Mark-10 WT3-201M Instruction Manual

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Model WT3-201M

MOTORIZED WIRE CRIMP PULL TESTER

User’s Guide

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

Thank you…

Thank you for purchasing a Mark-10 WT3-201M wire crimp pull tester, designed for pull test applications up to 200 lbF (1,000 N).

With proper usage, we are confident that you will get many years of great service with this product. Mark-10 instruments are ruggedly built for many years of service in laboratory and industrial environments.

This User’s Guide provides setup, safety, and operation instructions. Dimensions and specifications are also provided. For additional information or answers to your questions, please do not hesitate to contact us. Our technical support and engineering teams are eager to assist you.

Before use, each person who is to use the WT3-201M should be fully trained in appropriate operation and safety procedures.

TABLE OF CONTENTS

LIST OF INCLUDED ITEMS ............................................ 2

SAFETY ........................................................................... 2

SETUP .............................................................................. 3

HOME SCREEN AND CONTROLS ................................ 5

OPERATING MODES ...................................................... 9

UNITS OF MEASUREMENT ........................................... 9

DIGITAL FILTERS ........................................................... 9

PASS / FAIL LIMITS ..................................................... 10

SPEED .......................................................................... 11

AUTO START ............................................................... 12

PRELOAD ..................................................................... 12

PULL TO LOAD ............................................................ 13

LOAD HOLDING ........................................................... 13

BREAK DETECTION ..................................................... 14

AUTO SETTINGS ......................................................... 14

DATA MEMORY AND STATISTICS ............................. 16

COMMUNICATIONS AND OUTPUTS .......................... 17

PROFILES ..................................................................... 20

PASSWORDS ................................................................ 21

OTHER SETTINGS ........................................................ 22

FUNCTION ACTIVATION .............................................. 24

CALIBRATION ............................................................... 25

MAINTENANCE ............................................................. 28

SPECIFICATIONS ......................................................... 29

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

1 LIST OF INCLUDED ITEMS

Qty. Part No. Description

1 WT3-201M Wire crimp pull tester 1 - Power cord 1 - Certificate of calibration without data (standard) or with data (optional) 1 09-1165 USB cable 1 - Resource CD (USB driver, user’s guides, MESURTM Lite software,

MESUR 1 WT3002 Optional ring terminal fixture 1 WT3003 Optional blank terminal fixture 1 WT3004 Optional carrying case 1 AC1049 Optional calibration kit

gauge DEMO software, User’s Guide)

2 SAFETY

The following safety checks and procedures should be performed before and during operation:

1. Always consider the characteristics of the sample being tested before initiating a test. A risk assessment should be carried out beforehand to ensure that all safety measures have been addressed and implemented.

2. Wear eye and face protection when testing, especially when testing brittle samples that have the potential to shatter under force. Be aware of the dangers posed by potential energy that can accumulate in the sample during testing. Extra bodily protection should be worn if a destructive failure of a test sample is possible.

3. Keep away from moving parts of the tester. Loose articles of clothing should not be worn. Long hair should be covered to avoid a hazardous situation.

4. In those applications where samples can shatter, or other applications that could lead to a hazardous situation, use of a machine guard is strongly recommended.

5. When the tester is not in use, ensure that the power is turned off to prevent accidental engagement of any of the controls.

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

3 SETUP

3.1 Mechanical Setup

3.1.1 Assembly

The tester is shipped completely assembled.

3.1.2 Mounting

Place the tester on a clean, flat and level work area free from vibration. If desired, the tester can be secured to the work area with four 1/4-20 screws fastened into the underside of the base (depth of 0.5 in. [12 mm]).

3.1.3 Installing the ring terminal fixture or blank terminal fixture

To install or uninstall the standard terminal fixture or optional fixture, loosen the screw in the center of the fixture, remove, place the other fixture in the receptacle, and re-tighten the screw.

3.1.4 Sample setup

1. Secure the terminal into the standard terminal fixture or optional ring terminal fixture, as shown in the images below. Index the fixtures until the desired slot or ring size is aligned with the cam mechanism adjacent to the lever. The fixtures will click when indexing to each size selection.

2. Insert the loose end of the wire between the cams in the mechanism. Keep the wire taut as it is inserted. If auto-start is enabled, the test will begin when the switch is activated (refer to later sections for operational details). Refer to the image below:

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

3. Note the protective red safety guard (circled, below), which automatically rotates into position as the cam mechanism closes.

3.2 Connections and Outputs

1. Serial Connector

RS-232, set point, analog, Mitutoyo, and other outputs are provided. Refer to the

Communications and Outputs section for details.

2. Fuse

3. Power Switch

Use to turn power on and off.

4. Power Plug Receptacle

Plug the power cord in here. Refer to the Connecting power sub-section for important safety

information.

5. USB Connector

Plug the USB cable in here, for data output to a PC, PLC, printer, etc.

3.3 Installing the USB driver

If communicating via USB, install the USB driver provided on the Resource CD. Installation instructions may also be found on the CD or may be downloaded from www.mark-10.com

Caution!

Install the USB driver before physically connecting the tester to a PC with the USB cable.

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

Further instructions for configuring and using the gauge’s outputs are provided in the Communications and Outputs section.

3.4 Connecting power

Plug one end of the power cord into its receptacle at the rear of the stand and the other end into a wall outlet with local earth ground (3-prong connector).

Before turning on power, the following safety checks and procedures should be performed:

1. Never operate the tester if there is any visible damage to the power cord or the tester itself. The WT3-201M is powered by 110V/220V. Any contact with this high voltage can cause serious injury or even death.

2. Ensure that the tester is kept away from water or any electrically conductive liquids at all times.

3. Make sure the electrical outlet powering the tester has local earth ground (3-prong connector).

4. The tester should be serviced by a trained technician only. Power must be disconnected before disassembly.

After the above safety checks and procedures have been performed, the tester may be powered on and is ready for operation.

4 HOME SCREEN AND CONTROLS

4.1 Demo Mode Functions

The WT3-201M is shipped in Demo Mode, which provides full functionality of all available functions for an evaluation period of 160 operating hours. When this period has expired, any functions not purchased will no longer be accessible.

After the initial power-up sequence, the display appears as follows:

*** DEMO MODE ***

All functions are temporarily enabled. Remaining demo time:

160 hours

Press ENTER.

The available optional functions are as follows:

1. Profiles

Save and recall sets of test parameters, such as speed, pass/fail limits, unit of measurement, etc. Maximum of 500 profiles may be stored.

2. Load Holding

The tester will stop and maintain a specified load for a specified period of time.

3. Pull To Load

The tester will stop when the specified load has been reached.

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

4. Date & Time Stamp

A date and time stamp is assigned to each saved data point.

5. Complete Options Package

Includes all of the functions listed above.

Refer to the Function Activation section for further instructions on how to activate functions.

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

4.2 Home Screen

810

No. Name Description

Indicates one of the following statuses: STOPPED

1 Status

2 Position

3 / 7

4 Message

5 Primary reading

9 Mode

10 Profile name

12 Peak force

Upper / lower force limits

Unit of measurement

Break detection on/off

Number of data points

PULLING RETURNING (to the Home position) HOLDING (Load Holding sequence in progress) Indicates one of the following positions: HOME or LIMIT Indicates the upper and lower acceptable force limits, as configured in the Pass / Fail Limits menu. The upper and lower red “X” indicators adjacent to the values illuminate if the displayed force is less than the lower limit or greater than the upper limit. The green “checkmark” indicator illuminates if the displayed force is within range. Indicates one of the following messages: COVER - the actuator cover is removed. PL ON – Pull to Load (optional function) is active. LH ON – Load Holding (optional function) is active. The current displayed reading. See Operating Modes section for details. The current measurement unit. Abbreviations are as follows: lbF – Pound-force ozF – Ounce-force kgF – Kilogram-force N – Newton kN – Kilonewton The letter “B” appears if the Break Detection function is enabled. Refer to the Break Detection section for details. The current measurement mode. Abbreviations are as follows: RT – Real Time PK – Peak See Operating Modes section for details about each of these modes Indicates the currently selected profile. See Profiles section for details. The number of stored data points in memory, up to 2,000.

The maximum measured tension force. May be reset by pressing ZERO.

6 7

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

4.3 Controls

Primary

Label

ENTER

ZERO

MODE

Primary Function

Various uses, as described in the following sections. Zeroes the primary reading and peaks.

Enters the main menu.

Toggles between measurement modes.

Secondary

Label

(UP)

ESCAPE

(DOWN)

Secondary Function

Navigates up through the menu and sub-menus. Reverts one step backwards through the menu hierarchy. Navigates down through the menu and sub-menus.

Stores a value to memory, transmits

DATA

the current reading to an external device, and/or initiates automatic

DELETE

Enables and disables Delete mode

while viewing stored data. data output, depending on setup. Starts motion. Press and release to

START

produce maintained motion. In

Maintenance mode, a key press

results in momentary motion.

Reverses motion. Press and release

to produce maintained motion until

STOP

Stops motion.

RETURN

return to the Home position. In

Maintenance mode, a key press

results in momentary motion.

4.4 Menu navigation basics

Most of the tester’s various functions and parameters are configured through the main menu. To access the menu press MENU. Use the UP and DOWN keys to scroll through the items. The current selection is denoted with clear text over a dark background. Press ENTER to select a menu item, then use UP and DOWN again to scroll through the sub-menus. Press ENTER again to select the sub-menu item.

For parameters that may be either selected or deselected, press ENTER to toggle between selecting and deselecting. An asterisk (*) to the left of the parameter label is used to indicate when the parameter has been selected.

For parameters requiring the input of a numerical value, use the UP and DOWN keys to increment or decrement the value. Press and hold either key to auto-increment at a gradually increasing rate. When the desired value has been reached, press ENTER to save the change and revert back to the sub-menu item, or press ESCAPE to revert back to the sub-menu item without saving. Press ESCAPE to revert one step back in the menu hierarchy until back into normal operating mode.

Refer to the following sections for details about setting up particular functions and parameters.

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

5 OPERATING MODES

Caution!

In any operating mode, if the capacity of the tester has been exceeded by more than 110%, the display will show “OVER” to indicate an overload. A continuous audible tone will be sounded until the MENU key has been pressed or the load has been reduced to a safe level.

Three operating modes are possible with the WT3-201M. To cycle between the modes, press MODE while in the home screen.

5.1 Real time (RT)

The primary reading corresponds to the live measured reading.

5.2 Peak (PK)

The primary reading corresponds to the peak tension reading observed. If the actual force decreases from the peak value, the peak will still be retained in the primary reading area of the display. Pressing

ZERO will reset the value.

6 UNITS OF MEASUREMENT

The WT3-201M can display five different force measurement units. To change the unit, select Units from the menu. The display will list the available units, as follows:

UNITS

* lbF ozF kgF N kN

Note: Changing the unit within this menu will not set the default unit. To always power on automatically with the desired unit, configure the unit in the Initial Settings menu.

7 DIGITAL FILTERS

Digital filters are provided to help smooth out the readings in situations where there is mechanical interference in the work area or test sample. These filters utilize the moving average technique in which consecutive readings are pushed through a buffer and the displayed reading is the average of the buffer contents. By varying the length of the buffer, a variable smoothing effect can be achieved. The selection of 1 will disable the filter since the average of a single value is the value itself.

To access digital filter settings, select Filters from the menu. The display appears as follows:

DIGITAL FILTERS

(1 = Fastest)

Current Reading 8 Displayed Reading 512

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

Two filters are available:

Current Reading – Applies to the peak capture rate of the instrument.

Displayed Reading – Applies to the primary reading on the display.

Available settings: 1,2,4,8,16,32,64,128,256,512,1024. It is recommended to keep the current reading filter at its lowest value for best performance, and the displayed reading filter at its highest value for best stability.

8 PASS / FAIL LIMITS

8.1 General Information

Pass / fail limits are useful for tolerance checking with red and green indicators and audible tones. Set point outputs are also provided, for triggering an external device such as an indicator or alarm in process control applications. Two limits, high and low, are specified and stored in the non-volatile memory of the tester and the primary reading is compared to these limits. The results of the comparisons are indicated through the three outputs provided on the 15-pin connector, thus providing “under”, “in range”, and “over” signaling.

8.2 Configuration

To configure pass/fail limits, select Pass / Fail Limits from the menu. The display appears as follows:

PASS / FAIL LIMITS Upper Disabled * Upper Enabled

125.0 Lower Disabled * Lower Enabled

122.5

Either one, two, or none of the limits may be enabled.

The upper limit is displayed in the upper right corner of the display, and the lower limit is displayed in the lower right corner, as shown in the Home Screen and Controls section. If only one limit has been enabled, the word “OFF” appears in place of the other limit value. If neither limit has been enabled, the upper and lower right corners of the display will be blank.

If the application only requires that a sample withstand a minimum specified force, set only the lower pass/fail limit. If the value is below this limit, the lower red “X” illuminates. If the value is above this limit, the green “checkmark” illuminates.

Note: Pass / fail limits and set point outputs reference the displayed reading, not necessarily the current live load.

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

8.2.1 Set Point Outputs Schematic Diagram

9 SPEED

The speed may be adjusted to comply with various standards and test methods. Select Speed from the menu and press ENTER. The display appears as follows:

SPEED * in/min mm/min Pull Speed

4.0 Return Speed 96

in/min or mm/min Select inches per minute or millimeters per minute

Sets the speed at which the test takes place.

Pull Speed

Return Speed

Available settings:

0.4 – 12.0 in/min, in 0.1 increments, or 10 – 300 mm/min, in 0.5 mm increments Sets the return speed. This speed applies to a manual press of the RETURN key or the Auto Return sequence. Available settings:

12 – 96 in/min, in 1 in increments, or 300 – 2,400 mm/min, in 25 mm increments

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

10 AUTO START

Auto start increases testing efficiency by automatically starting the test when the sample has activated the switch, identified below:

To use Auto start, select Auto Start from the menu and press ENTER. The display appears as follows:

AUTO START

Disabled * Enabled

Select Enabled. It is recommended to combine Auto Start with Break Detection and Auto Return automation functions for maximum efficiency. Refer to the following sections for details.

11 PRELOAD

To improve testing efficiency, the initial speed may be faster than the test speed. When the mechanism engages the sample, definable as a preload, the speed reverts to the programmed test speed. Select Preload from the menu and press ENTER. The display appears as follows:

PRELOAD Disabled * Enabled Force

2.0 lbF Speed

12.0

Enabled

Force

Speed

When exiting the menu, press ZERO to arm the function.

Enables the Preload function. Sets the force at which the speed reverts to the programmed test speed. Available settings: 1 – 100 lbF, in 0.1 lbF increments (or equivalent range in other units) Sets the initial speed until preload. Available settings: 12 – 96 in/min, in 1 in increments, or 300 – 2,400 mm/min, in 25 mm increments

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

Note: To avoid overshoot in Load Holding or Pull to Load, make sure the preload force is set well below

the expected testing force. Some experimentation may be necessary for optimization depending on the wire sample’s elasticity. The same is true for the preload speed.

12 PULL TO LOAD (optional function)

For non-destructive testing and other applications, the tester can stop when a specified load has been reached. Select Pull to Load from the menu and press ENTER. The display appears as follows:

PULL TO LOAD

Disabled * Enabled Force

100.0 lbF

Disabled Enabled

Force

When exiting the menu, press ZERO to arm the function. The message changes from “LL” to “LL ON” in the upper right corner of the display.

The tester can perform a number of additional automatic functions upon completion of a pull to load sequence, further described in the Auto Settings section.

Disables the Pull to Load function. Enables the Pull to Load function. Sets the force at which the tester stops. Available settings: 0 – 200 lbF, in 0.1 lbF increments (or equivalent range in other units)

13 LOAD HOLDING (optional function)

Load Holding addresses certain test methods requiring a specified load to be maintained for a specified period of time, such as UL 486A/B. The motor dynamically reacts to changes in load, such as sample relaxation, in order to maintain the specified load until the period is complete. Select Load Holding from the menu and press ENTER. The display appears as follows:

LOAD HOLDING

* Enabled Time (mm:ss) 01 : 00 Hold Force

80.0 lbF

Enabled

Time

Hold Force

Enables the Load Holding function. Sets the period of time for which the tester maintains the load. Available settings: 0 – 60 minutes, in 1 second increments Sets the force which the tester will maintain for the specified period of time. Available settings: 0 – 200 lbF, in 0.1 lbF increments (or equivalent range in other units)

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

When exiting the menu, press ZERO to arm the function. The message changes from “LH” to “LH ON” in the upper right corner of the display. When the test has started, a counter appears on the top center of the screen, showing the time remaining.

The tester can perform a number of additional automatic functions upon completion of a Load Holding sequence, further described in the Auto Settings section.

14 BREAK DETECTION

The break detection function identifies when the termination has been removed from the wire. A break is defined as a force increasing beyond a configured force threshold, then decreasing to 2 lbF (or equivalent value in other units). Upon detection of the break, the tester can stop and reverse at full speed to the Home position, if Auto Return is enabled.

The tester can perform a number of additional automatic functions upon sample break, further described in the Auto Settings section.

Break detection functions and settings are configured from a central location, and apply to any mode in which it is enabled. Refer to the Operating Modes section for details on configuring each mode.

14.1 Configuration

To enable Break Detection, select Break Detection from the main menu. The display appears as follows:

BREAK DETECTION

* Disabled Enabled Threshold 5 %

Any combination of the above functions may be selected.

Function Description

Enables the break detection function. When enabled, the letter “B” appears on the

Enabled

Threshold

When exiting the menu, press ZERO to arm Break Detection. The message at the bottom of the screen changes from “B” to “B ON”.

If tones are enabled, a tone will sound when the output, storage, and zero functions have occurred.

home screen, between the Mode and Unit indicators. Refer to the Home Screen and Controls section for details. Sets the percentage of full scale at which the break detection function becomes active. This threshold is provided to ignore peaks that can occur during sample loading and unloading. Available settings: 1-90%, in 1% increments.

15 AUTO SETTINGS

The tester can perform one or several functions automatically when it has returned to the Home position. Return to Home can occur after a simple manual reverse, Auto Return, or a special event such as Break Detection, Pull to Load, or Load Holding:

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

The following automatic functions are available

1. Save the peak value to memory.

2. Transmit the peak reading.

3. Toggle an output pin.

4. Zero the primary and peak readings after a settable delay.

Scroll to Auto Settings in the menu and press ENTER to set the value. The display appears as follows:

AUTO SETTINGS

* Enabled * Memory Storage * RS232/USB Output Mitutoyo Output + More

AUTO SETTINGS 2

Output Pin: NONE * Auto Zero Auto Zero Delay 5 sec.

Enabled

Memory Storage RS232/USB Output Mitutoyo Output

Output Pin

Auto Zero

Auto Zero Delay

When enabled, all individual settings marked with an asterisk are active. When disabled, all settings are globally disabled, regardless of asterisks. Stores the peak reading to memory.

Outputs the peak via RS-232 and USB. Outputs the peak via Mitutoyo. Output Pin sets the selected SP1, SP2, or SP3 pin low until ZERO is pressed,

after which it reverts back to following the pass/fail limits if enabled. If not required, select “NONE”. Zeroes the display. Automatic zero is delayed for the specified period of time following return to the Home position.

16 DATA AND STATISTICS

The WT3-201M has storage capacity of 2,000 data points. Readings may be stored, viewed, and output to an external device. The most recent data point may be deleted. Statistics are calculated for the data presently in memory.

To enable memory storage, select DATA Key from the menu, then scroll to Memory Storage and press ENTER. Then exit the menu. In the home screen, the data record number 0000 appears below the primary reading. Press DATA at any time to save the displayed reading. The record number will increment each time DATA is pressed. If DATA is pressed when memory is full the message “MEMORY FULL” will be flashed at the bottom of the display and a double audio tone will be sounded.

To view, edit, and output stored readings and statistics, select Memory from the menu. The display appears as follows:

MEMORY

View Data

View Statistics Output Load Data Output Full Data Output Statistics Clear All Data

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

16.1 View Data

All the saved data points may be viewed. The record number is displayed, along with the corresponding value and presently set unit of measurement.

0001 24.8 lbF 0002 22.2 lbF 0003 24.6 lbF 0004 18.9 lbF

0005 20.0 lbF

0006 19.9 lbF 0007 20.2 lbF

10.1.1 Date & Time Stamp

If the optional Date & Time Stamp function is installed, pressing ENTER for the highlighted data point will display the associated date and time stamp, as well as the profile name (if the optional Profiles function is installed). The display appears as follows:

Data Point: 0005 Load: 20.0 lbF Date: 01/20/2015 Time: 11:35:08 AM Prof: PROFILE123

16.2 Delete Data

The last data point may be deleted. To do so, press DELETE while highlighting the last data point (Pressing DELETE while highlighting any other data point will have no effect). The letter “D” appears to the left of the record number, indicating that the tester is in Delete mode, as follows:

0001 24.8 lbF 0002 22.2 lbF 0003 24.6 lbF 0004 18.9 lbF 0005 19.9 lbF D 0006 20.0 lbF

Press ENTER to delete the value. The next most recent data point can then be deleted in the same fashion. To exit Delete mode, press DELETE again. To delete all data points, refer to the Clear All Data section.

16.3 Statistics

Statistical calculations are performed for the saved values. Calculations include number of readings, minimum, maximum, mean, and standard deviation.

16.4 Output Load Data

Press ENTER to output data to an external device. The display will show, “SENDING DATA…”, then “DATA SENT”. If there was a problem with communication, the display will show, “DATA NOT SENT”. Saved data can be downloaded by Mark-10 data collection programs. Refer to their respective user’s guides for details.

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

16.5 Output Full Data

Press ENTER to output data plus time, date, and profile name to an external device (optional Profiles and Date & Time Stamp functions required). The display will show, “SENDING DATA…”, then “DATA SENT”. If there was a problem with communication, the display will show, “DATA NOT SENT”. Saved data can be downloaded by Mark-10 data collection programs. Refer to their respective user’s guides for details.

16.6 Output Statistics

Press ENTER to output statistics to an external device. The display will show, “SENDING STATS…”, then “STATS SENT”. If there was a problem with communication, the display will show, “STATS NOT SENT”.

16.7 Clear All Data

Press ENTER to clear all data from the memory. A prompt will be shown, “CLEAR ALL DATA?”. Select Yes to clear all the data, or No to return to the sub-menu. Note: For convenience, clearing all data can also be accomplished by highlighting Memory in the main menu, then pressing DELETE.

17 COMMUNICATIONS AND OUTPUTS

Communication with the WT3-201M is achieved through the micro USB or 15-pin serial ports located at the bottom of the instrument, as shown in the illustration in the Setup section. Communication is possible only when the tester is in the main operating screen (i.e. not in a menu or configuration area).

17.1 Serial / USB

To set up RS-232 and USB communication, select Serial/USB Settings from the menu. The display appears as follows:

SERIAL/USB SETTINGS

* RS232 Selected USB Selected + Baud Rate + Data Format

Select either RS-232 or USB input (output is always simultaneous through both the USB and RS-232 ports). Communication settings are permanently set to the following: Data Bits: 8

Stop Bits: 1 Parity: None

Other settings are configured as follows:

17.1.1 Baud Rate

Select the baud rate as required for the application. It must be set to the same value as the receiving device.

17.1.2 Data Format

Select the desired data format. The display appears as follows:

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

DATA FORMAT

* Numeric + Units Numeric Only Invert Polarity Omit Polarity

Selection Description

Numeric + Units

Output format includes the value and unit of measure. Compression values have positive polarity, tension values have negative polarity.

Numeric Only Output format includes the value only. Polarity same as above.

Invert Polarity

Omit Polarity

Compression values have negative polarity, tension values have positive polarity. May be selected in addition to the Numeric + Units / Numeric Only selection. Both directions are formatted with positive polarity. May be selected in addition to the Numeric + Units / Numeric Only selection.

17.1.3 Data Communication

Individual data points may be transmitted by pressing DATA. The WT3-201M will also respond to the following ASCII commands:

? Request the displayed reading MEM Transmit all stored readings, without date, time, or profile name MEMFL Transmit all stored readings, with date, time, and profile name STA Transmit statistics CLRMEM Clear all stored readings from memory

All commands must be terminated with a Carriage Return character or with a Carriage Return/Line Feed combination. The tester’s responses are always terminated with a Carriage Return/Line Feed.

Any detected errors are reported back by means of error code *10 (illegal command).

17.2 Mitutoyo BCD settings

This output is useful for connection to data collectors, printers, multiplexers, or any other device capable of accepting Mitutoyo BCD data. Individual data points may be transmitted by pressing DATA or by requesting it from the Mitutoyo communication device (if available). To enable Mitutoyo output, select the desired format – either with polarity or without polarity. The display appears as follows:

MITUTOYO BCD

* Disabled Enabled * Without Polarity With Polarity

17.3 Analog Output

This output can be used for chart recorders, oscilloscopes, data acquisition systems, or any other compatible devices with analog inputs. The output produces ±1 volt at full scale of the instrument. The polarity of the signal is positive for compression and negative for tension.

17.4 DATA Key Functions

The DATA key can be configured to perform several functions. To configure the DATA key, select DATA Key from the menu. The display appears as follows:

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

DATA KEY * RS232/USB Output Mitutoyo Output * Memory Storage Profile Name Out. Date Output Time Output

Three options are available:

Selection Function when pressing DATA

RS232/USB Output Mitutoyo Output Memory Storage Profile Name Out. Date Output Time Output

Any combination of the above functions may be selected.

17.5 I/O Connector Pin Diagram (DB-9HD-15 female)

Outputs data via the serial and USB ports Outputs data via Mitutoyo (Digimatic) through the serial port Stores a reading to memory (refer to the Memory section for details) Outputs the Profile name (requires optional Profiles function) Outputs the date stamp (requires optional Date & Time Stamp function) Outputs the time stamp (requires optional Date & Time Stamp function)

Pin No. Description Input / Output

1 Signal Ground --2 * Tension Overload * Output * 3 RS-232 Receive Input 4 RS-232 Transmit Output 5 +12V DC Output 6 Analog Output Output 7 * Compression Overload * Output *

11 Set Point Pin 1 (SP1) Output 12 Set Point Pin 2 (SP2) Output 13 Set Point Pin 3 (SP3) Output 14 External Trigger Input

15 *

Mitutoyo Clock or Output Bit 2 (mutually exclusive) Mitutoyo Data or Output Bit 0 (mutually exclusive) Mitutoyo Request or Input Bit 3 (mutually exclusive)

Mitutoyo Ready or Output Bit 1 (mutually exclusive) *

Output

Input

Output *

* Maximum voltage: 40V.

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

18 PROFILES (optional function)

Groups of menu settings may be saved as profiles, and later recalled as required for the application. To save, edit, and recall profiles, select Profiles from the menu and press ENTER. The display appears as follows:

PROFILES Current: PROFILE123 Save to Current Prof. Select Profile Save as New Profile

PROFILE123

Delete Current Prof.

Selection Description

Indicates the currently selected profile. To rename it, press ENTER to highlight

Current

Save to Current Prof. Save settings to the currently selected profile (overwrite the current profile).

Select Profile

Save as New Profile Save settings to a new profile. The name can be entered as described above.

Delete Current Prof.

Note: If any settings are changed and the main menu is exited without first saving these changes to a new or current profile, the following message appears:

*** WARNING ***

A change was made. Save changes to current profile?

Yes

Selection Description

No Reverts to the home screen, and defaults to the profile “NO PROFILE”. Yes Save settings to the currently selected profile (overwrite the current profile).

When exiting the Profiles menu, the profile name will be shown in the lower left corner of the home screen, except if “NO PROFILE” is selected, in which case this part of the screen will be blank.

the name. The name may consist of up to 10 alphanumeric characters. Use the the

DATA key to advance to the next character. Press ENTER when done.

View a list of saved profiles. Scroll through the list and press ENTER to select the desired profile. Any data saved in memory will be deleted when selecting a different profile.

Note: One of the profiles listed is named “NO PROFILE”, which initially contains factory default settings. These settings can be edited, however, the profile name cannot be edited.

Delete the currently selected profile. Note: “NO PROFILE” may not be deleted.

and keys to increment and decrement the characters, and the

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

19 PASSWORDS

Two separate passwords may be configured to control access to the Calibration section and to the menu and other keys. To access the passwords setup screen, select Passwords from the menu. The display appears as follows:

PASSWORDS

Calibration MENU Key MODE Key ZERO Key DATA Key

19.1 Calibration Password

Select Calibration from the sub-menu. The display appears as follows:

CALIBRATION PASSWORD

* Disabled Enabled Set Password (0000 – 9999)

5000

To set the password, select Enabled, then Set Password. Use the UP and DOWN keys to increment and decrement the value, from 0 to 9999. When the desired value has been selected, press ENTER, then

ESC to exit the sub-menu.

19.2 MENU Key Password

If enabled, every time the MENU key is selected, a password must be provided. Select MENU Key from the sub-menu. Follow the same procedure as described in the previous sub-section.

19.3 Locking Out Other Keys

Other keys may be locked out individually. Select any combination of keys (MODE, ZERO, DATA) by pressing ENTER in the Passwords sub-menu. Pressing a locked key will prompt the message “KEY PROTECTED” and then revert to the previous screen.

19.4 Password Prompts

If passwords have been enabled, the following will be displayed when pressing the MENU key or accessing the Calibration section:

ENTER PASSWORD

(0000 – 9999)

5000

Use the UP and DOWN keys to select the correct password, then press ENTER to continue.

If the incorrect password has been entered, the display appears as follows:

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

INCORRECT PASSWORD

Reset password

Request code:

XXXX

Press ENTER or ESC

To re-enter the password, press ESC to exit to the home screen. Then, access the desired function and enter the password again when prompted.

If the password has been misplaced, it can be reset. Press ENTER to generate a request code. The

request code must be supplied to Mark-10 or a distributor, who will then provide a corresponding authorization code. Enter the activation code to disable the password.

20 OTHER SETTINGS

20.1 Date & Time (optional function)

If the Date & Time Stamp function is installed, the date and time may be configured in the Date & Time menu. The display appears as follows:

DATE & TIME * Date (MM/DD/YYYY) Date (DD/MM/YYYY) 01 / 20 / 2015 * Time (HH:MM:SS 12H) Time (HH:MM:SS 24H) 1 : 38 : 07 PM

Select the preferred date and time formats by highlighting and pressing the ENTER key. Then use the ENTER key to scroll between the fields within the date and time. Use the

increment and decrement the values. Pressing ESC will abort any changes.

20.2 LCD Contrast

The contrast of the display may be adjusted. Select LCD Contrast from the menu. The display appears as follows:

LCD CONTRAST

Set Contrast

and keys to

Press ENTER to modify the contrast. Select a value from 0 to 25, 25 producing the most contrast.

20.3 Tones

Audible tones can be enabled for all key presses and alerts, such as overload, pass/fail limit reached, etc. The pass/fail alert can be configured to be either a momentary tone or a continuous tone (until the load is

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

restored to a value between the fail limits). To configure the functions for which audible tones will apply, select Tones from the menu. The display appears as follows:

TONES

Keys * Alerts Pass/Fail Limits * Momentary Continuous

20.4 Initial settings

This section is used to configure the initial settings upon powering on the tester. The initial units of measurement and the primary reading measurement mode may be configured. To access these settings, select Initial Settings from the menu. The display appears as follows:

INITIAL SETTINGS

Units lbF Mode Real Time

The default values are lbF and Real Time.

20.5 Restore Default Settings

Default factory settings can be restored by selecting Restore Defaults from the menu. The settings may be found in the Specifications section. The display appears as follows:

RESTORE DEFAULT

SETTINGS?

Yes

20.6 Information / Welcome Screen

The following screen is displayed at power up and can be accessed at any time by selecting Information from the menu:

Wire Terminal Tester

Series WT3M Model No: WT3-201M Serial No: 1234567 Version: 1.0 (c) Mark-10 Corp.

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

21 FUNCTION ACTIVATION

A number of optional functions are available, which may be ordered upfront or enabled in the field via an activation code.

21.1 Activating Functions

Select Function Activation from the menu. The display appears as follows:

FUNCTION ACTIVATION

Profiles * Pull to Load

Load Holding

* Date & Time Stamp All Functions

Functions marked with an asterisk are installed. To install another function, scroll to it, then press ENTER. The display appears as follows:

FUNCTION ACTIVATION

Load Holding

Request code 1234567 Activation code 5555555

Supply the request code to Mark-10 or a distributor, who will then provide a corresponding activation code to activate the function. Use the

advance to the next character. Press ENTER when done. If the code has been entered successfully, the function will be permanently installed.

21.2 Demo Mode Functions

After the initial power-up sequence, the display appears as follows:

*** DEMO MODE ***

All functions are temporarily enabled. Remaining demo time:

160 hours

Press ENTER.

and keys to select each character, then press DATA to

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

22 CALIBRATION

22.1 Initial Physical Setup

The tester should be mounted vertically to a fixture rugged enough to withstand a load equal to the full capacity of the instrument. Certified deadweights or master load cells should be used, along with appropriate mounting brackets and fixtures. A calibration kit is available from Mark-10. Caution should be taken while handling such equipment.

22.2 Calibration Procedure

1. Select Calibration from the menu. The display appears as follows:

CALIBRATION

To invert the display, press the DIRECTION button, then press ENTER.

2. Press DIRECTION to invert the display, if desired. ENTER to continue. The display appears as follows:

CALIBRATION

Enter # cal points

(1 to 10)

The tester can be calibrated at up to 10 points. Enter the number of calibration points (at least one point must be selected).

Note: To achieve the accuracy specification of ±0.2%, it is recommended to calibrate the tester at 5 or more evenly spaced increments, such as 40, 80, 120, 160, and 200 lb loads.

3. To escape the Calibration menu at any time, press ESCAPE. The display appears as follows:

CALIBRATION

NOT COMPLETE

Cancel Exit w/o saving

Selecting “Cancel” will revert back to the Calibration setup. Selecting “Exit w/o saving” will return to the menu without saving changes.

4. After the number of calibration points has been entered, press ENTER. The display appears as follows:

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

CALIBRATION

OFFSET

Place force tester horizontal, then press ZERO.

5. Place the tester horizontally on a level surface free from vibration, then press ZERO. The tester will calculate offsets, and the display appears as follows:

CALIBRATION

OFFSET

Please wait…

CALIBRATION

OFFSET

Sensor passed Analog passed

CALIBRATION

OFFSET

Sensor failed

Analog failed

If failed:

6. The following message appears after the offsets have been calculated:

CALIBRATION

Attach necessary weight fixtures, then press ENTER.

Attach weight fixtures (brackets, hooks, etc), as required. Do not yet attach any weights or apply any calibration loads. Then press ENTER.

7. The display appears as follows:

CALIBRATION

Optionally exercise sensor, then press ENTER.

Optionally exercise the load cell several times (at full scale, if possible), then press ENTER.

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

8. The display appears as follows:

CALIBRATION

Gain adjust

Apply full scale load

200.0 lbF +/-20%,

then press ENTER.

Apply a weight equal to the full scale of the instrument, then press ENTER.

9. After displaying “Please wait…” the display appears as follows:

CALIBRATION

Ensure no load,

then press ZERO.

Remove the load, leave the fixtures in place, then press ZERO.

10. The display appears as follows:

CALIBRATION

Apply load

1 OF 5

Enter load:

40.0 lbF

Press ENTER.

Use the UP and DOWN keys to adjust the load value as required. The load values default to evenly spaced increments, as indicated by the previously entered number of data points. Apply the calibration load. Then press ENTER.

Repeat the above step for the number of data points selected.

11. After all the calibration points have been completed, the display appears as follows:

CALIBRATION

COMPLETE

Save & exit Exit w/o saving

To save the calibration information, select “Save & exit”. To exit without saving the data select “Exit w/o saving”.

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

12. Any errors are reported by the following messages:

CALIBRATION

Units must be lbF.

Please try again

Press ENTER.

Displayed at the start of calibration if a disallowed unit is selected.

CALIBRATION

Load not stable.

Please try again.

Ensure that the load is not swinging, oscillating, or vibrating in any manner. Then try again.

CALIBRATION

COMPRESSION

Load too low.

Please try again.

The calibration weight does not match the set value.

CALIBRATION

Load too close

to previous.

Please try again.

The entered calibration point is too close to the previous point.

23 MAINTENANCE

As wire terminals are removed, debris may fall into the cam mechanism area. This debris may be accessed by removing the cam mechanism cover. Ensure that the cam mechanism is in the maximum travel position (opposite the Home position) before removing the cover. Then loosen the three screws identified below, and carefully lift the cover straight up, ensuring that the auto-start switch (circled, below) is not damaged.

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

Use a small brush to collect and remove debris. To avoid possible damage to tester components, DO NOT use compressed air.

While the cover is removed, the status in the upper right corner will be flashing “COVER”. The START and STOP keys must be pressed and held to produce momentary motion. Normal testing cannot be performed while the cover is removed.

After reinstalling the cover, cycle the mechanism to the end of travel and back to the home position to ensure that the pinch guard has re-engaged.

24 SPECIFICATIONS

24.1 General

Force capacity x resolution:

Accuracy:

Wire diameter range:

Min. sample length:

Max. elongation:

Speed range:

Sampling rate:

Speed setting accuracy:

Speed variation with load:

Power:

Fuse:

Outputs:

Safe overload:

Weight:

Included accessories:

Environmental requirements:

Warranty:

200 x 0.1 lbF | 3200 x 2 ozF | 100 x 0.05 kgF | 1000 x 0.5 N | 1 x 0.0005 kN

±0.2% of full scale

AWG30 - AWG 3 [0.03 - 0.25 in (0.8 - 6.3 mm)]

Minimum 6.5 in [165 mm], excluding termination

1.7 in [43 mm]

0.4 - 12.0 in/min [10 - 300 mm/min]

7,000 Hz

±0.2%

±0% [Stepper motor driven]

Universal input 80-240 VAC, 50/60 Hz

1.2 A, 250V, 3AG, SLO BLO

USB / RS-232: Mitutoyo (Digimatic): Analog: General purpose: Set points:

150% of full scale (display shows “OVER” at 110% and above)

26.5 lb [12 kg]

Power cord, quick-start guide, USB cable, resource CD (USB driver, MESUR software, MESUR certificate of calibration.

40 - 100°F, max. 96% humidity, non-condensating

3 years (see individual statement for further details)

Fully configurable up to 115,200 baud.

±1 VDC, ±0.25% of full scale at capacity,

Three open drain outputs, one input.

Three open drain lines.

gauge DEMO software, and user’s guide), and NIST-traceable

Serial BCD suitable for all Mitutoyo SPC-compatible devices.

Lite

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

24.2 Factory Settings

Parameter Setting

Pass / Fail Limits Disabled Upper 160 lbF Lower 80 lbF Filters Current 512 Displayed 1024 DATA Key Functions RS-232/USB Output Enabled Mitutoyo Output Disabled Memory Storage Enabled Profile Name Output Disabled Date Output Disabled Time Output Disabled Speed Pull Speed 4.0 in/min Return Speed 96 in/min Unit in/min Auto Return Disabled Auto Start Disabled Serial/USB RS-232 Output Selected Enabled USB Output Selected Disabled Baud Rate 9,600 Data Format Numeric + units Mitutoyo BCD Output Disabled Polarity Without polarity Preload Enabled Force 5 lbF Speed 50 in/min Break Detection Disabled Threshold 10% of full scale Auto Settings Auto Zero Disabled Auto Zero Delay 5 sec. RS-232/USB Output Disabled Auto Storage Disabled Output Pin NONE Pull to Load (optional function) Disabled Force 50.0 lbF Load Holding (optional function) Disabled Hold Force 40.0 lbF Time 1 min. Date & Time (optional function) Varies Profile name (optional function) (blank) Tones Keys Enabled Alerts Enabled Pass / Fail Limits Momentary Initial Settings Unit lbF Mode Real Time Passwords All passwords disabled

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

24.3 Dimensions

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

NOTES:

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide

4.3 Dimensions (IN [MM])

Mark-10 Corporation has been an innovator in the force and torque measurement fields

since 1979. We strive to achieve 100% customer satisfaction through excellence in product

design, manufacturing and customer support. In addition to our standard line of products we

can provide modifications and custom designs for OEM applications. Our engineering team

is eager to satisfy any special requirements. Please contact us for further information or

suggestions for improvement.

Force and torque measurement engineered better

Mark-10 Corporation

11 Dixon Avenue Copiague, NY 11726 USA 1-888-MARK-TEN Tel: 631-842-9200 Fax: 631-842-9201 Internet: www.mark-10.com E-mail: info@mark-10.com

32-1183

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Mark-10 WT3-201M Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual