Check-line CTM2 Instruction Manual

Cable Tension Meter Distributed by: ABQ Industrial LP USA Tel: +1 (281) 516-9292 / (888) 275-5772 eFax: +1 (866) 234-0451 Web: https://www.abqindustrial.net E-mail: [email protected]

Dillon is part of Avery Weigh-Tronix. Avery Weigh-Tronix is a trademark of the Illinois Tool Works group of companies whose ultimate parent company is Illinois Tool Works Inc ("Illinois Tool Works"). Copyright © 2014 Illinois Tool Works. All rights reserved. No part of this publication may be reproduced by making a facsimile copy, by the making of a copy in three dimensions of a two-dimensional work and the making of a copy in two dimensions of a three-dimensional work, stored in any medium by electronic means, or transmitted in any form or by any means, including electronic, mechanical, broadcasting, recording or otherwise without the prior written consent of the copyright owner, under license, or as permitted by law. This publication was correct at the time of going to print, however Avery Weigh-Tronix reserves the right to alter without notice the specification, design, price or conditions of supply of any product or service at any time.

3 Table of Contents Chapter 1 General Information and Warnings ........................................................................................5 About this Manual ..............................................................................................................5 Text Conventions ........................................................................................................5 Special Messages .......................................................................................................5 Safe Handling of Equipment with Batteries .................................................................6 Routine Maintenance .........................................................................................................6 Cleaning the Machine ........................................................................................................6 Training ..............................................................................................................................6 Sharp Objects ....................................................................................................................6 FCC and EMC Declarations of Compliance .......................................................................7 Declaration of Conformity (Quick Check Red) ...................................................................8 Declaration of Conformity (EDX PSU) ...............................................................................9 Chapter 2 Introduction ............................................................................................................................10 Unpacking ........................................................................................................................10 Front Panel and Keys ......................................................................................................11 Important Features ...........................................................................................................12 Using Quick Check (Red) with EDXtreme PSU ...............................................................12 Quick Check Connector ............................................................................................12 External Power Supply ..............................................................................................13 Chapter 3 Operation ................................................................................................................................14 Typical Operation .............................................................................................................14 Measurement Practices ...................................................................................................15 Softkey Functions ............................................................................................................16 Top level Softkeys .....................................................................................................16 Chapter 4 Configuration Mode ...............................................................................................................26 Accessing the Configuration Mode ..................................................................................26 Chapter 5 Changing Sheaves .................................................................................................................30 Chapter 6 Achieving Best Accuracy ......................................................................................................31 Accuracy ..........................................................................................................................31 Calibration to Specific Wire Type .....................................................................................31 Loading Error ...................................................................................................................31 Non-repeatability ..............................................................................................................31 Non-linearity .....................................................................................................................32 Wire Characteristics .........................................................................................................32 Chapter 7 Troubleshooting .....................................................................................................................33 Quick Check .....................................................................................................................33 EDX PSU .........................................................................................................................34 Chapter 8 Specifications .........................................................................................................................35 EDX PSU Power Supply Specifications ...........................................................................36

5 1 General Information and Warnings 1.1 About this Manual This manual is divided into chapters by the chapter number and the large text at the top of a page. Subsections are labeled as shown by the 1 and 1.1 headings shown above. The names of the chapter and the next subsection level appear at the top of alternating pages of the manual to remind you of where you are in the manual. The manual name and page numbers appear at the bottom of the pages. 1.1.1 Text Conventions Key names are shown in bold and reflect the case of the key being described. This applies to hard keys and onscreen or soft keys. Displayed messages appear in bold italic type and reflect the case of the displayed message. 1.1.2 Special Messages Examples of special messages you will see in this manual are defined below. The signal words have specific meanings to alert you to additional information or the relative level of hazard. CAUTION! This is a Caution symbol. Cautions give information about procedures that, if not observed, could result in damage to equipment or corruption to and loss of data. NOTE: This is a Note symbol. Notes give additional and important information, hints and tips that help you to use your product.

1.1.3 Safe Handling of Equipment with Batteries 1.2 Routine Maintenance 1.3 Cleaning the Machine 1.4 Training Do not attempt to operate or complete any procedure on a machine unless you have received the appropriate training or read the instruction books. To avoid the risk of RSI (Repetitive Strain Injury), place the machine on a surface which is ergonomically satisfactory to the user. Take frequent breaks during prolonged usage. 1.5 Sharp Objects Do not use sharp objects such as screwdrivers or long fingernails to operate the keys. CAUTION: Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions. ATTENTION: Il y a danger d'explosion s'il y a remplacement incorrect de la batterie, remplacer uniquement avec une batterie du même type ou d'un type équivalent recommandé par le constructeur. Mettre au rebut les batteries usagées conformément aux instructions du fabricant. IMPORTANT: This equipment must be routinely checked for proper operation and calibration. Application and usage will determine the frequency of calibration required for safe operation. Table 1.1 Cleaning DOs and DON’Ts DO DO NOT Wipe down the outside of standard products with a clean cloth, moistened with water and a small amount of mild detergent Attempt to clean the inside of the machine Use harsh abrasives, solvents, scouring cleaners or alkaline cleaning solutions Spray the cloth when using a proprietary cleaning fluid Spray any liquid directly on to the display windows

7 1.6 FCC and EMC Declarations of Compliance United States Canada European Countries This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications. Le présent appareil numérique n’émet pas de bruits radioélectriques dépassant les limites applicables aux appareils numériques de la Classe A prescrites dans le Règlement sur le brouillage radioélectrique edicté par le ministère des Communications du Canada. WARNING: This is a Class A product. In a domestic environment, this product may cause radio interference in which the user may be required to take adequate measures.

2 Introduction This manual covers the setup and operation of the Quick-Check Clamp Line Tensiometer from Dillon. The Quick-Check is a simple, accurate strand dynamometer. It is can be clamped onto a cable, accurately determine the wire tension and be removed in seconds. The Quick-Check can handle multiple wire diameters, it can display live tension, dual live/peak tension, average tension captured from several tests, and a check-tensioning graphical display. With its battery-powered electronic interface, setup and operation is made simple with on-screen prompts. This manual covers the following: l Unpacking l Setup l Operation l Maintenance l Troubleshooting 2.1 Unpacking When you receive your Quick-Check, unpack it and inspect the container and the instrument for any damage. Report any problems to the shipping company immediately and save the packing materials. Insert 2 AA batteries into the battery compartment, shown in Figure 2.1. Your Quick- Check probably comes from the factory with the proper sheave size installed and calibrated for your application. If not, follow the setup directions later in section 3.0 Configuration Mode and section 4.0 Changing Sheaves. The Quick-Check is shown in Figure 2.1 with the different parts labeled. Figure 2.1 Quick-Check Parts Lever arm Front panel Battery compartment Sheaves Support arm

11 2.2 Front Panel and Keys The front panel of the Quick-Check is shown in Figure 2.2. The light located under the WIRE button illuminates green when changes in the menu are stored, purple when in diagnostics or uploading firmware and red when powering the unit down. Figure 2.2 Quick-Check Front Panel Following are descriptions of the keys and their functions: ON/OFF key. Press this key to power up and turn off the Quick-Check. ESC key. Press this key to escape an area of the menu or to clear the field when in data entry mode. WIRE key. Press this key to change the wire diameter you are testing with the Quick-Check. Choose from the listed selection and when the desired size is highlighted, press the ENTER softkey. Up to 20 sizes available. Soft key. Softkey function changes as needed for different tasks. The soft key labels appear above the keys themselves. You will use these for operation and configuration. Arrow key. Press this key to reveal more softkeys in a group of softkeys.

2.3 Important Features Quick to use Attaches and removes from tensioned line in seconds. Quick-tensioning readout for ultra fast line tensioning. Direct tension readings No more complicated lookup charts! Save time and improve accuracy. Portable & rugged Designed for outdoor use. Accurate Employs Weigh Bar® technology used for precise weighing. Multiple wire size storage Stores up to 20 different calibrations. 2.4 Using Quick Check (Red) with EDXtreme PSU The Quick Check can be connected to the EDX PSU via the Comm Port. This 120VAC/ 240VAC external power supply will supply power to the Quick Check instead of AA batteries. 2.4.1 Quick Check Connector The connector on the Quick Check is recessed for protection. Lift the protective cap to access the connector. It is used to connect the instrument to a printer, PC or external power supply. See your Dillon distributor for details. Figure 2.3 Quick Check Connector

13 2.4.2 External Power Supply Plug the 4-pin end of the power supply cable into the Quick Check 4-pin connector located on the side of the unit. Plug the power supply adapter into an AC power outlet. Refer to Figure 2.4 for a photo of the external power supply. Figure 2.4 External Power Supply Connection Figure 2.5 External Power Supply (EDX PSU) (120 - 240 VAC 50 - 60 Hz)

3 Operation Typical operation of the Quick-Check is covered below, followed by explanations of the various display modes, how to change wire size, how to change the unit of measure, etc. 3.1 Typical Operation To perform a typical tension measurement, see the note below and follow these steps: 1. Turn the unit on by pressing the ON/OFF key… The display shows DILLON briefly, then, in this example, the screen shows the following: Figure 3.1 Sample Display 2. This example shows the wire is a 7/16”, 6X19 stranded cable using the “S” Sheave and the unit of measure is lbf. Place the Quick-Check so the two outside sheaves hang on the wire. Insure that the wire rope is riding in the center groove for all three sheaves. See Figure 3.2. Press the Zero softkey to zero the display. 0 should be displayed. 3. Raise the lever arm until it locks in the upright position to apply tension to the wire. Read the line tension on the display. Take readings at three different places along the cable, moving the tension meter at least four inches for each reading. Take the average of the readings. The built-in average function is ideal for this task. The handle quick release pin should be used when the Quick-Check is attached to a cable that will be de-tensioned and re-tensioned. The pin prevents the handle from opening once the tension falls to a small level. The pin should also be used if the Quick-Check will be installed for a prolonged period. Zero Clear Mode Store lbf 7/16 6X19 Shv:S Unit of Measure Battery level Wire size Sheave to be used Tension of rope reading Press the WIRE key to list the stored calibrations.

15 4. Release the lever arm and you are ready to perform another measurement. Figure 3.2 Quick-Check Attached to Cable 3.2 Measurement Practices For best measurement, install the Quick-Check at least 2 feet (0.6 m) from terminations, clamps or other hardware. Do not install over the top of wire wrappings. Take readings at three different places along the cable, moving the tension meter at least four inches for each reading. Take the average of the readings. The built-in average function is ideal for this task. Do not use the Quick-Check to measure tension for wires if any of the following are true: 1. No wire calibrations are stored of the same diameter as the wire you are looking to measure, and/or 2. You do not have sheaves of the same diameter. If both of these conditions exist, contact your Dillon distributor. Contact your Dillon distributor to improve accuracy for a specific wire type by calibrating to it. Insure that the wire rope is riding in the center of the groove for all three sheaves. WARNING: Do not apply tension greater than rated capacity of the instrument or overload damage to the sensor may result. Do not use the Quick-Check with cable larger than indicated on the sheaves. Overload and damage to the instrument may result. Do not mix sheave sizes. This will result in inaccurate measurement and possible overload.

Insure sheaves installed agree with sheaves noted in the Wire calibration. Exception: Sheaves match the wire diameter of the cable to be measured and alternate calibration is selected as per section 5.2. The Quick-Check has an internal temperature sensor inside the electronics cavity. Dramatic temperature changes (such as moving from a warm vehicle to cooler outdoors) requires time for the sensor to reach the same temperature. Direct sunlight will heat the electronics cavity and cause higher readings than actual ambient temperature. NOTE: The temperature is only for the Quick Check electronics and does not compensate for the temperature of the wire rope. For best tension accuracy, use the exact temperature of the wire along with the cable manufacturer’s temperature compensation chart. This may be widely different from the ambient temperature if the cable has been sitting in direct sunlight. 3.3 Softkey Functions Now that you’ve seen a simple operation, we’ll explain the softkey functions. Figure 3.3 shows the softkeys available during normal operation. Figure 3.3 Normal Mode Softkeys 3.3.1 Top level Softkeys At any time, press the ESC key to return to the normal operating mode. If changes have been made to the configuration, you will be prompted to save them (Yes) or abort the changes (No) before exiting the configuration mode. Zero Press this softkey to zero the force display. You would usually press this at the beginning of a series of tension tests but would not need to do it for every test unless there is some zero drift. Clear Press this softkey and you are prompted to clear the Peak reading or the Average. Make your choice by pressing the appropriate softkey and that value is cleared from memory. Zero Clear Mode Store Press Units Log Setup Config lbf 7/16 6X19 Shv:S lbf 7/16 6X19 Shv:S

17 Mode Press the Mode key to scroll through the four display modes. These are explained below: Live Tension Mode: The display shows the live tension. Dual Peak Mode: The display shows the live tension on the top display and the peak force achieved on the bottom display. To clear the peak, remove any force on the Quick-Check, press the Clear softkey and follow the prompts. Average Capture Mode: This mode shows the live tension in the top display and the average of all captured readings on the bottom display. To capture a reading and add it to the average, press the Store softkey when a force is applied to the Quick-Check. Follow the prompts to add (or not) the reading to the average. NOTE: Must set Log>Setup to Disabled for the Average Mode to work. Check-tensioning Mode: Check-tensioning mode permits quick & easy graphical view of the applied tension versus the desired tension. This mode works well when you are repeatedly tensioning to the same tension range. This mode displays a bar graph representation of the tension being applied. See Figure 3.4. The black bar represents the range of the wire, from zero to ultimate wire rating. The wide white band is the tolerance window based on upper and lower thresholds you can enter. The live force is represented by the arrow and the white line on the black bar. When the force gets within ±5% of the acceptance window, a close-up of the acceptance window is displayed. See bottom example in Figure 3.4. The Quick-Check has automatic tension targeting. Points may be entered from a linear Tension supplied table for a wire cable. Figure 3.4 Check Tension Display To exit the check-tension mode, press any softkey to display the softkey labels, then press the Mode softkey to scroll to the next mode. The next mode is the first mode that was described, live tension mode. NOTE: Upper and lower thresholds are set in the Configuration WIRE menu. See page 27. UNDER 1960 5700 lbf 7/16 6X19 Shv:S lbf 7/16 6X19 Shv:S Display when tension is below the dotted, target box. Display when tension falls within the dotted, target box.

Store Press the Store softkey to store and add a displayed tension to the average of other entered readings. Follow the onscreen prompts. When Multi Leg/Wire is enabled in Log>Setup menu, each leg is identified by a letter rather than a number (A - I). Each tension wire (guy wire) is identified by a number. When the Store softkey is pressed, leg with be displayed. If more than one leg, use the Sel keys to select the desired Leg. Press Enter to go to the wire selections. Use the Num keys to select the wire number. Press Enter to store the tension reading. Refer to page 21 for more details. Press the key to move to the next set of softkeys. Units Press this key to set the Quick-Check for displaying: l Force in lbf, kgf or N Log Log mode is used to log/record force and peak data. Press this softkey to view the number of records logged. This can be done on each lift, during a timed duration, during an overload or on Print key operation. Figure 3.5 Log Menu Log Setup ID Send Clear Log Mode Disable On Print On Lift Timed Overload Auto ID increment (Enabled, Disabled) Auto ID prompt (Enabled, Disabled) Log rate (sec) 1 Log count (1 to 255) Auto send (Disabled, Enabled) Comm port (Disabled, Cell, COM1, RADIO) Threshold% 10 Re-arm% 2 Auto ID increment (Enabled, Disabled) Threshold% 5 Re-arm% 2 Holdoff Seconds 1 Comm port (Disabled, Cell, COM1, RADIO) Comm port (Disabled, Cell, COM1, RADIO) ONLY APPEARS IF AUTO ID INCREMENT IS DISABLED Auto send (Enabled, Disabled) Comm port (Disabled, Cell, COM1, RADIO) Multi Leg/Wire Max Legs (0-9) Max Wires (0-30) Comm port (Disabled, Cell, COM1, RADIO)

19 Setup: Setup allows the user to configure how the Quick Check stores data internally. This stored data can be downloaded via the 4 pin Lemo to a PC via a keyboard wedge or other device. l Log Mode: Disable: Turns the log feature off. On Print: Used when the operator wants to do a lift and store of the force and peak. Auto ID Increment: Enable/Disable This will increment the ID by 1 every time the "PRINT" key is pressed and store it with each force and peak. Auto ID Prompt: Enable/Disable (will only appear if Auto ID Increment is Disabled) If "Enabled", the operator will be prompted to key in an ID before storing that ID with the force and peak. Comm Port: This allows you to choose where to export the "ON PRINT" logged data. a. Cell = Setup Cell for data export (4 pin Lemo) b. Com1 = Not used c. RADIO = Future development d. Disabled = to turn off On Lift: Used when the operator wants the load to be automatically stored, once the load becomes stable. Note: additional filtering may be required, as the load must be steady before the load will be recorded. Maximum Records = 255 Threshold %: (based on capacity) This is the load above where the unit will record the stable load. Re-arm: (based on capacity) This is the load the force must drop below before the "ON LIFT" will reset (re-arm) and store another load. Auto ID Increment: Enable/Disable This will increment the ID by 1 every time the "PRINT" key is pressed and store it with each force and peak. Auto Send: Enable/Disable Can export the readings live if enabled. Note: All Log Modes will record Date and Time along with it's force and peak reading.

Comm Port: This allows you to choose where to export the "ON PRINT" logged data. a. Cell = Setup Cell for data export (4 pin Lemo) b. Com1 = Not used c. RADIO = Future development d. Disabled = to turn off Timed: This is used when the operator wants to record a live load/pull and store it internally. Can store up to 255 force readings. Log Rate: The speed at which the logging of force will be recorded. Based on seconds (Example 5 sec = Unit will record the force once every 5 seconds) Log Count: This is how many logs the operator wants to record. Range is 0 to 255 recorded readings. Auto Send: Enable/Disable Can export the readings live if enabled. Comm Port: This allows you to choose where to export the "ON PRINT" logged data. a. Cell = Setup Cell for data export (4 pin Lemo) b. Com1 = Not used c. RADIO = Future development d. Disabled = to turn off Overload: This is used when an operator or supervisor wants to know if their equipment is being overloaded. This will be a percentage based on capacity and will be below 100% of the Quick Check. (This not the same as the 120% overload that the Quick Check records based on capacity.) Maximum Records = 255 Threshold %: (based on capacity) This the percentage above where the unit will record the peak load. Re-arm %: (based on capacity) This is the load percentage the force must drop below before the "OVERLOAD" will reset (re-arm) and store another load. Holdoff Seconds: Once the unit has recorded this overload, how much time will pass before this unit will re-arm and allow to record the overload again.

21 Comm Port: This allows you to choose where to export the "ON PRINT" logged data. a. Cell = Setup Cell for data export (4 pin Lemo) b. Com1 = Not used c. RADIO = Future development d. Disabled = to turn off Multi Leg / Wire: This is used to measure tension on tower guyed wires. The readings can be stored (refer to page 18). Max Legs: Enter the number of legs the tower has. Max Wires: Enter the number of guy wires each leg has. Comm Port: This allows you to choose where to export the "ON PRINT" logged data. a. Cell = Setup Cell for data export (4 pin Lemo) b. COM1 = Not used c. RADIO = Future development d. Disabled = to turn off

The data will be exported to a computer via RS-232. Dillon recommends using “WedgeLink” software as a keyboard wedge. The data needs to be comma delimited and can be exported to an Excel spreadsheet. Refer to Figure 3.6 for an example. Figure 3.6 Example of Tower Data ID: An operater can key in either a User ID number or a Lift ID assigned to a particular product. This is a numeric number only and can be any number from 1 to 65,000. (if you want to turn the ID off, key in 0). Note: ID not used in Multi Leg/Wire mode. Send: This will export/send the Log information out the configured port. Clear: This will clear any data in the Log mode. Clearing "On Lift", "Timed", "Overload" and Multi Leg/Wire stored data. Auto-off can preserve battery life.

23 Setup Press the Setup softkey and you will see these choices; Power, PtFmt, Misc, About, Test and Clock. These are described below: Figure 3.7 Setup Menu Power: Use this to set power management features l Peak Capture Rate - Select a Peak Capture Rate by using the Sel keys to scroll through the choices. Choices are 100Hz - Normal, 1kHz - High Speed, and 10Hz - Battery Saver (default). Press Enter to accept the displayed setting. Setup Power PtFmt Misc. About Test Batt A-D Disp Keys Comm Setpts Setpt1 Setpt2 Cell COM1 Press KEY to test. Press ESC key to exit View Counts and Cal. factor Run display test View Battery Voltage Device Calib. 0.Load Zero Ntwrk View Radio information View Dead load Analysis View Over load counter and log Points Re-Cal Print Print Calibration report To view when calibration is due View all Calibration points Display Device info, SN, FW and PN Flash Zero Contr BLite Inten Mode Selected Backlight ON, OFF or Timer operation If Timer enabled then: Enter time in Seconds Choose Motion Reset Timer: (Yes or No) Choose backlight intensity: 1- 10 Adjust Contrast Up or DOWN Choose Zero Key clears Peak: (Yes or No) Set AZT (div): .5 Set Motion Range (div): 1 Enable Key Blink: (Yes or No) Choose default print format: 1 - 5 Set Filter (*40) Date/Time (Enabled, Disabled) Peak Capture Rate: (100Hz – Normal), (1KHz – High Speed), (10Hz – Battery Saver) Enable Auto- Shutdown: (Yes or No) RADIO Clock Be aware that 1kHz - High Speed mode will consume more battery power.

l Enable Auto-Shutdown - Auto-Shutdown powers off the instrument automatically. If Yes is chosen, the following options will be displayed: Shutdown Timer (Min): Program to shut down after a period of inactivity. Shutdown Type: Select a method of shutdown. Fixed: Set the amount of time for the unit to shut off No Load: No load of the tension meter No Change: No change in weight PtFmt: l Default Print Format l Print time and date Misc: Press this softkey to set the following: l Flash - Enables or disables the momentary blinking of the display to acknowledge a key press. l Zero - Enables the use of the Zero softkey to clear a peak tension value. l Contr - Press this key to adjust the contrast of the LCD display. Press the Up soft key to lighten the contrast. Press the Down softkey to darken the contrast. There is a keypad shortcut for increasing and decreasing contrast. While in normal display mode press the Arrow key and the 2nd softkey simultaneously to increase contrast. Press the Arrow key and first softkey simultaneously to decrease contrast. l Blite - Press this key to adjust the backlight brightness and sleep timer functions. Inten- Backlight intensity can be set to a value of 1 - 10. Default backlight value is 1. Press Arrow key and F4 simultaneously to increase intensity. Press Arrow key and F3 simultaneously to decrease intensity Mode- Select Backlight to operate as always “On”, “always Off” or the backlight can operate from a configurable “Timer”. If set to Timer, the operator will be asked to enter the Time in Seconds, after motion stops that the backlight will shut off. The next selection will allow the user to configure if motion resets timer. Choose Yes or No to have motion reset the Timer which turns off the backlight. Use of the backlight will affect battery life.

25 About: Press this softkey to see the following information: l Device - Press this softkey to show a list of information about the Quick- Check; serial number, capacity rating, hardware and software revision levels. Press any key to return to the previous softkey set. l Calib - Press this softkey to show Calibration Points and the calibration information for the current wire size. Follow the on-screen prompts. l O. Load - Press this softkey to show an audit count of the number of times the unit has been overloaded beyond 120% of capacity and the actual hours the unit is on (On Time). Press any key to return to the previous softkey set. l Zero - Press this softkey to show the deadload analysis of the Quick-Check. Press any key to return to the previous softkey set. l Ntwrk - Displays network information (Radio, Name, ID#). Future development. Test: Press this softkey and the following softkeys appear: l Batt - Press this softkey to test the battery level. l A-D - Press this softkey to display the A to D counts. l Disp. - Press this softkey to perform a test of the display pixels. l Keys - Press this softkey to test the keypad. l Comm - Press this softkey to test the RS-232 in a loopback test (Cell). Com1 is not used. l Setpts - Not used in the Quick-Check. Clock Enter the date and time. Use the Num softkeys to enter the correct number and use the Adv softkey to advance the cursor. When the entry is correct, press the Enter softkey. Config This is a password protected menu. See Configuration Mode on page 26.

4 Configuration Mode 4.1 Accessing the Configuration Mode You need to access the Configuration mode to perform certain tasks. Access to some of these tasks may be restricted by a supervisor password. To access Configuration mode: 1. From normal operating mode, press the Right Arrow softkey… A new softkey set, shown below, appears: 2. Press the Config softkey… The following is displayed: 3. Use the Num and Adv keys to enter the Config password. Default is 0. After the number is displayed, press the Enter key… The following is displayed: Units Log Setup Config lbf 7/16 6X19 Shv:S The Num keys increment and decrement the displayed numbers. The Adv key moves the cursor to the next digit position. Default Configuration password is 0. If a new password is lost or forgotten, contact your Dillon distributor.

27 4. The unit is now in the Configuration mode. To see the rest of the softkeys available in this mode, press the Right Arrow key. All the Config softkeys are shown below. The softkeys in the Configuration mode are Wire, Setup, Reso, Comm, Mode, Units, Power, ChPwd, and Reset. These are described below: Wire Press this softkey and the wire selection screen is displayed. Choose an existing wire to change its defining characteristics. You have the choice of changing the Range, which is used to set the check-tensioning function, or the Rating, which is the maximum rating of the cable. l Range - Use this item to set the parameters for the check tensioning display. Follow the prompts to set the following: Lower tension limit - This is the lowest acceptable force Upper tension limit - This is the highest acceptable force Units - Unit of measure used in defining the tension limit l Rating - Press this softkey and you are prompted to set the ultimate rating for the cable being used and the unit of measure for that rating. Setup Press the Setup softkey to view the Setup softkeys. This is the same as the Setup softkey described inTop level Softkeys on page 16. Reso Press the Reso softkey and you are prompted to enter a display, or count-by, resolution. Choose from Low, Medium or High. Low resolution provides the best stability and makes the display easiest to read. High resolution provides the finest graduations, but sees greater drift from wire creep and non-repeatability. If the reading is decreasing over time or differing between measurements on the same line, lowering the resolution will reduce these effects.

Comm Communication output (COM1) and RADIO are not supported at this time in the Quick- Check. Press the COMM key to select Cell. l Cell - Press this key to configure the RS-232 port (4 pin Lemo) l COM1 - Not used l RADIO - For specials and future development Mode Press this softkey to set the display mode on power up. Choices are Last*, Check, Avg, Peak, and Force. Use the Sel keys to display your choice and press Enter to accept it. Units Press this softkey to set the following: Unit of measure on power up - Choices are Last*, C2, C1, N, kgf, and lbf. Use the Sel keys to display your choice and press Enter to accept it. C2 and C1 are custom units. If you choose to have custom units, you are prompted to enter the number of pounds in each custom unit. The Quick-Check will then automatically calculate correct display for the applied force. l Enable lbf - Enable or disable the pound-force unit of measure. l Enable kgf - Enable or disable the kilogram-force unit of measure. l Enable N - Enable or disable the N unit of measure. l Enable CUST1 - Enable or disable the Cust1 unit of measure. l Enable CUST2 - Enable or disable the Cust2 unit of measure. Power Press this softkey to set the Peak Capture Rate and enable or disable the Auto- shutdown. Select a Peak Capture Rate using the Sel key to scroll through the choices. Choices are 100Hz - Normal, 1kHz - High Speed, and 10Hz - Battery Saver (default). Press Enter to accept the displayed setting. If you enable Auto-shutdown, you are prompted to set a period of time in minutes. Next, press the Enter softkey to accept this value. You are then asked to set the shutdown type; Fixed, No Load, or No Change. These are described below; Custom units of measure are handy when working with multi-part lines. Be aware that 1kHz - High Speed mode will consume more battery power.

29 l Fixed - The unit will shutdown after the set number of minutes no matter what happens. l No Load - The unit will shutdown after the set number of minutes only if there is no load on the unit. This prevents shutdown in the middle of line tensioning. l No Change - The unit will shutdown if there has been no keypad activity or change in tension after the set number of minutes. ChPwd Press this key and you are prompted to enter a new password to access the configuration menus. Use the softkeys to scroll in a new password and press the Enter softkey to accept it. Reset Press this key and you are asked if you wish to reset the system. Press the Yes softkey only if you want to reset the unit to factory default configuration. Press the No softkey to abort this and return to the previous screen. Default password is 0. If a new password is lost or forgotten, contact your Dillon distributor.

5 Changing Sheaves As you use the Quick-Check on different diameter cables you must change to the correct sheave size. To change sheaves, remove the hex head screws pointed out in Figure 5.1 below. Replace the sheaves with the correct letter sheave and reinsert the screws and tighten. Insure sheaves installed agree with sheaves noted in the Wire calibration. Exception: Sheaves match the wire diameter of the cable to be measured and alternate calibration is selected as per the section Calibration to Specific Wire Type on page 31. Insure that the wire rope is riding in the groove of all three sheaves. Figure 5.1 Changing Sheaves Do not use the Quick-Check with cable larger than indicated on the sheaves. Overload and damage to the instrument may result. Do not mix sheave sizes. This will result in inaccurate measurement and possible overload. Screws

31 6 Achieving Best Accuracy 6.1 Accuracy The Quick-Check is an instrument designed to give accuracy that typically exceeds normal requirements for wire tensioning. You should have an understanding of what factors affect tension measurement accuracy. 6.2 Calibration to Specific Wire Type While it is best to have the instrument calibrated to the specific wire size(s) and type(s) used, the Quick-check can often work adequately in other situations. If the best tension accuracy is required, Dillon recommends that a calibration be performed for that specific wire size and type. Do not use the Quick-Check to measure tension for wires if either of the following are true: 1. No wire calibrations are stored of the same diameter as the wire you are looking to measure, and 2. You do not have sheaves of the same diameter. If either of these conditions exist, contact your Dillon distributor. Contact your Dillon distributor to improve accuracy for a specific wire type by calibrating to it. 6.3 Loading Error A tensiometer works by deflecting the cable, which makes the cable path longer than when a tensiometer is not installed. When the tensiometer is removed, the wire tension decreases as the cable length is restored. This effect is known as loading error. The Quick-Check design elongates the cable by a mere 0.08 inch (2 mm), making loading errors extremely small. 6.4 Non-repeatability The Quick-Check’s sheave with bearing design provides the best mechanical performance. It is also superior at detecting tension that is being added or removed. Contact your Dillon distributor for any additional calibrations you may need.

6.5 Non-linearity Most three-point tension meters employ only linear characterization and have large errors at the midpoints (up to 15%). The Quick check uses multi-point segmenting to correct for non-linearity, reducing it to less than 0.2%. 6.6 Wire Characteristics Creep Every material including steel exhibits creep under load. It will neck down over time, quite quickly over the first few seconds and much slower as time progresses. A wire cable also sees creep from the wire spacing and wind. This effect is seen as a display that drifts lower after it has been clamped in line. Variations Material that varies in diameter or shape will have different output at the same tension Strands The best cable assembly is one that is perfectly round, as it will not change contact geometry with the wire twist. The closer the wire cable cross section appears to be round, the better the measurement performance will be.

33 7 Troubleshooting 7.1 Quick Check Problem Possible Cause Solution Powers on momentarily and turns off Low battery Replace with high quality alkaline batteries Bad keypad Have unit serviced Does not power on Low battery Replace with high quality alkaline batteries Batteries installed backwards or no spring contact Insure that positive terminals of both batteries (nub) face inward – towards the black cap. Check that spring is attached to the battery cap. Software reset Remove battery cap & reinstall after one minute. Attempt to turn power on again. Display contrast too light Hold the Right Arrow key down while pressing the F2 key several times to increase the display contrast. If nothing occurs, release both keys. Press the power button and try again. Bad keypad Have unit serviced Display is completely dark Display contrast too dark Hold the Arrow key down while pressing the F1 key several times to decrease the display contrast. Display drifts downward once installed Wire material is creeping and internal friction between wires is relieved. This is normal behavior of wire. Lower display resolution to mask this effect.

7.2 EDX PSU Problem Possible Cause Solution Quick Check powers on momentarily and turns off Low battery Bad keypad Replace with high quality alkaline batteries. Do not use rechargeable batteries. Have unit serviced. Quick Check does not power on Low battery Bad keypad Replace with high quality alkaline batteries. Do not use rechargeable batteries. Have unit serviced. Batteries installed backwards or no spring contact Insure that positive terminals of both batteries (nub) face inward – towards the black cap. Check that spring is attached to the battery cap. Software reset Remove battery cap & reinstall after one minute. Attempt to turn power on again. Display contrast too light Hold the Right Arrow key down while pressing the F2 key several times to increase the display contrast. If nothing occurs, release both keys. Press the power button and try again. EDX PSU Power Supply Remove Power Supply and install batteries to see if the Quick Check or Communicator II will power up. Return EDX PSU to factory for repair/ troubleshooting. Display is completely dark Display contrast too dark Hold the Arrow key down while pressing the F1 key several times to decrease the display contrast. Quick Check does not appear accurate Check installation & system Insure that shackles are in good working condition and aligned straight. Verify system is applying force directly through the dynamometer with no off center or torsional loads being applied to the instrument. Local gravitational variances If being compared against dead-weights, check your local gravitational constant. Use custom units to compensate or calibrate on-site. Check repeatability Place Quick Check in low-resolution mode. Lift an arbitrary weight several times as close to capacity as possible. Record each weight reading. Do the readings differ from each other? Calculate the standard deviation of the readings using a spreadsheet such as Microsoft Excel. See if the deviation is greater than 0.1% of the instrument capacity. Compare against a reference load. Place Quick Check in low-resolution mode. Apply a known load near instrument capacity. Check calibration date. Radio communications not working at all Dead batteries. Distance is excessive, dead radio pocket Bring remote closer to dynamometer. Allow several seconds to retrain. Operating channels mis- matched Remote and link must be on the same operating channel. See Quick Check and Communicator configurations of COM1 for radio (under Comm menu) and Common Configurations. Excessive radio noise or interference in environment Remove dynamometer and Communicator from the environment. Attempt communications in an area free of local radio signals. See Radio Information section of the manual. Remote reading changes to dashes Low batteries, lost communications See steps above for improving communications. Display locks up on DILLON marquee Poor connection between Quick Check and Communicator Remove batteries from Quick Check and Communicator, replace them and power up.

35 8 Specifications Power 2 AA, common alkaline batteries. Display Dot graphic LCD display Operational Keys Power, Wire, Escape/Clear (ESC), Next ( ) and four softkeys with changing function and label, depending on the specific menu in use Operational Annunciators Unit of measure, battery level Display Resolution 2,000 lbf/ 10 kN/ 1000 kgf Quick-Check instrument: 10,000 lbf/ 45 kN/ 4500 kgf Quick-Check instrument: For ease of use, the display always counts by a multiple of 1, 2 or 5. Displayed resolution setting Low Med High lbf (pound-force) 10 lbf 5 lbf 2 lbf kgf (kilogram-force) 5 kgf 2 kgf 1 kgf N (Newton) 50 N 20 N 10 N Custom units between 101 & 200 divisions between 201 & 500 divisions between 501 & 1000 divisions Displayed resolution setting Low Med High lbf (pound-force) 50 lbf 20 lbf 10 lbf kgf (kilogram-force) 20 kgf 10 kgf 5 kgf N (Newton) 200 N 100 N 50 N Custom units between 101 & 200 divisions between 201 & 500 divisions between 501 & 1000 divisions

Available Options Varied wire sizes Operating Environment Suitable for outdoor use Dimensions 10˝ x 23˝ x 3˝ (25 cm x 59 cm x 8 cm) approximately Weight 11 lb (5 kg) approximately 8.1 EDX PSU Power Supply Specifications Enclosure Designed for indoor use Input Voltage 100-240 VAC 50-60Hz, 0.55A Output Voltage 5 VDC Operating Temperature -4 F to 158 F (20 to 70 C) Connector Sealed connector to be used with Quick Check Approval CE Distributed by: ABQ Industrial LP USA Tel: +1 (281) 516-9292 / (888) 275-5772 eFax: +1 (866) 234-0451 Web: https://www.abqindustrial.net E-mail: [email protected]