Mark-10 WT3-201M User manual

Model WT3-201M
MOTORIZED WIRE CRIMP PULL TESTER
User’s Guide

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide
1
Thank you…
Thank you for purchasing a Mark-10 WT3-201M wire crimp
pull tester, designed for pull test applications up to 200 lbF
(1,000 N).
With proper usage, we are confident that you will get many
years of great service with this product. Mark-10 instruments
are ruggedly built for many years of service in laboratory and
industrial environments.
This User’s Guide provides setup, safety, and operation
instructions. Dimensions and specifications are also provided. For additional information or answers to
your questions, please do not hesitate to contact us. Our technical support and engineering teams are
eager to assist you.
Before use, each person who is to use the WT3-201M should be fully trained in appropriate
operation and safety procedures.
TABLE OF CONTENTS
LIST OF INCLUDED ITEMS...................................2
SAFETY ..................................................................2
SETUP ....................................................................2
HOME SCREEN AND CONTROLS .......................6
OPERATING MODES.............................................9
UNITS OF MEASUREMENT ..................................9
DIGITAL FILTERS................................................10
PASS / FAIL LIMITS.............................................11
SPEED ..................................................................12
AUTO START .......................................................13
PRELOAD.............................................................14
PULL TO LOAD (optional function)...................15
LOAD HOLDING (optional function)..................16
BREAK DETECTION............................................17
AUTO RETURN ....................................................18
AUTO SETTINGS .................................................19
DATA MEMORY AND STATISTICS ....................20
COMMUNICATIONS AND OUTPUTS .................22
PROFILES (optional function) ...........................26
PASSWORDS.......................................................27
OTHER SETTINGS...............................................29
FUNCTION ACTIVATION.....................................31
CALIBRATION .....................................................32
MAINTENANCE....................................................36
SPECIFICATIONS ................................................37

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide
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1 LIST OF INCLUDED ITEMS
Qty.
Part No.
Description
1
WT3-201M
Wire crimp pull tester
1
-
Power cord
1
-
Certificate of calibration without data (standard) or with data (optional)
1
09-1165
USB cable
-
USB driver, MESUR®Lite software, MESUR®gauge evaluation software, User’s Guide
Download at: www.mark-10.com/resources
2SAFETY
The following safety checks and procedures should be performed before and during operation:
1. Always consider the characteristics of the sample being tested before initiating a test. A
risk assessment should be carried out beforehand to ensure that all safety measures have been
addressed and implemented.
2. Wear eye and face protection when testing. Be aware of the dangers posed by potential
energy that can accumulate in the sample during testing. Extra bodily protection should be worn if
a destructive failure of a test sample is possible.
3. Keep away from moving parts of the tester. Loose articles of clothing should not be worn.
Long hair should be covered to avoid a hazardous situation.
4. In those applications which could lead to a hazardous situation, use of a machine guard
is strongly recommended.
5. When the tester is not in use, ensure that the power is turned off to prevent accidental
engagement of any of the controls.
Safety features provided by this tester may be impaired if it is not used in a manner not specified
by Mark-10.
3SETUP
3.1 Mechanical Setup
3.1.1 Assembly
The tester is shipped completely assembled.
3.1.2 Mounting and placement
Place the tester on a clean, flat and level work area free from vibration. If desired, the tester can be
secured to the work area with four 1/4-20 screws fastened into the threaded holes in the underside of the
base (depth of 0.5 in. [12 mm]).
Ensure that the rear of the tester is easily accessible, so that the power cord can be disconnected in an
emergency.
3.1.3 Installing the ring terminal fixture or blank terminal fixture
To install or uninstall the standard terminal fixture or optional fixture, loosen the screw in the center of the
fixture, remove, place the other fixture in the receptacle, and re-tighten the screw. Keep away from metal
particles that may have originated from testing samples, as there are magnets located inside the terminal
fixtures.

Model WT3-201M Motorized Wire Crimp Pull Tester User’s Guide
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3.1.4 Sample setup
1. Secure the terminal into the standard terminal fixture or optional ring terminal fixture, as
shown in the images below. Rotate the fixtures until the desired slot or ring size is aligned with
the cam mechanism adjacent to the lever.
2. Insert the loose end of the wire between the cams in the mechanism. Keep the wire taut
as it is inserted. If auto-start is enabled, the test will begin when the switch is activated (refer to
later sections for operational details). Refer to the image below:
3. Note the protective red safety guard (circled, below), which automatically rotates into
position as the cam mechanism closes.

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3.2 Connections and Outputs
1. I/O Connector
RS-232, set point, analog, Mitutoyo, and other outputs are provided. Refer to the
Communications and Outputs section for details.
2. Fuse
3. Power Switch
Use to turn power on and off.
4. Power Plug Receptacle
Plug the power cord in here. Refer to the Connecting power sub-section for important safety
information.
5. USB Connector
Plug the USB cable in here, for data output to a PC, PLC, printer, etc.
3.3 Installing the USB driver
If communicating via USB, install the USB driver available at: www.mark-10.com/resources
Caution!
Install the USB driver before physically connecting the tester to a PC with the USB cable.
Further instructions for configuring and using the tester’s outputs are provided in the Communications
and Outputs section.
4
5
1
2
3

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3.4 Connecting power
Plug one end of the power cord into its receptacle at the rear of the tester and the other end into a wall
outlet with local earth ground (3-prong connector).
Before turning on power, the following safety checks and procedures should be performed:
1. Never operate the tester if there is any visible damage to the power cord or the tester
itself. The WT3-201M is powered by 100-240VAC. Any contact with this high voltage can cause
serious injury or even death.
2. Ensure that the tester is kept away from water or any electrically conductive liquids at all
times.
3. Make sure the electrical outlet powering the tester has local earth ground (3-prong
connector).
4. The tester should be serviced by a trained technician only. Power must be disconnected
before disassembly.
5. Never use a detachable mains supply cord with inadequate ratings.
After the above safety checks and procedures have been performed, the tester may be powered on and
is ready for operation.

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4HOME SCREEN AND CONTROLS
4.1 Demo Mode Functions
The WT3-201M 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:
The available optional functions are as follows:
1. Profiles
Save and recall sets of test parameters, such as speed, pass/fail limits, unit of measurement, etc.
Maximum of 500 profiles may be stored.
2. Load Holding
The tester will stop and maintain a specified load for a specified period of time.
3. Pull To Load
The tester will stop when the specified load has been reached.
4. 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.
*** DEMO MODE ***
All functions are
temporarily enabled.
Remaining demo time:
160 hours
Press ENTER.

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4.2 Home Screen
No.
Name
Description
1 Status
Indicates one of the following statuses:
STOPPED
PULLING
RETURNING (to the Home position)
HOLDING (Load Holding sequence in progress)
2
Position
Indicates one of the following positions: HOME or LIMIT
3 / 7 Upper / lower
force limits
Indicates the upper and lower acceptable force limits, as configured in the
Pass / Fail Limits menu. The upper and lower red “X” indicators adjacent to
the values illuminate if the displayed force is less than the lower limit or
greater than the upper limit. The green “checkmark” indicator illuminates if
the displayed force is within range.
4 Message
Indicates one of the following messages:
COVER - the actuator cover is removed.
PL ON – Pull to Load (optional function) is active.
LH ON – Load Holding (optional function) is active.
5
Primary reading
The current displayed reading. See Operating Modes section for details.
6 Unit of
measurement
The current measurement unit. Abbreviations are as follows:
lbF – Pound-force
ozF – Ounce-force
kgF – Kilogram-force
N – Newton
kN – Kilonewton
8
Break detection
on/off
The letter “B” appears if the Break Detection function is enabled. Refer to the
Break Detection section for details.
9 Mode
The current measurement mode. Abbreviations are as follows:
RT – Real Time
PK – Peak
See Operating Modes section for details about each of these modes
10
Profile name
Indicates the currently selected profile. See Profiles section for details.
11
Number of data
points
The number of data points stored in memory, up to 2,000.
12
Peak force
The maximum measured tension force. May be reset by pressing ZERO.
1
3
5
7
8
10
11
12
6
2
4
9

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4.3 Controls
Primary
Label
Primary Function
Secondary
Label
Secondary Function
ENTER
Various uses, as described in the
following sections.
-
ZERO
Zeroes the primary reading and
peaks.
(UP)
Navigates up through the menu and
sub-menus.
MENU Enters the main menu. ESCAPE
Reverts one step backwards through
the menu hierarchy.
MODE
Toggles between measurement
modes.
(DOWN)
Navigates down through the menu
and sub-menus.
DATA
Stores a value to memory, transmits
the current reading to an external
device, and/or initiates automatic
data output, depending on setup.
DELETE Enables and disables Delete mode
while viewing stored data.
START
Starts motion. Press and release to
produce maintained motion. In
Maintenance mode, a key press
results in momentary motion.
-
STOP Stops motion. RETURN
Reverses motion. Press and release
to produce maintained motion until
return to the Home position. In
Maintenance mode, a key press
results in momentary motion.
4.4 Menu navigation basics
Most of the tester’s various functions and parameters are configured through the main menu. To access
the menu press MENU. Use the UP and DOWN keys to scroll through the items. The current selection is
denoted with clear text over a dark background. Press ENTER to select a menu item, then use UP and
DOWN again to scroll through the sub-menus. Press ENTER again to select the sub-menu item.
For parameters that may be either selected or deselected, press ENTER to toggle between selecting and
deselecting. An asterisk (*) to the left of the parameter label is used to indicate when the parameter has
been selected.
For parameters requiring the input of a numerical value, use the UP and DOWN keys to increment or
decrement the value. Press and hold either key to auto-increment at a gradually increasing rate. When
the desired value has been reached, press ENTER to save the change and revert back to the sub-menu
item, or press ESCAPE to revert back to the sub-menu item without saving. Press ESCAPE to revert one
step back in the menu hierarchy until back into normal operating mode.
Refer to the following sections for details about setting up particular functions and parameters.

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5 OPERATING MODES
Caution!
In any operating mode, if the capacity of the tester has been exceeded by more than 10%, the
display will show “OVER” to indicate an overload. A continuous audible tone will be sounded until
the MENU key has been pressed or the load has been reduced to a safe level.
Three operating modes are possible with the WT3-201M. To cycle between the modes, press MODE
while in the home screen.
5.1 Real time (RT)
The primary reading corresponds to the live measured reading.
5.2 Peak (PK)
The primary reading corresponds to the peak tension reading observed. If the actual force decreases
from the peak value, the peak will still be retained in the primary reading area of the display. Pressing
ZERO will reset the value.
6 UNITS OF MEASUREMENT
The WT3-201M can display five different force measurement units. To change the unit, select Units from
the menu. The display will list the available units, as follows:
Note: Changing the unit within this menu will not set the default unit. To always power on automatically
with the desired unit, configure the unit in the Initial Settings menu.
UNITS
* lbF
ozF
kgF
N
kN

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7DIGITAL 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.
DIGITAL FILTERS
(1 = Fastest)
Current Reading
8
Displayed Reading
512

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8PASS / 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
PASS / FAIL LIMITS
Upper Disabled
* Upper Enabled
125.0
Lower Disabled
* Lower Enabled
122.5

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9SPEED
The speed may be adjusted to comply with various standards and test methods. Select Speed from the
menu and press ENTER. The display appears as follows:
in/min or mm/min
Select inches per minute or millimeters per minute
Pull Speed
Sets the speed at which the test takes place.
Available settings:
0.4 – 12.0 in/min, in 0.1 increments, or 10 – 300 mm/min, in 0.5 mm increments
Return Speed
Sets the return speed. This speed applies to a manual press of the RETURN
key or the Auto Return sequence.
Available settings:
12 – 96 in/min, in 1 in/min increments, or 300 – 2,400 mm/min, in 25 mm/min
increments
SPEED
* in/min
mm/min
Pull Speed
4.0
Return Speed
96

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10 AUTO START
Auto start increases testing efficiency by automatically starting the test when the sample has activated the
switch, identified below:
To use Auto start, select Auto Start from the menu and press ENTER. The display appears as follows:
Select Enabled. It is recommended to combine Auto Start with Break Detection and Auto Return
automation functions for maximum efficiency. Refer to the following sections for details.
AUTO START
Disabled
* Enabled

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11 PRELOAD
To improve testing efficiency, the initial speed may be faster than the test speed. When the mechanism
engages the sample, definable as a preload, the speed reverts to the programmed test speed. Select
Preload from the menu and press ENTER. The display appears as follows:
After exiting the menu, press ZERO to arm the function.
Note: To avoid overshoot in Load Holding or Pull to Load, make sure the preload force is set well below
the expected testing force. Some experimentation may be necessary for optimization depending on the
wire sample’s elasticity. The same is true for the preload speed.
Enabled
Enables the Preload function.
Force
Sets the force at which the speed reverts to the programmed test speed.
Available settings: 1 – 100 lbF, in 0.1 lbF increments (or equivalent range in other units)
Speed
Sets the initial speed until preload. Available settings:
12 – 96 in/min, in 1 in/min increments, or 300 – 2,400 mm/min, in 25 mm/min increments
PRELOAD
Disabled
* Enabled
Force
2.0 lbF
Speed
12.0

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12 PULL TO LOAD (optional function)
For non-destructive testing and other applications, the tester can stop when a specified load has been
reached. Select Pull to Load from the menu and press ENTER. The display appears as follows:
After exiting the menu, press ZERO to arm the function. The message changes from “PL” to “PL ON” in
the upper right corner of the display.
The tester can perform a number of additional automatic functions upon completion of a pull to load
sequence, further described in the Auto Settings section.
Disabled
Disables the Pull to Load function.
Enabled
Enables the Pull to Load function.
Force
Sets the force at which the tester stops.
Available settings: 0 – 200 lbF, in 0.1 lbF increments (or equivalent range in other units)
PULL TO LOAD
Disabled
* Enabled
Force
100.0 lbF

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13 LOAD HOLDING (optional function)
Load Holding addresses certain test methods requiring a specified load to be maintained for a specified
period of time, such as UL 486A/B. The motor dynamically reacts to changes in load, such as sample
relaxation, in order to maintain the specified for the duration of the test. Select Load Holding from the
menu and press ENTER. The display appears as follows:
After exiting the menu, press ZERO to arm the function. The message changes from “LH” to “LH ON” in
the upper right corner of the display. When the test has started, a counter appears on the top center of
the screen, showing the remaining time.
The tester can perform a number of additional automatic functions upon completion of a Load Holding
sequence, further described in the Auto Settings section.
Enabled
Enables the Load Holding function.
Time
Sets the period of time for which the tester maintains the load.
Available settings: 0 – 60 minutes, in 1 second increments
Hold Force
Sets the force which the tester will maintain for the specified period of time.
Available settings: 0 – 200 lbF, in 0.1 lbF increments (or equivalent range in other units)
LOAD HOLDING
* Enabled
Time (mm:ss)
01 : 00
Hold Force
80.0 lbF

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14 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.
14.1 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.
Function
Description
Enabled
Enables the break detection function. When enabled, the letter “B” appears on the
home screen, between the Mode and Unit indicators. Refer to the Home Screen
and Controls section for details.
Threshold
Sets the percentage of full scale at which the break detection function becomes
active. This threshold is provided to ignore peaks that can occur during sample
loading and unloading.
Available settings: 1-90%, in 1% increments.
BREAK DETECTION
* Disabled
Enabled
Threshold 5 %

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15 AUTO RETURN
With this function, the tester reverses direction and proceeds at maximum speed to the home position.
Auto Return is triggered when one of the following conditions has been met, whichever occurs first:
1. Break has occurred
2. Target load has been reached
3. Load holding sequence has completed
4. End of travel has been reached
Function
Description
Disabled
Disables Auto Return.
Enabled
Enabled Auto Return.
AUTO RETURN
* Disabled
Enabled

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16 AUTO SETTINGS
The tester can perform one or several functions automatically when it has returned to the Home position.
Return to Home can occur after a simple manual reverse, Auto Return, or a special event such as Break
Detection, Pull to Load, or Load Holding:
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.
AUTO SETTINGS 2
Output Pin: NONE
* Auto Zero
Auto Zero Delay
5 sec.
AUTO SETTINGS
* Enabled
* Memory Storage
* RS232/USB Output
Mitutoyo Output
+ More