Forney “CO-PILOT” Digital Indicator

TA-1252 Version 3.3

MANUAL -- MN-TA-1252 Version 3.3

Forney Incorporated
1565 Broadway Avenue
Hermitage, PA 16148 USA
1-800-367-6397
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TA-1252
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TABLE OF CONTENTS

1 PRODUCT DESCRIPTION ............................................................................................................................... 4

1.1 Features.............................................................................................................................................................. 4
2 INSTALLATION.................................................................................................................................................. 4
2.1 Make certain that you have received these items:...................................................................................... 4
2.2 Install the unit................................................................................................................................................... 4
3 REAR PANEL....................................................................................................................................................... 5
3.1 ON/OFF Switch ............................................................................................................................................... 5
3.2 9V DC Input Jack ............................................................................................................................................ 5
3.3 Force Connectors............................................................................................................................................. 5
3.4 RS232 Port ........................................................................................................................................................ 5
4 FRONT PANEL .................................................................................................................................................... 6
4.1 16-Character LCD display. ............................................................................................................................ 6
4.2 LED Indicators ................................................................................................................................................. 6
4.3 Menu Keys........................................................................................................................................................ 6
4.4 Numeric Keys................................................................................................................................................... 6
5 OPERATION......................................................................................................................................................... 7
5.1 Power Up........................................................................................................................................................... 7
5.2 UTILITIES Menu ............................................................................................................................................ 7
5.2.1 UTILITIES - TEST FRAME.................................................................................................................... 7
5.2.2 UTILITIES – UNITS................................................................................................................................. 7
5.2.3 UTILITIES – AUTO-ID ........................................................................................................................... 8
5.2.4 UTILITIES – AUTO-SAVE .................................................................................................................... 8
5.2.5 UTILITIES – DATE.................................................................................................................................. 8
5.2.6 UTILITIES – TIME................................................................................................................................... 8
5.2.7 UTILITIES – RESOLUTION + .............................................................................................................. 8
5.2.8 UTILITIES – SAMPLE/SEC................................................................................................................... 9
5.2.9 UTILITIES – FILES + .............................................................................................................................. 9
5.2.10 UTILITIES – CALIBRATION +..................................................................................................... 10
5.2.11 UTILITIES – ENG/ESP..................................................................................................................... 11
5.2.12 UTILITIES – EXIT ............................................................................................................................ 12
6 QUICK GUIDE TO RUNNING A 6” X 12” CYLINDER TEST.............................................................. 12
6.1 Quick Guide to Running a Test................................................................................................................... 12
6.2 To Test Additional Specimens of the Same Type and Size:.................................................................. 13
7 SPECIFICATIONS............................................................................................................................................. 13
8 MENU TREE....................................................................................................................................................... 14
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1 Product Description
Congratulations on your purchase of the Forney CO-PILOT digital force indicator. This
instrument is designed specifically for materials testing and incorporates many features to
streamline that testing process. Please take a few minutes to read through this manual and
get acquainted with the many time-saving features of your CO-PILOT.

1.1 Features
Ø Compression testing
Ø 2 Force channels (in order to monitor 2 test frames)
Ø 7 digit display range
Ø Display live or peak force
Ø Display force rate
Ø Selectable units: in/lbf, mm/KN or mm/Kgf
Ø Store up to 500 tests
Ø Automatic Test Store
Ø Automatic Test ID increments
Ø English or Spanish language
Ø 16-Key keypad for easy setup and operation
Ø Large 16-Character backlit LCD display
Ø RS232 serial port
Ø Battery-backed clock with time and date

2 Installation
2.1 Make certain that you have received these items:
Ø CO-PILOT
Ø AC adapter
Ø AC power cord
Ø 2 Mounting knobs, 5/16”-18 x ¾”lg.
Ø 2 Rubber washers

2.2 Install the unit.

1. Mount the CO-PILOT unit to bracket using two mounting knobs with rubber washers
between the bracket and digital.
2. Set the ON/OFF switch to the OFF position.
3. Connect the AC adapter to the unit.
4. Connect the AC power cord to the AC adapter, and then plug it into AC power.
5. Connect force sensors as shown on the rear panel diagram.
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3 Rear Panel
3.1 ON/OFF Switch

3.2 9V DC Input Jack

Connect the +9VDC supplied with your CO-PILOT.

3.3 Force Connectors.

Two strain gage-type force/pressure connectors, LOAD1 and LOAD2 are located on the
back of the unit. Connect the Frame1 transducer to LOAD1, and then connect the Frame2
transducer to LOAD2.

3.4 RS232 Port

Allows the transfer of test data for stored test results to a computer.
A standard 9-pin serial cable and a communication software package such as
HyperTerminal, which is usually supplied with Microsoft® Windows is required. A 100 ft.
long serial cable is available from Forney, Item number TA-1247-09.
Serial port settings are 38.4Kbaud, No parity, 8 data bits and one stop bit (N-8-1); no
hardware handshaking required.
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4 Front Panel
4.1 16-Character LCD display.

4.2 LED Indicators

FRAME1 Indicates that the Frame1 is selected.
FRAME2 Indicates that the Frame2 is selected.
RATE Indicates that the rate of change for force is being displayed.
PEAK Indicates that the peak quantity for Force is currently being displayed.

4.3 Menu Keys

− Menu key. Access and advance through menu options.

− Enter key. Select a menu option or complete a numeric entry.

− Up Arrow key. Scrolls up through a menu list.

− Down Arrow key. Scrolls down through a menu list.

4.4 Numeric Keys

Numeric keys include digits 0-9, ‘.’ (decimal point) and ‘-‘ (minus sign). Seven keys are
assigned alternate functions that allow quick access to commonly used functions. Alternate
key functions are described in the table below.

__0__ Zero the Force channel. Note: only the channel currently being displayed is
ZERO zeroed.

__1__ View or edit the specimen ID number.

SPEC #

__3__ Enter or exit the ‘UTILITIES’ menu

UTIL
__5__ Store test results in non-volatile memory. This key is ignored if a test has
STORE already been stored.

__7__ Toggle the display between Force and Force rate. This key is ignored when
FORCE peak Force is displayed.

__9__ Toggle between Force and peak Force.

PEAK
__--__ Start a new test. Initializes the data logger, then pauses until the applied
NEW
force exceeds 0.25% of full scale.
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5 Operation
5.1 Power Up.
When switched on, the CO-PILOT briefly displays the model number and software version
followed by the date. The four LED mode indicators also flash briefly. It then restores the
test frame and settings from the most recent setup. The active test frame is shown by the
mode indicators and force is displayed. CO-PILOT is now in “live” display mode.
In general, the steps to set up a test are:
Ø choose a test frame and set preferences from the UTILITIES menu
Ø press New key
When repeated tests are run, and Auto-Store is turned on, pressing the New key is all that is
necessary to start another test.
See section 6 for more details on how to set up and run a test.

5.2 UTILITIES Menu

The UTILITITES + menu provides access to the following CO-PILOT settings:
Ø TEST FRAME Ø DATE Ø FILES +
Ø UNITS Ø TIME Ø CALIBRATION +
Ø AUTO-ID Ø RESOLUTION + Ø ENG/ESP
Ø AUTO-SAVE Ø SAMPLES/SEC Ø EXIT
You can access the UTILITIES menu by pressing the 3/UTIL key.

Press the key to scroll through menu options , then press to make your selection. To
exit the UTILITIES menu you can press 3/UTIL from any of the menu options or scroll to
EXIT and press .

5.2.1 UTILITIES - TEST FRAME

Selects test frame 1 or 2. To select a test frame press , then or . Then press
to return to the utility menu. Press to advance through the utility menu, or 3/UTIL to
exit and return to “live” mode.

5.2.2 UTILITIES – UNITS

Selects the units - in/lbf, mm/kN, or mm/Kgf. To select a units press , then or .
Then press to return to the utility menu. Press to advance through the utility menu,
or 3/UTIL to exit and return to “live” mode.
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5.2.3 UTILITIES – AUTO-ID

Automatically increments the specimen Id number of each test when set to ON. To set the

Auto-ID press , then (on) or (off). Then press to return to the utility menu.
Press to advance through the utilities menu, or 3/UTIL to exit and return to “live” mode.

5.2.4 UTILITIES – AUTO-SAVE

Automatically stores test results in non-volatile memory at the end of each test when set to

ON. To set Auto-Save press , then (on) or (off). Then press to return to
the utilities menu. Press to advance through the utilities menu, or 3/UTIL to exit and
return to “live” mode.

5.2.5 UTILITIES – DATE

Set the clock date. To enter the date press , then enter the date with the numeric keys.
The format is mm-dd-yy. Do NOT press again! This will clear the date and you will
have to re-enter it. Press to advance through the utilities menu, or 3/UTIL to exit and
return to “live” mode.

5.2.6 UTILITIES – TIME

Set the clock time. To enter the time press , then enter the time with the numeric keys.
The format is hh:mm:ss. Do NOT press again! This will clear the time and you will
have to re-enter it. Press to advance through the utilities menu, or 3/UTIL to exit and
return to “live” mode.

5.2.7 UTILITIES – RESOLUTION +

This option allows you to adjust the display resolution of each load transducer by a factor of
1, 5 or 10. This may be desirable in certain situations when less resolution is easier to read.
Resolutio n takes into account load full scale capacity and the “units” setting in the
UTILITIES menu. Internal resolution is greater than +/-200,000 counts and is not affected
by this setting.

To adjust display resolution press . Press to scroll through the transducer options,
then press to make your selection.

Press and to choose a resolution, then press to return to the transducer options
menu. You must select EXIT from the transducer options menu to return to the
RESOLUTION + menu. Then press to advance through the utilities menu, or 3/UTIL to
exit and return to “live” mode.
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5.2.8 UTILITIES – SAMPLE/SEC

This menu allows you to select one of four data sample rates – 10, 20, 30 or 60 samples per
second. Slower data rates have proportionally lower frequency response (more filtering).
Faster rates respond more quickly to dynamic signals and more accurately capture peaks.
The fastest setting is recommended for most applications, but if noise is causing a problem,
the lowest sample rate and the largest resolution number will make the read out more steady.

To select a sample rate press , and or . Then press to return to the utilities
menu. Press to advance through the utilities menu, or 3/UTIL to exit and return to “live”
mode.
Note: When the live force display is unstable, choose a low sample rate and the highest
possible resolution as shown in paragraph 5.2.7, to stabilize the display. The AC electrical
power feeding the testing machine may also cause display instability. The AC electrical
power should be observed using an AC voltmeter while the machine is in operation to
observe the electrical power stability.

5.2.9 UTILITIES – FILES +

CO-PILOT can store up to 500 test results in non-volatile memory. Test results may be
transferred to a computer via the RS232 serial port. (See section 3.4 for additional cable and
remote computer requirements).
Use the FILES + menu to download or erase all stored test results. The FILES + menu has
three options:
Ø SEND TO FILE
Ø ERASE ALL +
Ø EXIT

To access the FILES + menu press . Press to advance through menu options, then
to make your selection.
If SEND TO FILE is selected the transfer begins immediately. Upon completion CO-PILOT
returns to the FILES + menu.

5.2.9.1 UTILITIES – FILES – Hyper Terminal

To download a test, first a session of Hyper Terminal will need to be opened on a personal
computer attached to the Co-Pilot via. an RS232 cable. Hyper Terminal is found on most
Windows based computers under Programs/Accessories/Communications/Hyper Terminal.
It is recommended that an icon be added to the computer desktop for ease in opening Hyper
Terminal sessions.
From the Hyper Terminal pull-downs, go into transfer – capture text. At this point, a
window will pop up prompting the user to give a name and location to the file they are
creating. The file extension should be .csv for Microsoft® Excel to recognize the data.
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Hit the start button to close this window. Hyper Terminal is now ready to receive data from
the Co-Pilot.
Select “Send to File” from the Files menu of the Co-Pilot.
Note the Hyper Terminal screen is full of data – if the screen remains blank, the download
was unsuccessful.
From the Hyper Terminal pull-downs, go into transfer – capture text – stop.
At this point, the Hyper Terminal window can be closed or minimized.
Open a session of Microsoft® Excel. Open the file just created above, which should have a
.CSV extension on it. Note the data is imported, and should look similar to the example
below:

Test Results

Test_ID Date Time Pk_Load Units

986533 9/26/2005 14:34:52 123970 Lb
986534 9/26/2005 14:37:05 14555 Lb
986535 9/26/2005 14:55:58 0 Lb

If ERASE ALL + is selected a prompt ‘Erase All? No’ is displayed, where ‘No’ is the
default option. To abandon this action press or . To clear all stored tests press to
change the option from ‘No’ to ‘Yes’, then press or . This process may take a few
seconds.

When the operation is complete the message ‘Done. Press key’ is displayed. Press or
to return to the FILES + menu. Press to advance through the utilities menu, or
3/UTIL to exit and return to “live” mode.

5.2.10 UTILITIES – CALIBRATION +

Use this menu to calibrate transducers. Calibration may be done in any of the available units
systems (see section 5.2.2). Calibration supports piece-wise linearization of 2 to 5 points
(zero plus 1 to 4 additional points) The CALIBRATION + menu has three options:
Ø LOAD1
Ø LOAD2
Ø EXIT

To access the CALIBRATION+ menu press . Press to advance through menu

options, then to make your selection.
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Calibrations are password protected. At the ‘Passwrd’ prompt, Enter the password (call
Forney tech support for the password), then press . If you enter an incorrect password
CO-PILOT returns to the CALIBRATION menu.
WARNING: Entering the calibration function without the proper calibration
equipment, procedures and training will corrupt the existing calibration rendering the
CO-PILOT out of calibration and not capable of meeting ASTM testing requirements.

5.2.10.1 LOAD Calibration Procedure

1. After selecting a device and entering a password (see section 5.2.10) proceed as
follows.

2. At the prompt “Cap FS”. Press , enter the capacity (full scale range) of the
device in Lbf, kN or Kg as indicated, then press again. Press to advance to
the next step.

3. At the prompt “Points(2-5)?”. Press , then press and to scroll to the

desired number of calibration points. Press to make your selection. Press to
advance to the next step.
4. At the prompt “At Zero- #1?” start the hydraulic pump and raise the proving device
leaving 1/8” to 1/16” (1-2 mm) gap. Press to measure and store electrical zero
for the first calibration point. The display will automatically advance.

5. At the prompt “Value?” press to accept the default value of 0.00000. This is the
applied force associated with electrical zero stored in the previous step.
6. At the prompt “At Point2?” apply load to the proving device to obtain the first
calibration force, then press . The display will automatically advance.

7. At the prompt “Value?” press , enter the applied force obtained on the proving
device, then press again. Note: if you need to re-enter this value just press
again and repeat this step. Press to advance to the next step.
8. Repeat steps 6 to 7 until you have entered all calibration points.

9. At the prompt “Done. Save? Yes”, press to store the calibration, or press and
change your option to “No”, then press to abandon the calibration and restore the
previous one. CO-PILOT returns to the CALIBRATION + menu.

10. Press to advance to the next transducer or to EXIT, then press . Press to
advance through the utilities menu, or 3/UTIL to exit and return to “live” mode.

5.2.11 UTILITIES – ENG/ESP

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Select English or Spanish language. To select a language press , then or to

make your selection and press . Press to advance through the utilities menu, or
3/UTIL to exit and return to “live” mode.

5.2.12 UTILITIES – EXIT

Exit the UTILITIES menu. Press to exit the UTILITIES menu and return to live display
mode or to advance through the utilities menu. You may also press 3/UTIL to exit and
return to “live” mode.

6 Quick Guide to Running a 6” x 12” Cylinder Test

6.1 Quick Guide to Running a Test
1. Select a test frame and set user preferences in the UTILITIES menu (See section 5.2).
2. Load your specimen into the test frame. Zero the load channel (Zeroing is optional
since this is automatically done at the start of each test when the New key is pressed).
3. Press the NEW key to initiate the start of a test. If Auto-ID is turned off, or the
specimen ID is 0 you will be prompted to enter a specimen ID. Press , enter the
ID, then press again. Press to continue. Note: You cannot proceed unless
you enter a non-zero ID number.
4. The display flashes an “Initializing...” message briefly, then it returns to the live
display mode.
5. Move the piston so the specimen is within 1/16” of contact with the upper platen.
Press the Zero key to zero the load/strain channels.

6. Proceed with applying a load to the specimen per ASTM C39. When the load
exceeds 0.25% of capacity, data logging and break detection automatically engage.
7. Continue loading the specimen until break is detected (load decreases to 50% of
peak).

8. If Auto-Save is set to off, a message “Save Test? Yes” is displayed. Press to

store the results, or then to proceed without saving. After making your
selection the Peak Load indicator lights, and peak load is displayed.
9. Note: you may store results at any time up to the start of a new test or until the CO-
PILOT is switched off. To store test results at a later time Press 5/STORE.

10. Press 9/Peak to return to the live display mode.

11. If Auto-Save is set to on, results (peak load) are automatically calculated and stored,
the Peak Load indicator lights, and peak load is displayed. Press 9/Peak to return to
the live display mode.
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6.2 To Test Additional Specimens of the Same Type and Size:

If testing repeated specimens of the same type and size, with AUTO-ID and AUTO-
SAVE turned on, the only steps required from above are: 2, 3, 5, 6 & 11.

7 Specifications
Part Number TA-1252

Load Channels
No. of channels 2
Input type +/- 2mV/V to +/-4mV/V , 350 to1000 Ohm, Full Bridge
Display Range (Lbf) +9,999,950 / -999,950
Accuracy +/-.5% of reading from 1% of Full Scale to Full Scale
Linear Correction 5 (0 + 4) points
Resolution, A/D Counts 200,000 (note 1)
Display Resolution Selectivity 1 – 5 – 10 Least digit; User selectable
Load Units, Load Units Always displayed
Load Units, Lb Yes
Load Units, Kn Yes
Load Units, Kg Yes
Load Rate Units, Load Rate Units Toggle for Display
Load Rate Units, Kg/sec Yes
Load Rate Units, Lb/sec Yes
Load Rate Units, Kn/sec Yes
Data Options
Send stored tests (RS232) Yes
Display Date/Time Yes
Display Peak Load Yes
Auto Store Yes (optional)
Tests Stored in Memory 500
Specimen I.D. Yes, 6-digit numeric
Auto-Increment Specimen I.D. Yes (optional)
Sample Break/Peak Sensitivity Preset to 50% of Peak Load
Auto Data Log Start Sensitivity 0.25% of Channel Capacity
Date/Time Stamp Tests Yes
Negative Load Display Yes
Capacity Range 7 Digits
Calibration Units All Available
Languages English + Spanish
Function Indicator Lights Yes- 4 indicators
Password Protection Yes
Water/dust Resistant Case Yes
Simple Operation/Calibration Yes
Easy Channel Selection Yes
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Software Upgrade Capable Yes – Factory only

Numeric Keypad Calibration Yes
100-240 VAC, 47/63Hz
Power Requirements (9VDC @ 2.0Amps)
Battery Life 5 years typical
Battery Type BR-2032 Lithium
Note: Internal resolution is always at least +/-200,000 A/D counts. Display resolution least
digit is channel capacity and user resolution setting dependent.

8 Menu Tree
Ø UTIILITIES+
Ø TEST FRAME Ø TEST FRAME1
Ø TEST FRAME2

Ø in, lbf
Ø UNITS Ø mm,kN
Ø mm,Kgf
Ø On
Ø AUTO-ID Ø Off
Ø On
Ø AUTO SAVE Ø Off
Ø 01/01/05
Ø DATE
Ø 08:45:00
Ø TIME
Ø LOAD1 Ø 5, 10 or 50
Ø RESOLUTION+ Ø LOAD2
Ø EXIT Ø Exit

Ø 10
Ø SAMPLES/SEC Ø 20
Ø 30
Ø 60
Ø SEND TO FILE
Ø FILES+ Ø ERASE ALL
Ø EXIT

Ø LOAD1 Ø Capacity:
Ø CALIBRATION+ Ø LOAD2 Ø Points(2-5)?
Ø EXIT Ø At zero- #1?
Ø Value?
Ø At Point 2?
Ø Value?
Ø At Point 3,4?
Ø Value?
Ø Save?
Ø Yes
Ø No
Ø English
Ø ENG/ESP Ø Espanol
Ø EXIT