Mark-10 WT-205 Wire Crimp Pull Tester

Thank you...

Thank you for purchasing a Mark-10 WT-205 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 WT-205 should be fully trained in appropriate operation and safety procedures.

1 OVERVIEW

1.1 List of included items

Download at: www.mark-10.com/resources

1.2 Safety / Proper Usage

Caution!

Note the tester's capacity of 200 lbF [1,000 N]. Producing a force greater than 150% of capacity can damage the internal load cell. An overload can occur whether the tester is powered on or off.

Typical materials able to be tested include many manufactured items, such as wires, tubing, and other samples. Items that should not be used with the tester include potentially flammable substances or products, items that can shatter in an unsafe manner, and any other components that can present an exceedingly hazardous situation when acted upon by a force.

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

1. Never operate the tester if there is any visible damage to the AC adapter or the tester itself.
2. Ensure that the tester is kept away from water or any other electrically conductive liquids at all times.
3. The tester should be serviced by a trained technician only. AC power must be disconnected and the tester must be powered off before the housing is opened.
4. 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.
5. 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.
6. In certain applications, such as the testing of brittle samples that can shatter, or other applications that could lead to a hazardous situation, it is strongly recommended that a machine guarding system be employed to protect the operator and others in the vicinity from shards or debris.
7. When the tester is not in use, ensure that the power is turned off.
8. Pinch Hazard: Keep body parts clear of the lever mechanism during operation.

2 POWER

The tester is powered either by an 8.4V NiMH rechargeable battery or by an AC adapter. Since these batteries are subject to self discharge, it may be necessary to recharge the unit after a prolonged period of storage. Plug the accompanying charger into the AC outlet and insert the charger plug into the receptacle on the tester (refer to the illustration below). The battery will fully charge in approximately 8 hours.

Caution!

Do not use chargers or batteries other than supplied or instrument damage may occur.

If the AC adapter is plugged in, an icon appears as follows: [AC adapter icon]

If the AC adapter is not plugged in, battery power drainage is denoted in a five-step process:

1. When battery life is greater than 75%, the following indicator is present: [Battery indicator, 5 bars full]
2. When battery life is between 50% and 75%, the following indicator is present: [Battery indicator, 4 bars full]
3. When battery life is between 25% and 50%, the following indicator is present: [Battery indicator, 3 bars full]
4. When battery life is less than 25%, the following indicator is present: [Battery indicator, 2 bars full]
5. When battery life drops to approximately 2%, the indicator from step 4 will be flashing. Several minutes after (timing depends on usage and whether the backlight is turned on or off), a message appears, “BATTERY VOLTAGE TOO LOW. POWERING OFF”. A 4-tone audio indicator will sound and the tester will power off.

The tester can be configured to automatically power off following a period of inactivity. Refer to the Other Settings section for details.

If battery replacement is necessary, the battery may be accessed by removing the sheet metal cover on the underside of the base.

3 SETUP

3.1 Mechanical Setup

3.1.1 Assembly

The lever is shipped disassembled from the unit to prevent damage in transit. To install, match the pin on the handle with the corresponding blind hole on the mechanism. Then, tighten the plastic knob into the threaded hole in the lever hub.

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 three 1/4-20 screws fastened into the underside of the base.

3.1.3 Sample setup

1. Secure the terminal into the standard turret terminal fixture, optional ring terminal fixture, or optional wedge grip assembly, as shown in the figures below. Index the turret or ring terminal fixtures until the desired slot or ring size is aligned with the opposite grip.

2. Rotate the lever clockwise until its end of travel.
3. Insert the loose end of the wire through the mechanism near the lever, as illustrated below. Maintain tension on the wire as you insert it.

Figure 3.7: Rotating the lever

4. Rotate the lever counter-clockwise to engage the loose end of the wire, as shown in the figure below. Continue rotating to produce force on the sample. The lever will reach its end of travel before contacting the keypad / display housing.
5. When the test is complete, rotate the lever clockwise until the end of travel.

3.1.4 Installing the ring terminal fixture

To install or uninstall the standard or optional ring terminal fixture, loosen the center screw, remove the existing fixture, install the desired fixture, and re-tighten the screw.

3.1.5 Replacing terminal fixture with the wedge grip assembly (Grip A)

To install the optional wedge grip assembly, loosen the two screws nearest the keypad, remove the terminal fixture, install the provided intermediate plate, and then secure the wedge grip assembly to the plate.

3.1.6 Replacing the wedge grip assembly (Grip B)

To install the optional bollard grip or dual roller grip assembly, loosen and remove the two screws on the wedge grip. Align the dowel pin on the desired grip assembly with the blind hole in the mounting plate and tighten the screws.

3.2 Installing the USB driver

If communicating via USB, install the USB driver available at: www.mark-10.com/resources

Caution!

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

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

4 HOME SCREEN AND CONTROLS

4.1 Home Screen

4.2 Controls

4.3 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.

4.5 Demo Mode Functions

The WT-205 is shipped in Demo Mode, which provides full functionality of all available optional 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:

An additional 160-hour demo period can be enabled when the original 160 hours have expired. To do so, select Reset Demo Time from the Function Activation menu shown in the next sub-section, and follow the request code / activation code procedure described.

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. Date & Time Stamp: A date and time stamp is assigned to each saved data point. Refer to the Function Activation section for further instructions on how to activate functions.

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.

Two operating modes are possible with the WT-205. 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

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 CHANGING THE UNITS

The WT-205 can display five different measurement units. To change the unit, select Units from the menu. The display will list the available units, as follows:

• lbF
• ozF
• kgF
• N
• kN

The tester will always power on with the unit selected in this sub-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:

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. 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:

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.

8.2.1 Set Point Outputs Schematic Diagram

9 BREAK DETECTION

The break detection function senses when the wire-terminal separation occurs. 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 return 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.

9.1 Configuration

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

Any combination of the above functions may be selected.

After 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 been triggered.

10 AUTO SETTINGS

The tester can perform one or several functions automatically when Break Detection is enabled, and after a break occurs.

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:

Enabled: When enabled, all individual settings marked with an asterisk are active. When disabled, all settings are globally disabled, regardless of asterisks.

Memory Storage: Stores the peak reading to memory.

RS232/USB Output: Outputs the peak and date / time stamp (if this function is installed) via RS-232 and USB.

Mitutoyo Output: Outputs the peak via Mitutoyo.

Output Pin: 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”.

Auto Zero: Zeroes the display.

Auto Zero Delay: Automatic zero is delayed for the specified period of time following return to the Home position.

11 DATA MEMORY AND STATISTICS

The WT-205 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:

11.1 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

11.1.1 Date & Time Stamp (optional function)

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:

11.2 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 reading was marked for deletion, 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.

11.3 Statistics

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

11.4 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 communication problem, the display will show, “DATA NOT SENT”. Saved data can be downloaded to Mark-10 data collection programs. Refer to their respective user's guides for details.

11.5 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 communication problem, 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.

11.6 Output Statistics

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

11.7 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.

12 COMMUNICATIONS AND OUTPUTS

Communication with the WT-205 tester is achieved through the micro-USB or 15-pin serial ports, as shown in the illustration in the Power section. Communication is possible only when the tester is in the main operating screen (i.e. not in a menu or configuration area).

12.1 Serial / USB

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

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:

12.1.1 Baud Rate

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

12.1.2 Data Format

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

12.1.3 Data Communication

Individual data points may be transmitted by pressing DATA. The WT-205 may also be controlled by an external device through the RS-232 or USB channels. The following is a list of supported commands and their explanations. All commands must be terminated by a CR (Carriage Return) character, 0x0D, or a CR-LF (Carriage Return – Line Feed) pair, where the Line Feed, 0x0A, is ignored.

• ? Request the displayed reading
• MEM Transmit all stored readings
• STA Transmit statistics
• CLRMEM Delete all stored readings from memory

12.1.4 Command Responses

In response to the reading request command ‘?' the tester will return a string with the load data, followed by a space, then the load unit (if enabled, as described above). It will be terminated by a CR-LF pair.

Example return string: 124.8 lbF<CR><LF> 124.8 lbF of pull force

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

12.2 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, make the appropriate selection. The screen appears as follows:

12.3 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. Note that the polarity of the signal is negative.

12.4 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:

Three options are available:

Any combination of the above functions may be selected.

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

13 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:

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:

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.

14 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:

14.1 Calibration Password

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

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.

14.2 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.

14.3 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.

14.4 Password Prompts

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

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:

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.

15 OTHER SETTINGS

15.1 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:

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 ▲ and ▼ keys to increment and decrement the values. Pressing ESC will abort any changes.

15.2 LCD Contrast

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

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

15.3 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 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:

15.4 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:

The default values are lbF and Real Time.

15.5 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:

16 FUNCTION ACTIVATION

15.6 Information / Welcome Screen

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

16.1 Demo Mode Functions

The WT-205 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:

An additional 160-hour demo period can be enabled when the original 160 hours have expired. To do so, select Reset Demo Time from the Function Activation menu shown in the next sub-section, and follow the request code / activation code procedure described.

16.2 Activating Functions

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

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

Supply the request code to Mark-10 or a distributor, who will then provide a corresponding activation code to activate the function. Use the ▲ and ▼ keys to select each character, then press DATA to advance to the next character. Press ENTER when done. If the code has been entered successfully, the function will be permanently installed.

17 CALIBRATION

17.1 Initial Physical Setup

The tester should be mounted vertically to a test stand or fixture rugged enough to withstand a load equal to the full capacity of the instrument. The lever mechanism should be removed. 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.

17.2 Calibration Procedure

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

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

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:

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:

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:

If failed:

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

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:

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

8. The display appears as follows:

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

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

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

10. The display appears as follows:

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:

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

12. Any errors are reported by the following screens:

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

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

The calibration weight does not match the set value.

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

18 SPECIFICATIONS

18.1 General

18.2 Factory Settings

18.3 Dimensions (IN [MM])