Alluris FMT-W30C5 User manual

Digitales Auszugskraftmessgerät für Kabelverbindungen
Digital Force Gauge For Wire Terminals
Dynamomètre Numerique par Jonctions de Câbles
Dinamométrico Digital Por cables con unions Adecuadas
Dinamometri Digitales a di Cavi con Connettori
(BDA Version 2.4)
Bedienungsanleitung
Operation Manual
Notice d’utilisation
Instrucciones de servicio
Istruzioni per l’uso

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
Content
1. Safety Precautions ...........................................................................................................................................................................................17
2. General Information.........................................................................................................................................................................................17
2.1. Scope of Supply, unpacking and Setting Up ..............................................................................................................................................17
2.2. Ernergy Harvesting (manual pull tester FMT-W30 only) ..............................................................................................................................17
2.3. Attach the 24V DC power supply (motorized pull tester FMT-W40 only)......................................................................................................17
2.3 Instrument overview ................................................................................................................................................................................. 18
3. Operating procedures..................................................................................................................................................................................... 18
3.1 Turn the instrument ON/OFF ...................................................................................................................................................................... 18
3.2 General information about the display und function of the keypad during and in between the measurements .......................................... 18
3.3 Preparing the measurement ...................................................................................................................................................................... 19
3.4 Start measuring (AutoTara) with manual pull tester FMT-W30.................................................................................................................... 20
3.5 Memorize measuring values with manual pull tester FMT-W30 .................................................................................................................. 20
3.6 Start measuring (AutoTara) with motorized pull tester FMT-W40.................................................................................................................21
3.7 Automatic memorizing of measured values with motorized pull tester FMT-W40 ........................................................................................21
3.8 Display statistical data ............................................................................................................................................................................. 22
3.9 Delete displayed data and statistics ......................................................................................................................................................... 22
4. Tensile force limit control ............................................................................................................................................................................... 22
4.1. Setting of limits........................................................................................................................................................................................ 23
5. Data transfer and generating a test report with FMT-W_Connect...................................................................................................................... 23
5.1 System requirements................................................................................................................................................................................. 23
5.2 Installation / Activate the Excel AddIn....................................................................................................................................................... 24
5.3 Start FMT-W_Connect ................................................................................................................................................................................ 24
5.4 Save and printout measuring protocol....................................................................................................................................................... 26
6. General settings (P1), Setting of memory (P2) and reset works defaults (Po) ................................................................................................... 27
7. Technical data ................................................................................................................................................................................................ 28
8. Maintenance and calibration.......................................................................................................................................................................... 28
8.1 5-Years extended warranty ........................................................................................................................................................................ 28
8.2 Register for updates.................................................................................................................................................................................. 29
9.0 Trouble shooting (FAQ)................................................................................................................................................................................. 30
10.0 Accessories (Exchangable terminal fixtures) ............................................................................................................................................... 30

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Thank you for choosing one of our high quality instruments. Please read the entire operation manual thoroughly before using this instrument for
the first time. The information contained herein will help you to achieve accurate and reproducible results and to avoid misuse or damages.
This instrument is designed for measuring tensile strength of soldered or solder-free (crimped) cable joints with end sleeves, pins, solder pins or
similar wire terminal components in the field of quality control or design validation.
1. Safety Precautions
The load cell can be damaged if the measuring system is overloaded. The maximal measuring range limit of 1000N
(100kg/220lb) must not be exceeded.
Transport and store the instrument with care. This reduces the risk of damage to the load cell, caused by accidental
mechanical effects.
Operate the instrument in appropriate environments only. The instrument is equipped with a temperature compensation for
5°...40°C. Use the instrument in this temperature range only.
Very frequent use of the motorized pull tester FMT-W40(higher 1 test cycle per minute) may lead to overheating of the motor. A
overheat protection is implemented; nevertheless you may use the instrument in environments up to 30°C (86°F) only.
Due to the nature of the material small particles may occur in the moment of the tensile break of wires. You may wear
protection glasses and protection gloves in order to prevent injuries.
Don’t touch during the pull test or while the roller cam returns to its home position the rotating parts of the instrument. Do not
take your hand into the gap between the cable, the terminal adapter and clamp cam. In spite of the low speed or the manual
operation of the lever you may injure yourself.
2. General Information
2.1 Scope of Supply, unpacking and Setting Up
The scope of supply consists of:
Measuring instrument with integrated electronics
Hand lever or roller grip
USB Interface cable for optional software FMT-W_Connect
CD with software FMT-W_Connect (without license key)
Operation manual
24V DC power supply (Part. no.: FMT-958) for motorized pull tester FMT-W40
Remove the transportation cover and position the main instrument on a level, stable surface. The surface should be clean and grease-free, so
that the instrument does not slip. Please bear in mind that the instrument weighs approximately 14 kg.
Please retain the transport packing in case you would like to return the instrument for the recommended annual recalibration.
2.2 Ernergy Harvesting (manual pull tester FMT-W30 only)
The instrument utilizes, also when turned off, the ambient light at the work place as energy source and charges an internal
storage, to ensure that tests can be made even if the solar cell is covered for a short while. After storing the instrument for
more than 2 month in the dark, you should expose it at least for 8 hours in regular working environment (> 250 Lux) before
use.
2.3 Attach the 24V DC power supply (motorized pull tester FMT-W40 only)
The motorized pull tester FMT-W40 is delivered with universal power supply for 110-220VAC (50/60Hz) and power cords with EU-plug and US-
plug. Choose the power cord accordingly and connect first the DC plug into the socket on the rear side of the instrument. Then you may connect
the power cord to your wall socket or AC power net.
The power consumption is related to the operation state of the motor, the 3A power supply delivers always enough energy to generate the
action. You may not replace it by any other power supply but the delivered one (Part no.: FMT-958). In case you do not utilize the instrument for a
longer period, you may disconnect from the power net in order to prevent waste of energy in standby mode.

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2.4 Instrument overview
1. I-Button turns the instrument on and off (keep pressed for > 2s) and to start the measurement.
2. S-Button to save test results, to recall statistical data and to start the setting menu (keep pressed
for > 2s).
3. 0-Button delete (tare) measured values and statistical data, to navigate during setting processes
and to change measuring units (N/kg/lb). The units can be changed only before you start the first
measurement or after deleting all memorized values.
4. Display with:
5-digit indication of the measured valued and measuring units;
indication of the operation mode, memory and limits;
indication of results with up/down pointers for tensile force limits.
5. USB-socket for data transfer with FMT-W_Connect software to produce a test protocol.
6. Hirose-socket for service, adjusting the load-cell and limit signal output.
7. Solar cell to power the instrument without USB interface connected.
8. Terminal adapter with 12 slots to place the connector.
9. Rotating wire clamp with hand lever to clamp and pull the cable. Motorized version FMT-W40 with
eccentrically spring loaded roller grip.
10. Motorized version FMT-W40 DC-socket for 24V power supply and red status LED.
3. Operating procedures
3.1 Turn the instrument ON/OFF
Switch the instrument on by pressing the I-Button Taste until all display symbols light up.
After a self-test routine 3 information displays are shown to inform about the model
number, the recommended date of next calibration and the nominal measuring range (Fn).
To turn the instrument off you may press the I-Button for 2 seconds, else the AUTO-OFF
function will turn the instrument off automatically (manual pull tester FMT-W30 only; see
chap. 6).
Indication of the instrument type (W30 manual version; W40
motorized version)
Display next recommended calibration date (YY.MM)
Display measurement range [N]
Start display with default setting; mode PEAK with drag
function and MEM for active memory and calculation of
statically values.
3.2 General information about the display und function of the keypad during and in between the measurements
After the self-test routine the display shows the symbols PEAK and MEM and the SI-dimension Newton [N]. These symbols indicate the default
setting in operation mode PEAK with high measuring rate (app. 1 kHz) and drag functions with the possibility to save measuring results for
statistical calculations. Whenever you want to change the default settings, you have to return to this display.
S
<<
>>
If you want the updated actual force values to be shown during testing instead of
the drag function with PEAK values, you press the S-Button. The PEAK symbol
starts flashing. Please consider that in the combination of this mode with memory
is not advisable as the memory always captures the actually displayed value. By
pressing the S-Button again you return to the PEAK mode with dragging function.
0
>>>
0
>>>
If you would like to get your measuring values in other
units then the SI-dimension N you press the O-button.
Every time you press the button (in start menu only)
the units changes between N >> kg >> Lb

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3.3 Preparing the measurement
Select the smallest slot suitable for the test sample diameter and rotate the fixture so the selected slot is in
the 3 o’clock position, closest to the wire clamp fixture.
Place the cable connection into the adapter, so that the sleeve of the cable connector stays securely inside
the ring and cannot be pulled out through the slot.
The wire clamp fixture should be positioned in the full open position.
The manual pull tester needs a free length of the cable off minimum 14cm (5.5“), the motorized version a
length of 10cm (4“).
Soft cable coatings may slide through the clamp fixture or be pulled out of the crimp sleeve. In this case
please cut off the coating in 4cm to 8cm (2...3“) distance to the cable joint under test.

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3.4 Start measuring (AutoTara) with manual pull tester FMT-W30
I
>>
By pressing the I-Button you start the
measurement, the symbol of the measuring
dimension (N) flashes and the instrument
performs an AUTO-TARA to reset.
Insert the free end of the cable using a small
amount of tension in the wire clamp fixture.
The groove in the fixture helps to align the
cable properly. Now close the clamp by
pulling the lever.
As you continue to pull the hand lever slowly,
the tensile force increases, which works upon
the cable as a retention force. An additional
tensile force develops, which works upon the
cable connection.
5s
>>>
As you continue to pull the hand lever slowly,
the tensile force increases, which works upon
the cable as a retention force. An additional
tensile force develops, which works upon the
cable connection.
The peak value, which mostly appears before
the connection snaps up, is captured at
1000Hz and is indicated in the display.
After 5 seconds of unchanged measuring
values, the instrument stops the
measurement automatically and the letter
„S“ flashes in the display indicates that you
might save the data.
3.5 Memorize measuring values with manual pull tester FMT-W30
S
>>>
I
>>>
With the manual pull tester FMT-W30 you can save the
test result by pressing the S-Button as long as the unit
symbol (N) flashes and the letter „S” in the main
display prompts the memory. Two short beeps
indicate that the value is stored. After saving the value
the display is resetted to 0.0 and you can start the
next test by pressing the I-Button.
(With the motorized version FMT-W40 you may save a
value at any time by pressing the S-Button. The
measuring mode will not be stopped at this point but
after the drive has returned to its home position.)

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3.6 Start measuring (AutoTara) with motorized pull tester FMT-W40
I
>>
By pressing the I-Button you start the
measurement, the symbol of the measuring
dimension (N) flashes and the instrument
performs an AUTO-TARA to reset. Now the
motor starts with the setted pull speed.
If the minimal force of the automatic break
detection (activate with P18) is not reached
the cable clamp rotates to its maximum
position and returns to the home position. If
you press the I-button during the
measurement it also returns to its home
position and the measuring will be stopped.
If a setted force limit is reached an adjustable
dwell time starts. (Default 0s). After the dwell
time the drive either returns to ist home
position or tears the cable until it breaks
depending on the chosen operation mode.
An automatic break detection (activate with
P18) becomes active if 25% of the force limit
(minimum tensile strength) (P3) or a force of
40N is reached. If the actual measured force
falls below this level the cable clamp returns
to its home position and the measuring will
be stopped.
>>>
By pressing the S-button during the
measurement (unit flashes) you can save the
value to the memory. Two short beeps
indicate that the value is prompted.
The indicated value can be saved to the
memory only once.
3.7 Automatic memorizing of measured values with motorized pull tester FMT-W40
The motorized pull tester FMT-W40 is able to memorize the measured values automatically. The memory function has to be activated (submenu
P21=1), and the submenu P22 defines one of three possibilities to capture the value. You may choose to memorize the force value:
While reaching the force limit (minimum tensile strength) or start of the dwell time; (1)
At the end of the dwell time; (2)
At the break; (3)
or not automatically; (0)
See also chapter 6 for detailed information. All settings can also be done via USB using FMT-W_Connect software.

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3.8 Display statistical data
(nur bei FMT-W30)
S
>>>
S
>>>
After you finish the (last) measurement you can recall
the statistical results by pressing the S-Button.
S
>>>
Highest value of all saved tests.
S
>>>
Lowest value of all saved tests.
S
>>>
Average (arithmetic medium) of all saved tests.
S
>>>
Standard deviation related to the average.
Using the optional Software FMI-S_Connect the statistic data can be replenished with the instruments base data and the work order data. If the
USB interface is connected the single test values can be transferred and documented also. To capture single test values of the manual pull
tester FMT-W30, the USB connection to your PC has to be established during the entire test cycle.
3.9 Delete displayed data and statistics
To delete the actually displayed data you press the 0-Button, the display shows the
value “0.0”. By pressing the 0-Button for a longer time (>2s) you delete all memorized
data at the same time. Subsequently you can change the setting or load new test
limits.
The memory and static function can be turned off. (see chap. 6)
0
2S
4. Tensile force limit control
Depending on the wire strength and the related standard, the following tensile strength should at least be achieved. All below mentioned
standards can be performed with a pull speed of 100mm/min (4“/min), the default speed oft he motorized pull tester FMT-W40. Utilizing the
optional software FMT-W_Connect other pull speeds can be setted.
AWG Cross section Cable diameter SAE AS7928 Table II IEC 60352 Teil 2 UL 486 C NASA Std 8739.4
30 0,06 mm² 0,36 mm 6 N 6 N
28 0,09 mm² 0,38 mm 11 N 11 N 22 N
26 0,14 mm² 0,48 mm 32 N 18 N 18 N 36 N
24 0,22 mm² 0,61 mm 45 N 28 N 28 N 36 N
22 0,34 mm² 0,76 mm 67 N 40 N 40 N 57 N
20 0,56 mm² 0,97 mm 85 N 60 N 45 N 92 N
18 0,93 mm² 1,27 mm 170 N 90 N 45 N 142 N
16 1,25 mm² 1,44 mm 223 N 135 N 68 N 183 N
14 1,93 mm² 1,80 mm 312 N 200 N 100 N 290 N
12 3,16 mm² 2,29 mm 490 N 275 N 138 N 459 N
10 4,65 mm² 3,10 mm 355 N 707 N
Remarks: DIN 41611/3 is replaced by DIN IEC 60352 Part 2
MIL-T-7928 is replaced by SAE AS7928 Table II
BS5B178 corresponds to IEC 60352 Part 2
UL486A corresponds to IEC 60352 Part 2

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You can set these values in the limit comparator function. The lower limit activates the buzzer (with FMT-W30 only if USB-cable is connected)
and an interrupted peep signalizes that the limit is not reached (yet). After exceeding the upper limit, the displayed pointer changes from down
to up and the continuous peep indicates that the minimum tensile strength was reached. You may use this function also for non-destructive
testing.
4.1 Setting of limits
In order to set the limits easily and in accordance to the above mentioned standards we recommend the use of the optional Software FMI-
W_Connect, where you can choose the appropriate limit from a table accordingly after selecting the test standard. Nevertheless you can adjust
the limits directly after you have restarted the instrument or deleted all saved data, by pressing the S-Button for 2 seconds until the display
shows P1. Select the setting menu P3 for the upper limit and P4 for the lower limit by pressing the I-Button and adjust the limit values.
S 0
Pressing the o-Button you enter into the submenu level P11 to P17 (see chap. 6)
With a short press on the S-Button you return to the main setting menu.
I
0Pressing the o-Button you enter the submenu P2 (see chap. 6)
With a short press on the S-Button you return to the main setting menu.
I
0
Press the 0-Button to select the digit you
want to change, the digit starts flashing.
With the I-Button you scroll the desired
value.
With a short press on the S-Button you return to the main setting menu.
I
0
Press the 0-Button to select the digit you
want to change, the digit starts flashing.
With the I-Button you scroll the desired
value.
The submenu P4 does not apply with the
motorized version FMT-W40. The lower
limit is adjusted automatically to 25% (or
max. 40N) of the upper limit.
With a short press on the S-Button you return to the main setting menu.
I
0Pressing the o-Button you enter the submenu P0 (see chap. 6)
By pressing the S-Button for a longer time (>2s) you return to the main
operation menu.
The limit comparator function is deactivated by setting the limit back to „0000.0“ or by resetting the instrument to the original works defaults by
using the setting menu P0 (see chap. 7). The auto break detection stays active at 40N even if P3 = 0.
5. Data transfer and generating a test report with FMT-W_Connect
The optional software FMT-W_Connect enables you to utilize the USB-interface in connection with your PC or notebook. The data transfer can be
used to:
Increase the measuring resolution
Configure the operation modes, the automatic memorizing and the pull speeds of the motorized pull tester FMT-W40
Set the limit comparator function based on international standards for minimum tensile strength of crimped connectors easily
Generate a test report as PDF format and to print and file the customized report
Adjust the calculation base between the international standard (SI) for the dimension force in Newton [N] to weight dimension Pounds
[lb] or Kilograms [kg] according to the effective gravitation at the place of operation
5.1 System requirements
To install the software a PC or notebook with available USB-port is needed. The operation system Windows XP or Windows 7 (32 bit or 64 bit),
and MsOffice 2007 or MsExcel 2007 and higher (32 bit) should be installed. To load the software you need administration rights on the work
station. You should install the software with the appropriate USB drivers before you connect the pull tester the first time to your workstation.
USB drivers can be found on the installation CD-Rom.

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5.2 Installation / Activate the Excel AddIn
The installation process automatically after you loaded the CD. After the installation process you have to activate the Add-In for MsExcel. Please
consult your MsExcel help to add C:\Programme\Alluris\FMT-W_Connect\Add-In\FMI-W_Connect.xla to your Add-In folder.
In Excel 2007 you have to click on the Office button (left upside), in Excel 2010 you have to click the file tab (left upside). Click Options, and then
click the Add-Ins category. Near the bottom of the Excel Options dialog box, make sure that Excel Add-ins is selected in the Manage box, and
then click Go. In the Add-Ins dialog box, select search and choose C:\Programme\Alluris\FMT-W_Connect\Formular.xlsx. Then exit all dialogs
with OK.
After activation open the template C:\Programme\Alluris\FMT-W_Connect\Formular.xlsx. For using the software to protocoling and data
streaming you have to choose FMT-W_Connect > START in the tab for Add-Ins. The submenues are explained as follow:
Version
The table informs about the version of the installed software.
License
After installing the software a license file has to be generated and saved in the
Alluris folder. Please enter the received license key and the serial no. of your pull
tester and click “generate license file”. The license key has to match the serial no.
of the instrument it was ordered for.
Language
Select the desired language for all tables and reports.
5.3 Start FMT-W_Connect
Open MS Excel with Windows Start Menu > All Programs > Alluris >
FMT-W_Connect>Formular.
By clicking the button [Option Force Gauge] you access a table for
general settings of the pull tester.
Enter all necessary protocol data for your specific test procedure.
The total quantity is needed to calculate the respective relative
number of tests. The entered data will be completed with the basic
information about the force testing equipment.
Now select a specific standard. According to the choosen standard
a table will open with cable dimensions. The field Limit shows the
minimum tensile strength required according to the choosen
standard and cable dimensions. By selecting the option >User
defined< in the field Standard you may set the limit manually in
the field Limit.
You may enter manually an individual description of the the
standard in the field Standard below.
Click the [>>] button to download the entered data to the pull tester
and to the test report.