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AutoSet User Manual

1137200

Troubleshooting

5-3

•

The Load LED display flashes on each strain link channel at fault

•

The message “HI” flashes in the corresponding Setpoints LED display(s)

•

On AutoSet 1504 and 1504 Plus units, the Total LED display flashes

Repeatability Faults

AutoSet displays a repeatability fault when variation in tonnage from one stroke to the next
exceeds the repeatability setpoint. A repeatability fault is indicated on the front panel as
follows (see Figure 5-2):

•

The Load LED display flashes on each strain link channel at fault

•

The message “rEP” flashes in the corresponding Setpoints LED display(s)

•

On AutoSet 1504 and 1504 Plus units, the Total LED display flashes

High Setpoint and Repeatability Faults

AutoSet displays both high tonnage and repeatability faults when tonnage on one or more
strain link inputs exceeds the high tonnage setpoint and stroke-to-stroke tonnage variation on
one or more strain links exceeds the repeatability setpoint. High tonnage and repeatability
faults are indicated simultaneously on the front panel as follows (see Figure 5-3, page 5-4):

Figure 5-2. AutoSet 1504 Plus Front Panel Displaying Repeatability Fault

AutoSet 1504

®

WINTRISS LOAD ANALYZER

PLUS

SETPOINTS

RIGHT

LEFT

ZERO CAM

REAR LOAD

SETPOINTS

FRONT LOAD

TOTAL

DISPLAY

HIGH

RESET

REPEATABILITY

REVERSE

Flashing Total

tonnage value

(AutoSet 1504 only)

Flashing tonnage

value on channel

at fault

Flashing rEP

message on

channel at fault

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Summary of Contents for autoset 1500

Page 1: ...504 Plus Four channel Models 1137200 Rev L November 2016 User User User Manual Manual Manual User Manual Tech Support Hotline 800 586 8324 8 5 EST www wintriss com Wintriss Controls Group LLC 100 Discovery Way Unit 110 Acton MA 01720 USA Phone 800 586 8324 Fax 978 263 2048 PRINTED IN USA DA71510 ...

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Page 3: ...e returning We ask that you either fax us a PO for that amount or enclose the PO with the returned item This will enable us to ship the item back to you as soon as the repair has been completed If the item cannot be repaired or there are additional charges you will be contacted for approval Please be sure to carefully pack all returned items and ship to our Acton MA location Expedited Repair Progr...

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Page 5: ...Changes for Revision L of the AutoSet User Manual 1137200 This revision of the AutoSet user manual covers AutoSet software version 2 28 and higher The changes include Removed obsolete references ...

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Page 7: ...d AutoSets 2 16 Using a Zero Cam on AutoSet Plus Units 2 17 Installing the Latching Magnetic Cam Switch LMCS 2 17 Optional Wiring Connections 2 20 Wiring a Remote Reset Switch 2 20 Wiring an Oscilloscope 2 21 Wiring a Setup Mode Circuit AutoSet Plus Only 2 22 Connecting an AutoSet to SmartPAC 2 23 Connecting an AutoSet to SmartPAC 2 2 23 Connecting an AutoSet to SmartPAC 1 2 25 Connecting AC Wires...

Page 8: ...everse Load AutoSet Plus Only 4 13 Four Channel to Two Channel Conversion 4 14 Disabling AutoSet 4 14 Turning Off and Restoring Power 4 15 Chapter 5 Troubleshooting 5 1 Responding to AutoSet Faults 5 1 High Tonnage Faults 5 2 Repeatability Faults 5 3 High Setpoint and Repeatability Faults 5 3 Offset Errors 5 4 Troubleshooting Common AutoSet Problems 5 5 Load or Setpoints LED Displays Are Blank 5 5...

Page 9: ...ver 3 2 Figure 3 2 AutoSet 1500 Calibration Kit Processor Board Old Style 3 6 Figure 3 3 AutoSet 1500 Calibration Kit Processor Board New Style 3 7 Figure 3 4 Tonnage Dial Indicators Old style Board Left New style Board Right 3 9 Figure 3 5 Mode Switch 3 Set to Decimal Point Off Position Old style Processor Board 3 9 Figure 3 6 Load Cell Gain Adjustment Potentiometer with Adjustment Screw 3 10 Fig...

Page 10: ...1137200 AutoSet User Manual iv Table of Contents Figure 5 4 AutoSet 1504 Plus Front Panel Displaying Offset Error 5 5 ...

Page 11: ... 11 Communications Wiring Connections AutoSet and SmartPAC 2 27 Table 3 1 Strain Link Potentiometer Direction of Screw Adjustment 3 3 Table 3 2 AutoSet Load Cell Tonnage Display Formats 3 10 Table 3 3 AutoSet 1500 and 1500 Plus Tonnage Display Formats 3 14 Table 3 4 AutoSet 1504 and 1504 Plus Tonnage Display Formats 3 15 Table 3 5 Gain Adjustment Potentiometer and High Low Gain Jumper Identifiers ...

Page 12: ...d wire AutoSet Chapter 3 shows you how to calibrate AutoSet Chapter 4 shows you how to make the settings AutoSet uses to calculate setpoints and how to establish setpoints for your press Chapter 5 shows you how to respond to AutoSet faults troubleshoot common AutoSet problems and use the LEDs on the AutoSet processor board as diagnostic tools Appendix A provides tables of wiring connections and Au...

Page 13: ...which if not avoided will result in death or serious injury A WARNING symbol indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION symbol indicates a potentially hazardous situation which if not avoided may result in property damage A NOTICE symbol indicates important information that you should remember including tips to aid you in perf...

Page 14: ...l within the applicable period after shipment be returned to Wintriss Controls freight prepaid and which are after examination disclosed to the satisfaction of Wintriss to be defective This warranty shall not apply to any equipment which has been subjected to improper installation misuse misapplication negligence accident or unauthorized modification The provisions of this warranty do not extend t...

Page 15: ...ss capacity Since AutoSet displays the exact tonnage produced by each die you can avoid using large capacity presses for smaller jobs or overloading a small capacity press with too large a job Monitoring of tonnage variations allows you to detect misfeeds slug stacking misuse of stop blocks changes in material thickness and hardness broken stripper springs and broken punches in the die One operato...

Page 16: ... The Total Load LED display flashes when a fault occurs on any channel Channel Setpoints LED Display Each of these three digit LED displays shows the load limit or setpoint that has been established for the corresponding strain link On AutoSet 1500 units there are two displays on 1504 AutoSets there are four Setpoints displays on standard 1500 and 1504 AutoSets show setpoints for high tonnage Setp...

Page 17: ... Right channel setpoint LED display Screws 2 to secure cover to enclosure AutoSet 1504 WINTRISS LOAD ANALYZER PLUS Rear channel load LED displays Left and Right Rear channel setpoint LED displays Left and Right Zero cam LED Keylock DISPLAY switch Total load LED display REVERSE button Front channel setpoint LED displays Left and Right Front channel load LED displays Left and Right SETPOINTS RIGHT L...

Page 18: ...n Pressing the REVERSE button again returns the Load LED displays to forward tonnage values Keylock and Screws AutoSet 1500 and 1500 Plus The keylock enables the AutoSet enclosure to be locked and the key removed preventing unauthorized changes to settings In addition the cover can be secured to the enclosure with two Phillips screws To make settings inside the enclosure simply loosen the screws t...

Page 19: ... tolerance and percent repeatability tolerance to calculate setpoints for all dies used on the press If you want different settings used for individual dies you must change settings AutoSet displays the results of its calculations in the Setpoints LED displays on the front panel Two setpoints are shown for 1500 and 1500 Plus AutoSets four setpoints for 1504 and 1504 Plus units Only high setpoints ...

Page 20: ...Set specifications are shown in Table 1 1 Table 1 1 AutoSet Specifications Equipment System enclosure 10 25 260 4 mm x 12 304 8 mm x 4 101 6 mm NEMA 12 shock mounted Power 115 or 230 Vac 15 50 60 Hz 30 W Operating temperature 32o to 122o F 0o to 50o C Relay contact rating 4 amps 120 or 240 Vac Normally open held closed Speed to 2000 SPM Display AutoSet 1500 1500 Two 3 digit 43 10 9 mm high for ton...

Page 21: ...d setup personnel can easily see the readouts and access the RESET button or DISPLAY switch AutoSet should be installed at a height convenient for all users Strain link cables must be capable of reaching the mounting site Mounting an AutoSet Enclosure AutoSet 1500 see Figure 2 1 page 2 2 and 1504 see Figure 2 2 page 2 2 enclosures have roughly the same mounting dimensions AutoSet 1504 enclosures a...

Page 22: ... Allow sufficient clearance for opening door 4 15 105 4 12 75 323 9 12 22 310 4 4 75 120 7 On AutoSet 1500 Plus units add 0 4 in 10 2 mm for DISPLAY switch 10 60 269 2 8 00 203 2 11 69 296 9 13 50 342 9 Note Allow sufficient clearance for opening door 4 18 106 2 12 75 323 9 12 28 311 9 4 78 121 4 On AutoSet 1504 Plus units add 0 4 in 10 2 mm for DISPLAY switch 10 66 270 8 ...

Page 23: ...r console to mount the AutoSet considering the factors discussed on page 2 1 The panel mount is usually installed from outside the enclosure Be sure to allow at least 4 100 mm of clearance behind the panel mounting plane for the wiring connections 2 Cut out a hole in your enclosure or console referring to Figure 2 3 for cutout dimensions Drill and tap fourteen holes for 1 4 20 screws also referrin...

Page 24: ... 14 places YOUR PANEL Allow at least 4 100 mm clearance behind panel When wiring allow at least 9 230 mm service loop 13 50 342 9 Dimensions inches mm 12 25 311 2 12 75 323 9 10 38 263 7 9 625 244 5 8 95 227 3 3 75 95 3 4 125 104 8 0 34 8 6 0 25 6 4 11 25 285 8 7 50 190 5 0 35 8 9 8 25 209 6 0 50 12 7 AutoSet panel mount ...

Page 25: ...ure 2 4 or Figure 2 5 It should be set to 115 V the factory setting If your AutoSet will be used with 230 Vac push the switch down to the 230V position using your fingernail or a screwdriver 4 Run the power and stop circuit wires through flexible liquid tight conduit to the enclosure The AutoSet enclosure is rated NEMA 12 protected against dust and oil You must use conduit of the same rating and m...

Page 26: ...5 S106 S103 TONNAGE 100s 1s 10s S102 ZERO SET CALFACTOR 115V K101 DS109 Rx Tx DS107 DS106 XU106 5V DS110 part no 9644202 AUTOSET 4CH Version 1 67 OPERATE DS111 DS112 12V 12V F102 1 4 AMP 250VAC 4 AMP 250VAC TB105 TB106 1 2 3 4 5 6 DS101 DS102 DS103 DS108 DS104 DS105 MODE S110 Communications connector Connector for zero cam strip chart recorder etc Gain adjustment potentiometer High low gain jumper...

Page 27: ...3 0 TOL REP S104 S107 S105 S106 S103 TONNAGE 100s 1s 10s S102 ZERO SET CALFACTOR 115V K101 DS109 Rx Tx DS107 DS106 XU106 5V DS110 part no 9644202 AUTOSET 4CH Version 1 67 OPERATE DS111 DS112 12V 12V F102 1 4 AMP 250VAC 4 AMP 250VAC TB105 TB108 TB107 TB106 1 2 3 4 5 6 DS101 DS102 DS103 DS108 DS104 DS105 MODE S110 Strain link connectors Power and stop circuit connector Communications connector Conne...

Page 28: ...nect the remaining AC wires as shown in Figure 2 6 and Table 2 1 Ground wire green or green yellow should be connected to ground stud on ceiling of enclosure Figure 2 6 AC Power Connections Table 2 1 AC Power and Stop Circuit Wiring Connections TB103 Pin Label Function Wire Color 1 HI AC power Black 2 NEU AC power White 115 VAC Red 230 VAC 3 GND AC power Not used 4 GND AC power Connected to case l...

Page 29: ... not connect wires to the AC power source until you are done with all other installation procedures Also make sure you number all wires in a way consistent with your press s electrical prints A ground wire is attached from pin 4 on the TB103 connector to a case lug as shown in Figure 2 6 It is recommended that you not remove this wire while making connections but if you do make sure to reconnect i...

Page 30: ...wing steps referring to Figure 2 8 for mounting dimensions Table 2 2 Strain Link Part Numbers with Cable Length or Connector Type Part Number Standard Part Number Metric Cable Length or Connector Type 9647101 9647301 30 ft cable 9647102 9647302 100 ft cable 9647103 9647303 12 in cable with MS in line connector 9647104 9647304 60 ft cable 9647201 9647305 Hirschman connector Figure 2 8 Strain Link M...

Page 31: ...On 4 channel units strain links are mounted on all four corners 2 Sand down the frame s surface to remove all paint or plastic filler which will affect strain link readings Cast frames may need light grinding to provide a flat surface STRAIN LINKS MUST BE MOUNTED ON A FLAT SURFACE Make sure there are no imperfections ridges or cavities on the mounting surface If strain links are not mounted on a f...

Page 32: ... where they will be subjected to harsh chemicals If necessary use a cover to protect strain links DRILLING AND TAPPING FOR METRIC SCREWS If you are installing metric strain links use a 5 mm drill bit drill the hole 12 mm deep and tap with an M6X1 thread When drilling make sure the holes are at right angles to the surface The strain link will not work properly if the mounting holes are cocked or an...

Page 33: ... links drill 12 mm deep holes with a 5 mm drill bit 6 Remove the drill jig and tap the three holes Bottom tap for a 1 4 20 thread For metric strain links tap with an M6X1 thread 7 Mount the strain link loosely on the press using the four short mounting screws Figure 2 11 Strain Link Drill Jig Mounting Dimensions INSTALLING METRIC STRAIN LINKS If you are installing metric strain links the drill jig...

Page 34: ...onnector on the AutoSet processor board see Table 2 3 and allowing for a service loop inside the enclosure then cut the cable 3 Strip the outer cable 1 to 2 25 4 to 50 8 mm from the end so you can easily separate and work with individual wires then strip wires 1 4 6 4 mm from the end 4 Remove one of the strain link connectors TB105 through TB108 referring to Table 2 3 STRAIN LINKS SHOULD BE MOUNTE...

Page 35: ...train link cables repeating steps 4 through 6 Shield should be connected to ground stud on enclosure nearest entry of strain link wiring Shield should be connected to ground stud on enclosure nearest entry of strain link wiring INCORRECT WIRING CAN DAMAGE STRAIN LINKS Make sure to connect the black and red wires to the correct terminals as shown in Table 2 4 or Table 2 5 If you reverse the wiring ...

Page 36: ... and 1504 load analyzers and is required for AutoSet 1500 Plus and 1504 Plus units A latching magnetic cam switch LMCS to provide the zero signal is available from Wintriss Using a Zero Cam on Standard AutoSets A zero cam is recommended for standard AutoSet load analyzers and is required in the following cases When your press operates at speeds greater than 400 strokes per minute AutoSet cannot ze...

Page 37: ...g Magnetic Cam Switch LMCS available from Wintriss consists of the following parts A sensor mounted on a bracket with wiring for connection to the AutoSet processor board A red magnet to attach to the crankshaft or other rotating member at 240 of press rotation A blue magnet to mount at 30 of press rotation Two brass screws one for mounting each magnet To install the LMCS do the following 1 Select...

Page 38: ...n the AutoSet enclosure or to the appropriate location on your console Measure and cut the cable so it reaches TB101B or TB101A easily The AutoSet enclosure is rated NEMA 12 protected against dust and oil If you ordered the enclosure you must use conduit rated NEMA 12 and make proper conduit connections to ensure NEMA 12 protection 6 Remove the connector from the TB101B or TB101A terminal block an...

Page 39: ...ro signal is on when the Zero Cam LED is illuminated Table 2 6 LMCS Zero Cam Wiring Connections TB101B or TB101A AutoSet Model Terminal Block Pin Label Wire Color 1500 or 1500 Plus TB101B 2 Zero Cam White or clear 4 12Vdc Red 5 Ground Black 1504 or 1504 Plus TB101A 2 Zero Cam White or clear 4 12Vdc Red 10 Ground Black WIRING FOR DEVICES OTHER THAN LMCS Mechanical switches and programmable limit sw...

Page 40: ... AutoSet processor board referring to Figure 2 4 or Figure 2 5 Figure 2 14 AutoSet 1504 Processor Board Mode Switch 2 Set to ON Zero Cam Enabled The RESET button standard AutoSet or DISPLAY switch AutoSet Plus on the AutoSet front panel is still functional when a remote reset switch is connected F101 T101 HI NEU GND GND N O C TB103 TB101A P102 TB104 10 9 8 7 6 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 RIGHT F...

Page 41: ...ch strain link The AutoSet outputs for this function are 4 688 to 4 688 Vdc At 120 of press capacity output of each strain link is 4 688 Vdc Output is ratiometric so at 100 of press capacity output of each strain link is 3 907 Vdc For example for an AutoSetPAC 1504 unit with press capacity of 100 tons the output for each strain link is 3 907 Vdc at 25 tons of load 1 563 Vdc at 10 tons etc Follow t...

Page 42: ...us Typically the Setup Mode circuit is connected to the Inch position of your clutch brake control When you run the press in Inch mode AutoSet Plus does not generate a repeatability fault and stop the press To wire a Setup Mode circuit do the following 1 Open the cover of the AutoSet enclosure and locate terminal block TB101B AutoSet 1500 Plus or TB101A AutoSet 1504 Plus at the lower left of the A...

Page 43: ...nal block TB103 on the SmartPAC 2 processor board and terminal block TB104 on the AutoSet 1500 see Figure 2 4 or 1504 see Figure 2 5 processor board 2 Run the five conductor shielded communications cable through flexible liquid tight low voltage conduit from SmartPAC 2 to AutoSet If you have SmartPAC 2 and AutoSet enclosures they are rated NEMA 12 protected against dust and oil You must use Table ...

Page 44: ...on the other AutoSet identifying it as AutoSet 2 Table 2 10 Communications Wiring Connections AutoSet and SmartPAC 2 AutoSet TB104 Pin SmartPAC 2 TB103 Pin 1 GND 240 GND 2 TXD 241 RXD2 3 TXD 242 RXD2 4 RXD 243 TXD2 5 RXD 244 TXD2 Figure 2 15 AutoSet 1504 Processor Board Mode Switch 6 Set to OFF AutoSet 1 F101 T101 HI NEU GND GND N O C TB103 TB101A P102 TB104 10 9 8 7 6 5 4 3 2 1 5 4 3 2 1 5 4 3 2 ...

Page 45: ...h initialization 10 Set the capacity of your press on the Tonnage Monitor Initialization Menu and enable or disable the repeatability setpoint the startup counter and setup mode 11 Select SECURITY ACCESS on the Tonnage Monitor Initialization Menu and configure AutoSet security the way you want it 12 When you are ready to make parts go to Program mode and enter setpoint percentages and a sample per...

Page 46: ... in your SmartPAC manual d Disconnect the multi colored ribbon cable and the brown 3 conductor plug located at the right edge of the SmartPAC processor board To remove the ribbon cable push the tabs at both ends of the connector outward simultaneously To remove the brown connector squeeze the outer tabs e Remove the top board by removing the 3 nuts on the edge and the 6 spacer nuts f Replace the c...

Page 47: ... select SELECT CAM NAMES you recorded in step 2 referring to your SmartPAC user manual if necessary 12 Select TONNAGE MONITOR on the Main Initialization Menu to display the Tonnage Monitor Initialization Menu 13 Select INITIALIZE PARAMETERS on the Tonnage Monitor Initialization Menu Press ENTER when the warning message displays to confirm that you want to continue with initialization 14 Set the ca...

Page 48: ...ET position close the cover and turn power on The Load LED displays should show 0 s or other numbers The Setpoints displays should show either numbers dashes or the letters HI LO or rEP 3 If the displays are not active turn off power to the AutoSet Re check connections for power and strain links Make sure that the voltage selector switch is set correctly either 115V or 230V and that switch S102 is...

Page 49: ...rrect Tonnage page 3 15 AutoSet should be calibrated after installation and whenever Strain links are moved to a different location on the press Tie rods are restressed Major repair work is performed on the press frame Before starting calibration make sure the press is adjusted for optimal operation Check to make sure that the ram is parallel to the bed and that the gib ways adjustment and tie rod...

Page 50: ...d LED display shows a value greater than 50 the corresponding Setpoints LED display shows the message HI When a Load display is greater than 50 that Setpoints LED display shows the message LO If the strain link zero offset reading is greater than 99 the corresponding Load LED display shows in flashing letters the message HI if 99 or LO if 99 and the Setpoints LED display shows the message Err All ...

Page 51: ...you have adjusted the strain link The Setpoints LED display for the strain link will show the message Err until the zero adjustment reading has been brought within the 99 window and the unit has been reset at which time the Setpoints display will change to either HI or LO The Setpoints display will change to dashes when the zero adjustment reading has been brought within 50 Table 3 1 Strain Link P...

Page 52: ...meter to Zero Strain Links Perform the following procedure if the AutoSet LED displays cannot be used to zero strain links i e displays are too far away or are obstructed 1 On the AutoSet processor board place the leads of a voltage meter on the pins holding the white and green wires i e pins 2 and 3 in the cable from the strain link you are zeroing 2 Adjust the potentiometer screw on that strain ...

Page 53: ...ore connecting rods Load cells are placed under the connecting rods To adjust the calibration kit to display the correct tonnage applied to the load cells perform the following steps referring to Figure 3 2 page 3 6 or Figure 3 3 page 3 7 for location of components on old and new style processor boards If your AutoSet calibration kit has the current version 2 0 processor board installed refer to F...

Page 54: ... OPERATE F2 TB6 TB7 S7 7 6 5 4 3 2 1 1 2 8 7 6 5 4 9 3 0 1 2 8 7 6 5 4 9 3 0 15 STROKES ZERO CAM DISABLE DECIMAL POINT ON ON 1 STROKE ZERO CAM ENABLE DECIMAL POINT OFF OFF Honeywell part no 9644202 AUTOSET 1500 Version 1 41 HI LOW GAIN HI GAIN LOW GAIN MODE SELECTOR 1 2 8 7 6 5 4 9 3 0 1 4 3 2 O N E P Connectors for cables from calibration modules Voltage selector switch Zero Set Operate Calfactor...

Page 55: ... TB6 TB7 DS3 DS1 DS4 S10 8 7 6 5 4 3 2 1 U15 1 2 8 7 6 5 4 9 3 0 1 2 8 7 6 5 4 9 3 0 1 2 8 7 6 5 4 9 3 0 1 2 8 7 6 5 4 9 3 0 1 2 8 7 6 5 4 9 3 0 CPU NO S9 S8 1s 10s 5 6 7 8 15 STROKES ZERO CAM DISABLE DEC PT ON ON 1 STROKE ENABLE OFF OFF Honeywell part no 9644202 AUTOSET 1500 Version 1 41 S11 TB8 HI GAIN LOW GAIN HI GAIN LOW GAIN 1 4 3 2 O N E P Connectors for cables from calibration modules Volta...

Page 56: ...al indicators labelled TONNAGE S1 S4 and S5 in Figure 3 2 S3 S4 and S5 in Figure 3 3 on the right side of the AutoSet processor board Each dial indicator has an arrow you can turn using a small screwdriver to the numerical setting you want The indicator labelled 100s represents the hundreds position in the full scale tonnage setting the indicator labelled 10s represents the tens position and the i...

Page 57: ...ards The switch block on new style boards uses slightly different labels When switch 3 is in the OPEN position AutoSet LED displays include a decimal place When switch 3 is in the CLOSED position no decimal point is shown The decimal point is not active for full scale tonnage settings between 201 and 1500 tons Table 3 2 page 3 10 summarizes your tonnage display options Figure 3 4 Tonnage Dial Indi...

Page 58: ...R25 to the left of the strain link inputs at the bottom center of the enclosure A tiny screw protrudes from the upper left corner of each potentiometer as shown in Figure 3 6 14 If you are using one load cell for calibration turn the screw on gain adjustment potentiometer R17 clockwise or counterclockwise until the left channel Load LED display reads 157 2 If you are using two load cells for calib...

Page 59: ...sing 1 to 2 thick steel plates or parallels above and below the load cells to distribute the load more evenly on the bed and ram Even load distribution helps to improve calibration accuracy and linearity see Checking Linearity page 3 19 2 Bring the ram to bottom dead center BDC and turn off power to the press Use a dial indicator if necessary to make sure that the press is at 180 3 Place the load ...

Page 60: ...s which is currently being applied to the load cells connected to the calibration unit do the following 1 Open the cover of the AutoSet control enclosure and locate the three dial indicators labelled TONNAGE S103 S104 and S105 at the upper right of the AutoSet processor board see Figure 3 7 page 3 13 Each dial indicator has an arrow you can turn using a small screwdriver to the numerical setting y...

Page 61: ...tion AutoSet LED displays include a decimal place When switch 3 is in the ON position no decimal point is shown The decimal point is not active for full scale tonnage settings between 201 and 1500 tons on AutoSet 1500 and 1500 Plus load analyzers or between 401 and 3000 tons on AutoSet 1504 and 1504 Plus units Figure 3 7 AutoSet 1504 Processor Board Tonnage Dial Indicators F101 T101 HI NEU GND GND...

Page 62: ...ons OFF ON Tenths of a ton e g 5 5 55 tons 25 0 250 tons 99 9 999 tons ON OFF Whole tons e g 6 60 tons 25 250 tons 100 1000 tons F101 T101 HI NEU GND GND N O C TB103 TB101A P102 TB104 10 9 8 7 6 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 RIGHT FRONT 5 4 3 2 1 LEFT FRONT 5 4 3 2 1 RIGHT REAR 5 4 3 2 1 LEFT REAR 1 2 3 4 5 6 7 8 S101 REM RST Z CAM SETUP RESET REP SEL REV SEL J115 R144 J116 R133 J117 R161 J118 R17...

Page 63: ...s and high low gain jumpers to the left of the strain link inputs at the bottom of the AutoSet processor board see Figure 2 4 or Figure 2 5 Table 3 5 page 3 16 shows the processor board labels that identify potentiometers and jumpers for each AutoSet model Table 3 4 AutoSet 1504 and 1504 Plus Tonnage Display Formats Load Cell Tonnage Range ModeSwitch 3 Setting Decimal Point ON OFF Channel Load LED...

Page 64: ... unit Table 3 5 Gain Adjustment Potentiometer and High Low Gain Jumper Identifiers AutoSet Model Strain Link Input Connector Gain Adjustment Potentiometer High Low Gain Jumper 1500 Left TB105 R144 J115 Right TB106 R133 J116 1504 Left Rear TB105 R144 J115 Right Rear TB106 R133 J116 Left Front TB107 R161 J117 Right Front TB108 R173 J118 Figure 3 9 AutoSet 1504 Processor Board High Low Gain Jumper an...

Page 65: ...eached the 12 turn limit on the adjustment screw and you have not been able to increase the tonnage on your AutoSet so it matches the tonnage on your calibration unit you must change jumper J115 to its HI setting To do so Power down the AutoSet Remove the jumper from the two lower pins and place it over the two upper pins see Figure 3 9 Power up the AutoSet Cycle the press to display a tonnage rea...

Page 66: ...settings for your AutoSet 11 Record the calfactor and high low gain jumper setting for each strain link channel on your AutoSet two pairs of settings for AutoSet 1500 four pairs of settings for AutoSet 1504 If you need to replace a processor board you can use these settings to calibrate the new board without repeating the lengthy calibration process documented here Simply set switch S102 to CALIBR...

Page 67: ...linearity change the load on the press For instance if you calibrated AutoSet at 75 of press capacity reduce the load on the load cells to about 45 If you calibrated at 50 decrease the load to about 30 When you compare the new load readings on the AutoSet with the load displays on the calibration unit readings should continue to be identical If tonnage readings on the AutoSet and calibration unit ...

Page 68: ... Setpoints LED display s for the out of range strain link s and that the tonnage values flash in the Load LED display s on the affected channels 5 If AutoSet displays a message but the press does not top stop there is a problem in your top stop circuit Recheck all wiring and trace the cause of the problem Do not continue with this procedure until the press top stops when you trip the high tonnage ...

Page 69: ...s setpoints automatically based on settings you make on the AutoSet processor board On standard AutoSet units you make two settings sample period and percent high tolerance On AutoSet Plus models you make three settings sample period percent high tolerance and percent repeatability tolerance The sample period is the number of strokes during which AutoSet collects tonnage information for calculatin...

Page 70: ...et to 15 the percent repeatability tolerance to 5 and the sample period to 15 strokes The DISPLAY switch is turned to the RESET position and held for at least two seconds to initiate the setpoint calculation process The Setpoints displays on the AutoSet front panel change to 60 0 tons each i e 120 of 50 tons which is the full scale tonnage for each corner of the press Then the press is run for 15 ...

Page 71: ...bility tolerance setting On AutoSet 1500 Plus and 1504 Plus units both high and repeatability setpoints are active while the press is running regardless of the DISPLAY switch setting Setpoints can be recalculated even when the press is running AutoSet uses the settings you specify for percent high tolerance and percent repeatability tolerance to calculate setpoints for all dies used on the press I...

Page 72: ... or On AutoSet Plus units turn the DISPLAY switch on the front panel to the RESET position and hold it for at least two seconds until the Setpoints displays flash and the setpoint readings change to 120 of full scale tonnage A new sample period will be initiated the next time you run the press Figure 4 2 AutoSet 1504 Processor Board Mode Switch 1 Set to OFF 15 Stroke Sample Period F101 T101 HI NEU...

Page 73: ...tting for your standard AutoSet or AutoSet Plus unit refer to Determining the Correct High Tolerance Setting Standard AutoSet page 4 8 or Determining the Correct High Tolerance and Repeatability Settings AutoSet Plus page 4 9 Figure 4 3 AutoSet 1504 Plus Processor Board Percent High Tolerance Dial F101 T101 HI NEU GND GND N O C TB103 TB101A P102 TB104 10 9 8 7 6 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 RIGHT...

Page 74: ...nclosure and locate the REP indicator dial labelled S106 at the upper right of the AutoSet processor board see Figure 4 4 page 4 7 Table 4 1 Percent High Tolerance Selector Settings Numeric Setting on Dial High Tolerance Percent 1 2 2 5 3 10 4 15 5 20 6 25 7 35 8 50 9 100 0 Disable setpoints DISABLING SETPOINT CALCULATION When the TOL indicator dial is set to 0 the high setpoint calculation functi...

Page 75: ...lity Percent 1 1 2 2 3 3 4 5 5 7 6 10 7 15 8 25 9 50 0 Disable setpoints F101 T101 HI NEU GND GND N O C TB103 TB101A P102 TB104 10 9 8 7 6 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 RIGHT FRONT 5 4 3 2 1 LEFT FRONT 5 4 3 2 1 RIGHT REAR 5 4 3 2 1 LEFT REAR 1 2 3 4 5 6 7 8 S101 REM RST Z CAM SETUP RESET REP SEL REV SEL J115 R144 J116 R133 J117 R161 J118 R173 0 4 6 2 8 0 4 6 2 8 1 2 8 7 6 5 4 9 3 0 1 2 8 7 6 5 4 ...

Page 76: ...n the press is restarted The Setpoints displays flash and the setpoint readings change to values that are 120 of the full scale tonnage of the press 3 If you are operating in Continuous mode start and run the press until the sample period is completed and AutoSet displays new values in the Setpoints displays then run the press for an additional 20 strokes DISABLING SETPOINT CALCULATION When the RE...

Page 77: ...re the cause of the press stopping turn the TOL indicator dial back to its previous position This is the correct setting for the job c If AutoSet does not stop the press turn the TOL indicator dial to the next lower position and repeat steps 2 and 3 d If AutoSet stops the press repeat step 5b If AutoSet does not stop the press repeat step 5c Determining the Correct High Tolerance and Repeatability...

Page 78: ...onal 20 strokes If you are operating in Single stroke mode start and cycle the press until the sample period is completed and AutoSet displays new values in the Setpoints displays then cycle the press for a few additional strokes High tonnage setpoints are displayed when the DISPLAY switch is turned to the HIGH position Repeatability setpoints are displayed when the DISPLAY switch is turned to the...

Page 79: ...ty and high tonnage fault indicated by a flashing channel Load display and the abbreviations rEP and HI appearing alternately in the corresponding Setpoints display do the following a Establish that the press stopped due to low setpoints by checking for malfunctions such as a stuck part load imbalance misfeed etc b If the press stopped because repeatability and high tonnage setpoints were too low ...

Page 80: ... established setpoint percentages for high tonnage standard AutoSet or for high tonnage and repeatability AutoSet Plus on one die you can use these settings for all other dies you run on the press There may be situations however in which you will want to change setpoint percentages For example you may want to create tighter setpoints for some jobs to provide greater protection for the press on oth...

Page 81: ...s displays show high tonnage setpoints if the DISPLAY switch is turned to the HIGH position and repeatability setpoints if the DISPLAY switch is turned to the REPEATABILITY position Displaying Reverse Load AutoSet Plus Only AutoSet 1500 Plus and 1504 Plus load analyzers enable you to display reverse tonnage To do so perform the following step 1 On the AutoSet front panel press the REVERSE button A...

Page 82: ...Set Plus units turn both the TOL and REP indicator dials to zero 0 see Setting the Percent Repeatability Tolerance AutoSet Plus Only page 4 6 Figure 4 6 AutoSet 1504 Processor Board Mode Switch 7 Set to ON 2 Ch Operation Wintriss does not recommend the disabling of AutoSet Disabling the load analyzer may result in damage to the press and tooling F101 T101 HI NEU GND GND N O C TB103 TB101A P102 TB1...

Page 83: ...re 120 of press capacity Turning Off and Restoring Power When power to the AutoSet is turned off Load and Setpoints LED readings are lost However since calibration and full scale tonnage settings are intact AutoSet will display correct Load and Setpoints values when power is restored and setpoints recalculated When power is first restored the Load displays will read zero and the Setpoints displays...

Page 84: ...1137200 AutoSet User Manual 4 16 Operation ...

Page 85: ...e fault with the RESET button standard AutoSet or DISPLAY switch AutoSet Plus make sure to determine whether the fault was simply a nuisance stop or was caused by an actual press or die malfunction If the fault was the result of a nuisance stop you need to reset the percent high tolerance dial all AutoSet models percent repeatability dial AutoSet Plus units only or both dials AutoSet Plus units on...

Page 86: ...scribed below High Tonnage Faults AutoSet displays a high tonnage fault when the tonnage on one or more strain link inputs exceeds the high tonnage setpoint A high tonnage fault is indicated on the front panel as follows see Figure 5 1 HOLD THE RESET BUTTON OR DISPLAY SWITCH FOR LESS THAN TWO SECONDS If you press the RESET button standard AutoSet or hold the DISPLAY switch at the RESET position Au...

Page 87: ...AutoSet 1504 and 1504 Plus units the Total LED display flashes High Setpoint and Repeatability Faults AutoSet displays both high tonnage and repeatability faults when tonnage on one or more strain link inputs exceeds the high tonnage setpoint and stroke to stroke tonnage variation on one or more strain links exceeds the repeatability setpoint High tonnage and repeatability faults are indicated sim...

Page 88: ...ge Err flashes in the Setpoints display s for each strain link channel at fault The message HI or LO flashes in the corresponding Load display On AutoSet 1504 and 1504 Plus units the message Err flashes in the Total LED display To correct the problem Check wiring of the strain link s on the affected channel s Rewire if necessary Check mounting of the strain link If the strain link has loosened rem...

Page 89: ...ys do the following Check to see whether you have power referring to Powering Up AutoSet page 2 28 Also check to see whether power is present on both sides of fuse F102 on the AutoSet processor board see Figure 2 4 or Figure 2 5 Check the wiring of the strain links Refer to Wiring Strain Links page 2 14 If you are still having difficulty contact Wintriss Tech Support Figure 5 4 AutoSet 1504 Plus F...

Page 90: ...mounting and wiring of the corresponding strain link s were performed correctly Verify that the strain links are mounted on a flat clean surface and are wired correctly See Installing Strain Links page 2 10 Tonnage Shown in Load LED Displays Is Too Low If the tonnage shown in one or more Load LED displays is lower than you think it should be do the following New Installation or Calibration Check t...

Page 91: ...riss Tech Support for assistance Reset Repeatability Select and Reverse Select LEDs These three red LEDS are located just beneath the Mode switch block S101 on the left side of the AutoSet processor board and are labelled Reset DS101 Rep Sel DS102 and Rev Sel DS103 On AutoSet Plus units these LEDs indicate whether the DISPLAY switch and REVERSE button on the front panel are working properly On sta...

Page 92: ... power connections at TB103 If input power connections check out and all three LEDs are still unlit call Wintriss Tech Support Also contact Wintriss Tech Support when only one or two LEDs are unlit Relay Status LED The LED labelled DS109 located just below the solid state output relay K101 at the top right of the AutoSet processor board indicates the status of the K101 relay When the relay is ener...

Page 93: ...ound stud on enclosure nearest entry of strain link wiring Table A 1 AC Power and Stop Circuit Wiring Connections TB103 Pin Label Function Wire Color 1 HI AC power Black 2 NEU AC power White 115 VAC Red 230 VAC 3 GND AC power Not used 4 GND AC power Connected to case lug 5 N O Stop circuit N A 6 C Stop circuit N A Table A 2 Strain Link Wiring Connections TB105 TB108 Tension Pin Wire Color Function...

Page 94: ...d Settings are OFF 15 strokes ON 1 stroke 2 Zero Cam Enable Disable Enables and disables the zero cam function Settings are OFF Disable Zero Cam ON Enable Zero Cam 3 Decimal Point On Off Indicates whether a one position decimal point e g 55 5 is used in tonnage displays Settings are OFF Decimal point on ON Decimal point off 4 Unused 5 Setup Mode Enable Disable Enables or disables the Setup Mode ci...

Page 95: ... stops the the press only when the load exceeds 120 of the full scale tonnage Table A 6 Percent High Tolerance Selector S107 Settings Numeric Setting on Dial High Tolerance Percent 1 2 2 5 3 10 4 15 5 20 6 25 7 35 8 50 9 100 0 Disable setpoints Table A 7 Percent Repeatability Selector S106 Settings Numeric Setting on Dial Repeatability Percent 1 1 2 2 3 3 4 5 5 7 6 10 7 15 8 25 9 50 0 Disable setp...

Page 96: ...1137200 AutoSet User Manual A 4 Wiring and Settings Tables ...

Page 97: ...xceeded causing unnecessary press shutdowns reference tonnage The highest tonnage measured by AutoSet during the sample period repeatability setpoint The limit in tonnage variation from one stroke to the next above which AutoSet generates a repeatability fault stopping the press and displaying a fault message AutoSet calculates the repeatability setpoint by multiplying the percent repeatability to...

Page 98: ...s on at approximately 240 and turns off at 30 The zero cam signal zeroes or clears the tonnage reading on each stroke and prevents AutoSet from registering tonnage events within the zero cam window Zero cam ensures that AutoSet records only tonnage that occurs at the bottom of the stroke ...

Page 99: ...r AutoSet 3 12 G gain potentiometers adjusting on AutoSet 1500 calibration kit 3 10 adjusting on your AutoSet 3 17 H high low gain jumper changing the setting on your AutoSet 3 17 L latching magnetic cam switch LMCS installing 2 17 wiring connections 2 19 LEDs processor board using to troubleshoot 5 7 linearity checking 3 19 LMCS See latching magnetic cam switch load displays 1 2 M Mode switches S...

Page 100: ...ecifications 1 6 stop circuits wiring 2 5 strain links models available from Wintriss 2 10 mounting 2 10 wiring 2 14 zeroing 3 1 switch See Mode switches S101 T tension mounting strain links to measure 2 11 2 12 strain link wiring connections for 2 15 A 1 tonnage dials setting full scale tonnage on the AutoSet 1500 calibration kit 3 9 setting full scale tonnage on your AutoSet 3 13 troubleshooting...

Page 101: ...ace Electrocraft Wintriss DA71417 DA71443 Servofeed Interface Indramat Wintriss DA71418 DA71443 Servofeed Interface ProCam DA71431 DA71447 Servofeed Interface SmartPAC DA71420 DA71443 Servofeed Interface Waddington Wintriss DA71419 DA71443 SFC Machine Interface SMI N A 1140800 Shadow 8 Safety Light Curtain N A 1139300 Shadow V Safety Light Curtain DA71433 DA71449 Shadow VI Safety Light Curtain DA7...

Page 102: ...1137200 AutoSet User Manual Wintriss Manuals ...

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