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auto grip pull tester doc no: tm-638019100 release date: 08-10-09 uncontrolled copy page 1 of 15 revision: b revision date: 10-01-09 pt-1500 auto grip pull tester operation manual order no. 63801-9100 description operation maintenance
auto grip pull tester doc no: tm-638019100 release date: 08-10-09 uncontrolled copy page 2 of 15 revision: b revision date: 10-01-09 warning never operate, service, install, or adjust this pull tes ter without proper instruction and without first reading and understan ding the instructions in this manual. never regardless of whether the display module (force ga uge) 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 4 40 lbf (200 kgf), or the load cell will be damaged. avoid shock load. warning! failure to allow for sufficient overload capacity i n the load, structure and mounting elements, may result in property damag e, serious injury, and even death. caution when mounting display module, after recalibration o r repair, use m4 mounting screws with a maximum insertion depth of 5mm into the display mod ule. only use mounting hardware supplied. caution hand tighten wire terminal grip only. do not use t ools. 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 use d 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
auto grip pull tester doc no: tm-638019100 release date: 08-10-09 uncontrolled copy page 3 of 15 revision: b revision date: 10-01-09 table of contents section 1 general description 2 setup and operation 3 maintenance
auto grip pull tester doc no: tm-638019100 release date: 08-10-09 uncontrolled copy page 4 of 15 revision: b revision date: 10-01-09 section 1 general description 1.1 description 1.2 features 1.3 technical specifications 1.4 delivery check 1.5 tools
auto grip pull tester doc no: tm-638019100 release date: 08-10-09 uncontrolled copy page 5 of 15 revision: b revision date: 10-01-09 1 2 3 4 5 figure 1-1 general description 1.1. description the pt-1500 auto grip pull tester, order no. 63801- 9100, is a manual, lever-operated digital pull test er for checking pull strength of crimped terminals. the t ester 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 adapt er/charger for the display module. it has a 3-point, nist cer tification. principal mechanical parts of the auto grip pull te ster see figure 1-1 1. 63801-9100 pt-1500 pull tester assembly 2. 63801-9101 multi-terminal grip 3. 63801-9102 clamp type terminal grip 4. 63801-9103 a.c. adapter / charger, 120 vac 63801-9105 a.c. adapter / charger, 230 vac 5. 63801-9104 display module 1.2. features single-stroke, ergonomic pull-down motion automatically grips sample wire as lever is pulled grips wire diameters up to 0.23" (8-30 awg) lbf, kgf, and newton units are push-button selectab le digimatic and analog outputs display module is easily removed for recalibration or repair runs on internal rechargeable batteries or ac adapt er (120 or 230 vac) nist calibration certificate included 1.3. technical specification dimensions see figure 1-2 width: 475.0 to 5.45.0mm (18.70 to 21.45") (depending on the handle position) depth: 150.00mm (5.90") height: 400.0mm (15.74") weight 10.88kg (24 lbs)
auto grip pull tester doc no: tm-638019100 release date: 08-10-09 uncontrolled copy page 6 of 15 revision: b revision date: 10-01-09 figure 1-2 63801-9100 range (resolution) 0.2% f.s. 1 lsd capacity (resolution) model pound-force kilogram-force newtons 63801-9100 220.0 (0.1 lbf) 100.0 (0.1 kgf) 1000 (1 n) 1.4. delivery check carefully remove the assembly from its shipping con tainer and determine that the following items are i ncluded 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
auto grip pull tester doc no: tm-638019100 release date: 08-10-09 uncontrolled copy page 7 of 15 revision: b revision date: 10-01-09 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
auto grip pull tester doc no: tm-638019100 release date: 08-10-09 uncontrolled copy page 8 of 15 revision: b revision date: 10-01-09 read the following instructions before attempting t o 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 st eps 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. on / off button power on, capacity is displayed. after 10 minutes, unit powers down if no key is pressed. peak button press to activate the peak mode. send button transmits display value. zero button tares weight of attachment and resets peak value. measuring shaft attach any of the included standard attachments or optional special attachments to measure tension. charger port recharge the internal nimh battery or connect direc tly to an ac power supply by using one of the inclu ded ac charger / adapters, appropriate for your local elec trical 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. figure 2-1 send button measuring shaft charger port display peak button on / off button zero button rs-232 port
auto grip pull tester doc no: tm-638019100 release date: 08-10-09 uncontrolled copy page 9 of 15 revision: b revision date: 10-01-09 figure 2-3 ac adapter cap screw display module hex nut grip 5mm hex wrench 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. 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. 2.3 installation ( see figure 2-3) 1. place the auto grip pull tester securely on a stabl e work surface. 2. to adjust clearance between the two wire gripping f ixtures if necessary, loosen the cap screw on the d isplay- module mounting bracket. adjust the position and the re-tighten the cap screw. 3. to remove the grip, use a 10mm open-end wrench to hold the hex nut while turning the grip counter- 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 battery. 2.4 general operation ( see figure 2-4) 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 turr et 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. figure 2-2 negative sign compression icon tension icon peak icon go / no go indicator battery icon units indicator
auto grip pull tester doc no: tm-638019100 release date: 08-10-09 uncontrolled copy page 10 of 15 revision: b revision date: 10-01-09 figure a figure b figure c figure d 4. thread the wire between the gripper and the cylinde r which is attached to the end of the hand lever. see figure c. 5. slowly pull the hand lever back to automatically gr ip the wire and pull off the terminal. see figure d . note : pull the lever slowly and steadily to insure cons istent readings. 6. read the result from the display module and press t he zero button to reset for the next test. 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. mounting plate cap screw figure 2-5 5mm hex wrench figure 2-4
auto grip pull tester doc no: tm-638019100 release date: 08-10-09 uncontrolled copy page 11 of 15 revision: b revision date: 10-01-09 2.6 settings and functions rs-232c bi-directional interface functions (see chart below) connect the gauge to an external data receiving dev ice, with the optional rs-232c cable (order no. 638 01- 9151). 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 charac ter 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 forma t) command function response* k [enter] select kgf/gf units n [enter] select n units o [enter] select lbf/ozf units p [enter] select peak mode t [enter] select real time mode z [enter] tare display q [enter] turn off power ehhhhllll [enter] ** set high/low set points(4 digit) hhhh=high, llll=lo w r [enter] executed e [enter] error* e [enter] ** read high/low set points ehhhhllll [enter] ** set point values (4 digit) hhhh=high, llll=low d [enter] transmit display data [value][units][mode ][enter] * e [enter] response if the command is not accepted. ** ignore decimal point for high low set points 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 stan dard deviation. order no. description type 63901-9150 software, data acquisition. 63801-9151 rs-232c cable (10', 9 pin female) 63801-9152 rs-232c to usb adapter recharging ni-mh battery 1. to maximize the life of the battery, power is shut off after 10 minutes of non-use. automatic shut of f 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 / c hargers provided, 63801-9103 for 120vac, 63801- 9105 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 adap ter/charger is disconnected to avoid overcharging.
auto grip pull tester doc no: tm-638019100 release date: 08-10-09 uncontrolled copy page 12 of 15 revision: b revision date: 10-01-09 section 3 maintenance 3.1 cleaning 3.2 calibration
auto grip pull tester doc no: tm-638019100 release date: 08-10-09 uncontrolled copy page 13 of 15 revision: b revision date: 10-01-09 3.1 cleaning caution : always disconnect power supply before all mainten ance the auto grip pull tester maintenance will increase instrument life and produce a consistent, crimp st rength measurement capability. the following procedure sh ould be followed at the end of each operation. 1. always disconnect the power supply from this tool w hen 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 gri p and clamp. 3.2. calibration the display module should be calibrated on a regula r schedule (usually annually). molex does not offe r a calibration service for the display module. a loca l calibration service should be used.
auto grip pull tester doc no: tm-638019100 release date: 08-10-09 uncontrolled copy page 14 of 15 revision: b revision date: 10-01-09 for more information use the quality crimping handb ook and industrial crimping handbook there is no charge for these books, they can be fou nd on the molex website (www.molex.com) or contact you local molex sales engineer
auto grip pull tester doc no: tm-638019100 release date: 08-10-09 uncontrolled copy page 15 of 15 revision: b revision date: 10-01-09 2 year warranty (restrictions apply) molex warrants its products to the original purchaser to be free from defects in workmanship and material un der normal use and proper maintenance for two years (on e year for adapters, attachments, batteries, and ca bles) from original purchase. this warranty shall not be effe ctive 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. plea se call our customer service department for a return authorizat ion number and return the defective product to us w ith freight prepaid. the foregoing warranty constitutes the sole and exc lusive warranty, and we hereby disclaim all other warranties, express, statutory or implied, applicab le to the products and/or software, including but n ot limited to all implied warranties of merchantability, fitness, non -infringement, results, accuracy, security and free dom from computer virus. in no event shall molex be liable for any incidental, consequential or punitive damag es in connection with the use of its products and/or soft ware. caution : to prevent injury, wear eye protection when usin g this tool. http://www.molex.com

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