 41.5 0.066 0.00259

29.5 0.269 0.01059 42.0 0.064 0.00249

30.0 0.254 0.01000 42.5 0.061 0.00240

31.0 0.226 0.00893 43.5 0.053 0.00208

31.5 0.213 0.00838 44.0 0.051 0.00198

32.0 0.203 0.00795 44.5 0.048 0.00188

32.5 0.191 0.00751 45.0 0.0447 0.00176

33.0 0.180 0.00708 46.0 0.0399 0.00157

33.5 0.170 0.00669 47.0 0.356 0.00140

34.0 0.160 0.00630 48.0 0.0315 0.00124

34.5 0.150 0.00590 49.0 0.0282 0.00111

35.0 0.142 0.00561 50.0 0.0251 0.00099

35.5 0.135 0.00531 51.0 0.0224 0.00088

36.0 0.127 0.00500 52.0 0.0198 0.00077

36.5 0.199 0.00468 53.0 0.0178 0.00070

37.0 0.114 0.00445 54.0 1.0157 0.00061

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9.0 FLOW CHART

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10.0 WARRANTY REPAIR POLICY

Limited Warranty On Products

Any Cooper Instruments product which, under normal operating conditions, proves defective in material or in
workmanship within one year of the date of shipment by Cooper will be repaired or replaced free of charge provided
that a return material authorization is obtained from Cooper and the defective product is sent, transportation
charges prepaid, with notice of the defect, and it is established that the product has been properly installed,
maintained, and operated within the limits of rated and normal usage. Replacement or repaired product will be
shipped F.O.B. from our plant. The terms of this warranty do not extend to any product or part thereof which, under
normal usage, has an inherently shorter useful life than one year. The replacement warranty detailed here is the
buyer’s exclusive remedy, and will satisfy all obligations of Cooper whether based on contract, negligence, or
otherwise. Cooper is not responsible for any incidental or consequential loss or damage which might result from a
failure of any and all other warranties, express or implied, including implied warranty of merchantability or fitness for
particular purpose. Any unauthorized disassembly or attempt to repair voids this warranty.

Obtaining Service Under Warranty

Advance authorization is required prior to the return to Cooper Instruments. Before returning the item, contact the
Repair Department c/o Cooper Instruments at [phone] for a Return Material Authorization number.
Shipment to Cooper shall be at buyer’s expense and repaired or replacement items will be shipped F.O.B. from our
plant in Warrenton, Virginia. Non-verified problems or defects may be subject to a $100 evaluation charge. Please
return the original calibration data with the unit.

Repair Warranty

All repairs of Cooper products are warranted for a period of 90 days from date of shipment. This warranty applies
only to those items that were found defective and repaired; it does not apply to products in which no defect was
found and returned as is or merely recalibrated. It may be possible for out-of-warranty products to be returned to
the exact original specifications or dimensions.

* Technical description of the defect: In order to properly repair a product, it is absolutely necessary for Cooper to
receive information specifying the reason the product is being returned. Specific test data, written observations on
the failure and the specific corrective action you require are needed.

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