638019100 规格书

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Auto Grip Pull Tester
Doc No: TM-638019100 Release Date: 08-10-09 UNCONTROLLED COPY Page 1 of 17
Revision: D Revision Date: 11-11-15
PT-1500
Auto Grip Pull Tester
Operation Manual
Order No. 63801-9100
Description
Operation
Maintenance
Keeg this manual available when using this tool. SAFETY ALERT SYMBOL cou he A A A A CAUTION: A WARNING A WARNING A Heavy Object A WARNING A WARNING A Do not use compressed air to clean this equipment. A WARNING! Do not exceed the capacity of the display module, regardless ofwhetherthe display module (force gauge) is on or off, Never exceed the maximum capaCity of 440 LBF (200 kgfl or the load cell will be damaged. Avoid shock load. Failure to allow for sufficient overload capacity in the load, structure and mounting elements, may result in property damage UNCONTROLLED COPY
Auto Grip Pull Tester
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Revision: D Revision Date: 11-11-15
Safety Warnings and Information
Read and understand all of the instructions and safety information in this manual before
operating or servicing this tool.
Keep this manual available when using this tool.
Replacement manuals are available for download at no charge at www.molex.com.
SAFETY ALERT SYMBOL
This symbol is used to call your attention to hazards or unsafe practices which could result in an injury
or property damage. The signal word, defined below, indicates the severity of the hazard. The message
after the signal word provides information for preventing or avoiding the hazard.
DANGER
DANGER:
Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.
WARNING
WARNING:
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION:
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION may also be used to alert against unsafe practices associated with events that could lead
to personal injury.
WARNING
Always wear proper eye protection when
Operating or servicing this equipment.
Failure to wear eye protection could result
in serious eye injury from flying debris.
WARNING
WARNING
Never operate, service, install, or adjust this
machine without proper instruction and without
first reading and understanding the instructions
in this manual and all applicable press and/or
wire processing machine manuals.
Do not use compressed air to clean this equipment.
The forces created by compressed air can force
debris into the tool.
Failure to observe these precautions may
result in injury or property damage
WARNING!
Do not exceed the capacity of the display module, regardless of whether the display module (force gauge) is on or off,
at 230 lbf (105 kgf), the display will flash
Never exceed the maximum capacity of 440 LBF (200 kgf), or the load cell will be damaged. Avoid shock load.
Failure to allow for sufficient overload capacity in the load, structure and mounting elements, may result in property damage,
Serious injury, and even death
Tooling Manual Applicator Tooling Specification Sheet UNCONTROLLED COPY
Auto Grip Pull Tester
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Revision: D Revision Date: 11-11-15
CAUTION
When mounting display module, after recalibration or repair, use M4 mounting screws with a maximum insertion depth of 5mm
into the display module.
Only use mounting hardware supplied.
Hand tighten wire terminal grip only. Do not use tools
Do not remove the warranty seal or disassemble the display module. Disassembly will void the warranty.
Never perform any service or maintenance other than as described in this manual.
Never modify, alter or misuse the equipment
Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling.
Failure to observe this precaution may result in injury and property damage.
Tooling Technical Assistance
Molex offers tooling technical assistance for customers who may need some guidance for tooling adjustments.
This support can be obtained by calling either of the two numbers listed below and asking for the Molex Tooling
Group.
Call Toll Free 1-800-786-6539 (US) 1-630-969-4550 (Global).
This assistance is limited to the operation and set-up of a customer’s Molex Tester. Questions with regard to
Molex connector products or how to identify the proper tooling and/ or tooling documentation should be directed to
your local Molex personnel or Customer Service Representative.
When calling for service on the press a copy of the Tooling Manual and Specific Applicator Tooling Specification
Sheet should be present and a person that is familiar with the applicator should be present. Be sure the following
information is supplied:
1. Customer name
2. Customer address
3. Person to contact such as (name, title, e-mail, and telephone number
4. Pull Tester order number
5. Serial number (Lease number also if applicable)
6. Molex Connector product order number
7. Urgency of request
8. Nature of problem
Molex Application Tooling Group
2200 Wellington Court
Lisle, IL 60532, USA
Tel: +1 (630) 969-4550
Fax:+1 (630) 505-0049
Visit our Web site at http://www.molex.com
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Table of Contents
Contents
Auto Grip Pull Tester ............................................................................................................................................................................... 1
Operation Manual .................................................................................................................................................................................... 1
Order No. 63801-9100 ............................................................................................................................................................................. 1
Safety Warnings and Information ............................................................................................................................................................ 2
Table of Contents .................................................................................................................................................................................... 4
Section 1 .................................................................................................................................................................................................. 6
General Description............................................................................................................................................................................. 7
1.1 Description ............................................................................................................................................................................. 7
1.2 Features ................................................................................................................................................................................. 7
1.3 Technical Specification .......................................................................................................................................................... 7
1.4 Delivery Check ....................................................................................................................................................................... 8
1.5 Tools ...................................................................................................................................................................................... 8
Section 2 .................................................................................................................................................................................................. 9
Set-Up and Operation ......................................................................................................................................................................... 9
2.1. Display Module Operation .................................................................................................................................................... 10
2.2 LCD Display ......................................................................................................................................................................... 10
2.3 Installation ............................................................................................................................................................................ 11
2.4 General Operation ................................................................................................................................................................ 11
2.5 Removing the Display Module ............................................................................................................................................. 12
2.6 Settings and Functions ......................................................................................................................................................... 13
Section 3 ................................................................................................................................................................................................ 14
Maintenance ...................................................................................................................................................................................... 14
3.1 Cleaning ............................................................................................................................................................................... 15
3.2 Calibration ............................................................................................................................................................................ 15
For more information use the Quality Crimping Handbook ............................................................................................................... 16
2 YEAR WARRANTY ........................................................................................................................................................................ 17
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Table of Contents
SECTION
1 General Description
2 Setup and Operation
3 Maintenance
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Section 1
General Description
1.1 Description
1.2 Features
1.3 Technical Specifications
1.4 Delivery Check
1.5 Tools
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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 tester for
checking pull strength of crimped terminals. The tester is designed to automatically grip the wire as the hand
lever is pulled down.
The unit is complete with display module, two multi-terminal grips, pull tester frame, and an AC adapter/charger
for the display module. It has a 3-point, NIST certification.
Principal Mechanical Parts of the Auto Grip Pull Tester
See Figure 1-1
1. 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 selectable
Digimatic and analog outputs
Display module is easily removed for recalibration or repair
Runs on internal rechargeable batteries or AC adapter (120 or 230 VAC)
NIST Calibration Certificate included
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)
560 (22.04“) 400 15 74") 150 (5 so”) _ 400 (15 74“) 4757545 (1570721 45“) Capacity (Resolution) Pound-force Kilogram-lore: Newton 03001-9100 220.0 (0.1 \bf) 100 0 (0.1 kgf) 1000 (1N) UNCONTROLLED COPY
Auto Grip Pull Tester
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Revision: D Revision Date: 11-11-15
Figure 1-2
63801-9100 Range
(Resolution) ± 0.2% F.S. ± 1 LSD
Model
Capacity (Resolution)
Pound-force
Kilogram-force
Newton
63801-9100
220.0 (0.1 lbf)
100.0 (0.1 kgf)
1000 (1N)
1.4 Delivery Check
Carefully remove the assembly from its shipping container and determine that the following items are included in the
package.
Description Quantity
63801-9100 Pull Tester assembly 1
63801-9102 Clamp type terminal grip 1
63801-9103 A.C. Adapter / charger (120 VAC) or 1
63801-9105 A.C. Adapter / charger (230 VAC) 1
TM-638019100 Operation Manual 1
1.5 Tools
The following tools are recommended for set up and maintaining the tester:
Open end wrench, 10mm
Hex wrench, 5mm
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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
MEASURING SEND CHARGER R3432 UNCONTROLLED COPY
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Read the following instructions before attempting to operate the Auto Grip Pull Tester.
2.1. Display Module Operation
See Figure 2-1.
Display
To set the measurement units to pound-force (lbf), kilogram-force (kgf), or Newtons (N), follow the steps below:
1. Turn off the display module.
2. Hold the ZERO button and press the ON/OFF button once.
3. Press the ZERO button to change to the desired units.
4. Push the SEND button to select.
5. 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 directly to an AC
power supply by using one of the included AC charger /
adapters, appropriate for your local electrical requirements. (See
Figure 1.1).
RS-232 Port
For data transmission to the external device.
2.2 LCD Display
See figure 2-2.
Compression Icon
Indicates the compression measurement.
Figure 2-1
SEND
BUTTON
MEASURING
SHAFT
CHARGER
PORT
DISPLAY
PEAK
BUTTON
ON / OFF
BUTTON
ZERO
BUTTON
RS-232
PORT
COMPRESSION TENSION ICON NEGATIVE UNITS GO 1 No Go BATTERY Figure 2-2 Q \ UNCONTROLLED COPY
Auto Grip Pull Tester
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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 stable work surface.
2. To adjust clearance between the two wire gripping fixtures if necessary, loosen the cap screw on the display-
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 turret to select an appropriate aperture and bring the hand lever
forward. See Figure A.
3. Insert the sample so that the wire terminal is held in place by the grip. If necessary, press the ZERO button to
reset. See Figure B.
Figure 2-2
NEGATIVE
SIGN
COMPRESSION
ICON
TENSION
ICON
PEAK ICON
GO / NO GO
INDICATOR
BATTERY
ICON
UNITS
INDICATOR
MOUNTING CAP SCREW /'6 =JJV\ 5mm HEX Figure 2-5 UNCONTROLLED COPY
Auto Grip Pull Tester
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Figure A
Figure B
Figure C
Figure D
4. Thread the wire between the gripper and the cylinder which is attached to the end of the hand lever. See
Figure C.
5. Slowly pull the hand lever back to automatically grip the wire and pull off the terminal. See Figure D.
NOTE: Pull the lever slowly and steadily to insure consistent readings.
6. Read the result from the display module and press the ZERO button to reset for the next test.
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
RS-ZSZC Interface Functions (Upper case ASCII lcrmat) Command Function Response‘ K [Enter] Select “kgf/gl“ units N [Enter] Select “ units 0 [Enter] Select “lbf/ozi‘ 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 p0mls[4 digit) HHHH=Htgn, LLLL=Low EHHHHLLLL [Enler]" D [Enter] Transmit display data [value][units][mode][Enter] 'E [Enter] response if the command is not accepted. Order No. Description Type 63801-9150 Software] Data Acquisition. 63801—9152 RS—ZSZC to USB Adapter UNCONTROLLED COPY
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2.6 Settings and Functions
RS-232C Bi-directional Interface Functions (See Chart below)
Connect the gauge to an external data receiving device, with the optional RS-232C cable (Order No. 63801-
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 character format followed by [Enter].
Signal level: RS-232C, 8 data bits, 1 stop bit, and no parity bit.
Baud rate: 19200 bps.
RS-232C Interface Functions (Upper case ASCII format)
Command
Function
Response*
K [Enter]
Select “kgf/gf” units
R [Enter] executedE [Enter] error*
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=Low
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 standard deviation.
Order No.
Description
Type
63801-9150
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 off is
bypassed when used with the AC adapter/charger.
2. Battery icon will flash when the gauge needs to be recharged.
3. Turn off power. Only use one of the AC adapter / chargers provided, 63801-9103 for 120VAC, 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 adapter/charger is disconnected to avoid overcharging.
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Section 3
Maintenance
3.1 Cleaning
3.2 Calibration
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3.1 Cleaning
CAUTION: Always disconnect power supply before all maintenance
The Auto Grip Pull Tester maintenance will increase instrument life and produce a consistent, crimp strength
measurement capability. The following procedure should be followed at the end of each operation.
1. Always disconnect the power supply from this tool when not in use.
2. For efficient operation, the Auto Grip Pull Tester should be cleaned daily. Use a soft bristle brush to remove
debris from critical areas such as the terminal grip and clamp.
3.2 Calibration
The display module should be calibrated on a regular schedule (usually annually). Molex does not offer a
Calibration service for the display module. A local calibration service should be used.
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For more information use the Quality Crimping Handbook
And Industrial Crimping Handbook
There is no charge for these books, they can be found on the Molex Website (www.molex.com) or contact you
local Molex sales engineer
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2 YEAR WARRANTY
(RESTRICTIONS APPLY)
Molex warrants its products to the original purchaser to be free from defects in workmanship and material under
normal use and proper maintenance for two years (one year for adapters, attachments, batteries, and cables) from
original purchase. This warranty shall not be effective if the product has been subject to overload, shock load,
misuse, negligence, accident, or repairs attempted by others than Molex.
During the warranty period, we will, at our option, either repair or replace defective products. Please call our
customer service department for a return authorization number and return the defective product to us with freight
prepaid.
The foregoing warranty constitutes the SOLE AND EXCLUSIVE WARRANTY, and we hereby disclaim all other
warranties, express, statutory or implied, applicable to the products and/or software, including but not limited to all
implied warranties of merchantability, fitness, non-infringement, results, accuracy, security and freedom from
computer virus. In no event shall Molex be liable for any incidental, consequential or punitive damages in
connection with the use of its products and/or software.
CAUTION: To prevent injury, wear eye protection when using this tool.
Visit our Web site at http://www.molex.com