Wintriss AutoSet PAC 120 VAC User Manual Download Page 4

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Summary of Contents for AutoSet PAC 120 VAC

Page 1: ... 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 DA46021 AutoSet PAC Wintriss Load Analyzer A SmartPAC Module 1101600 Rev N December 2018 ...

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Page 3: ...ision of the AutoSetPAC user manual covers AutoSetPAC software version 2 28 and higher The changes include Addition of SmartPAC PRO installation usage information and wiring diagrams 8 12 AutoSetPAC 1500 and 1504 references changed to 2 channel and 4 channel respectively ...

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Page 5: ...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 7: ...Signal to SmartPAC 2 or SmartPAC PRO 48 Connecting Communications Wiring to SmartPAC 2 or SmartPAC PRO 50 Wiring an Oscilloscope Optional 51 Connecting AC Wires to Power Source 53 Connecting a New AutoSetPAC to Original SmartPAC 53 Connecting an AutoSet to SmartPAC 54 Connecting AutoSet to SmartPAC Pro or SmartPAC 2 54 Connecting an AutoSet to Original SmartPAC 56 Powering Up AutoSetPAC 57 Install...

Page 8: ...age History for a Selected Strain Link Input 115 Viewing History for the Total Strain Link Tonnage 118 Clearing Tonnage History 119 Recalculating Setpoints 119 Viewing Reverse Tonnage 120 Loading a New Tool 121 Chapter 6 Troubleshooting 123 Responding to AutoSetPAC Faults 123 Setpoint Faults 125 Offset Errors 126 Troubleshooting Common AutoSetPAC Problems 127 Glossary 129 Index 131 Wiring Diagrams...

Page 9: ...try Window Displayed 67 Figure 3 8 Numeric Entry Window Superimposed on Tonnage Monitor Initialization Menu 69 Figure 3 9 Security Access Menu with Load Monitor Setting Highlighted 70 Figure 3 10 COMMUNICATIONS Item on Diagnostic Menu in Initialization Mode 71 Figure 3 11 Communication Data Viewer Screen 71 Figure 3 12 Communications Transmit Receive Screen 72 Figure 3 13 Calibration Screen Curren...

Page 10: ...18 Tool Loading Message 122 Figure 6 1 AutoSetPAC Tonnage Fault Message High Setpoint Exceeded 123 List of Tables Table 1 1 Original SmartPAC and SmartPAC 2 Panel Features 22 Table 1 2 SmartPAC PRO Panel Features 24 Table 1 3 AutoSetPAC Specifications 27 Table 2 1 AutoSetPAC AC Power and Stop Circuit Wiring Connections TB103 40 Table 2 1 AutoSetPAC 24 VDC Power Wiring Connections TB109 40 Table 2 ...

Page 11: ...onnage Monitor Programming Menu Settings 99 Table 5 1 Tonnage History Information for Each Strain Link Input 117 Table 5 2 Tonnage History Information for Total Tonnage 118 Table 6 1 Common Causes of Tonnage Faults 124 Table 6 2 Setpoint Faults Possible Causes 126 ...

Page 12: ...12 Table of Contents ...

Page 13: ...librate AutoSetPAC Chapter 4 shows you how to establish AutoSetPAC setpoint percentages and a sample period for each tool in SmartPAC Program mode Chapter 5 shows you how to view and adjust programmed AutoSetPAC settings in SmartPAC Run mode Chapter 6 shows you how to respond to AutoSetPAC faults and troubleshoot common AutoSetPAC problems The Glossary provides definitions of some of the terms use...

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Page 15: ...ided 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 CAUTION A CAUTION symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTICE A NOTICE symbol indicates important information that you should remember including tips to aid you in perfo...

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Page 17: ... subjected to improper installation misuse misapplication negligence accident or unauthorized modification The provisions of this warranty do not extend the original warranty of any product which has either been repaired or replaced by Wintriss Controls No other warranty is expressed or implied Wintriss accepts no liability for damages including any anticipated or lost profits incidental damages c...

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Page 19: ...d the instructions on the display and the labels for the function keys This manual shows original SmartPAC screens SmartPAC 2 and SmartPAC PRO screens are similar The menu organization is the same on all versions Chapter 2 gives instructions for installing AutoSetPAC on a SmartPAC Refer to the appropriate wiring diagrams at the end of the manual Chapters 3 through 6 tell how to initialize program ...

Page 20: ...s when these and other malfunctions are detected Diagnoses tool wear by monitoring tonnage increases as a die is re used This enables you to schedule repairs to dies and punches resulting in more efficient use of the press faster parts production and higher quality parts In addition SmartPAC keeps track of the number of hits on the tool being run helping you determine when the die requires mainten...

Page 21: ...ve labels on or next to the function keys before you press an F key NOTICE On many screens you can press the HELP or key see Figure 1 1 and Figure 1 2 to display instructions showing you how to use the screen If you need additional help using AutoSetPAC with SmartPAC SmartPAC 2 or SmartPAC PRO refer to the appropriate manual 1 4 7 2 3 5 6 8 9 0 CLEAR Contrast CURSOR INTERRUPTED STROKE BRAKE WARNIN...

Page 22: ...Number keys are used with the display to make settings Cursor keys Enable you to select a display item with the highlight bar Also allow you to select alphabetic characters and special symbols when naming the press tools cam channels and sensors Number keys Enable you to input numeric values such as counter presets or tool numbers Function keys Eight keys labelled F1 to F8 that perform specific ta...

Page 23: ...n with on screen buttons to enable you to navigate through its menus and make setting for your tools In addition SmartPAC PRO utilizes several different on screen keypads for entering alpha numeric data or to navigate through certain legacy screens using cursor arrow keys These keypads are described below in Table 1 2 NOTICE You may plug a USB keyboard into the USB port on the front panel of the S...

Page 24: ...disabled The keypad value must be entered or cancelled before you can access any other buttons on the screen On Screen Keyboard Whenever you select a field that requires the input of a combination of letters symbols and or numbers SmartPAC PRO displays its on screen keyboard The backspace key will clear the value The Cancel key will close the numeric keypad without making any changes and the Enter...

Page 25: ...the on screen navigation highlight to increment and decrement numeric values and to set the on and off angles for programmable limit switch outputs and die protection ready signals Strain Links AutoSetPAC receives its tonnage information from strain links which are mounted to the press frame or other structural members and wired to the load analyzer Strain links measure the forces acting on the pr...

Page 26: ...shown for two channels on AutoSetPAC 2 Channel load analyzers and for four channels on AutoSetPAC 4 Channel units During the sample period setpoints are maintained at 120 of the full scale capacity of the press to provide overload protection NOTICE AUTOSETPAC SETPOINTS NEVER EXCEED 120 AutoSetPAC will not create setpoints greater than 120 of the full scale capacity of the press AutoSetPAC calculat...

Page 27: ...PM Setpoints High low and repeatability setpoints for peak forward load stored with each tool number High limit for reverse load based on press capacity Optional display Two or four 3 digit 43 10 9 mm high for tonnages Two or four 3 digit 30 7 6 mm high for setpoints One 4 digit 43 10 9 mm high for total tonnage AutoSetPAC 4 Channel display only Strain links Size Cable Two AutoSetPAC 2 Channel or ...

Page 28: ...1101600 AutoSetPAC User Manual 28 Chapter 1 Installation ...

Page 29: ...PAC Enclosure with AutoSet 2 Channel 4 Channel Display 31 Installing the AutoSetPAC Panel Mount 32 Installing the AutoSetPAC Processor Board 85 to 264 Vac Version No Enclosure 34 Installing the AutoSetPAC Processor Board 24 Vdc Version 35 Connecting AC and Stop Circuit Wiring 36 Installing Strain Links 41 Mounting Strain Links 42 Wiring Strain Links 46 Connecting the Zero Cam Signal to SmartPAC 2 ...

Page 30: ... Determine a convenient mounting location considering the following factors Strain link cables must be capable of reaching the mounting site The mounting location must allow enough room for the door to open at least 120 The enclosure can be mounted to the press or on a free standing pedestal 2 Drill holes for mounting referring to Figure 2 1 Tap holes and mount the enclosure using the enclosed sho...

Page 31: ...p personnel can easily see the readouts Strain link cables must be capable of reaching the mounting site The mounting location must allow enough room for the door to open at least 120 The enclosure can be mounted to the press or on a free standing pedestal 2 Drill holes for mounting referring to Figure 2 1 AutoSet 2 Channel and standard AutoSetPAC enclosures have identical dimensions and Figure 2 ...

Page 32: ...onnections 1 Determine a convenient location within your enclosure to mount the AutoSetPAC Ideally AutoSetPAC should be mounted close to the SmartPAC where operators and setup personnel can easily see the readouts and reach the keyboard NOTICE MOUNT AUTOSETPACPAC AT A CONVENIENT HEIGHT AutoSetPAC should be installed at a height convenient for all users Experiment with placement to determine a good...

Page 33: ...two of the left holes in the panel to the corresponding holes in the unit creating a hinge 4 Perform wiring connections as shown in the following sections Make sure all cables will reach the connectors on the panel mount allowing at least 9 of service loop 5 When the final checkout has been completed see Final Checkout page 92 install the AutoSetPAC panel mount in the enclosure using fourteen 1 4 ...

Page 34: ...hin your enclosure in which to mount the AutoSetPAC board allowing enough room for installation and maintenance of the board 2 Mount the board using the eight 8 standoffs provided referring to Figure 2 4 for mounting dimensions Figure 2 4 shows the AutoSetPAC 4 Channel board Dimensions of the 2 Channel board are identical Standoffs are 6 32 and 1 2 long Recommended screw size is 6 32 x 3 8 Figure ...

Page 35: ...g 1 Determine a convenient accessible location in which to mount the board allowing enough room for installation and maintenance 2 Mount the board using the four 4 standoffs provided referring to Figure 2 5 for mounting dimensions Standoffs are 6 32 and 1 2 in long Recommended screw size is 6 32 x 3 8 in Figure 2 5 AutoSetPAC Processor Board 24 Vdc Version Mounting Dimensions ...

Page 36: ...herwise SmartPAC cannot stop the press if AutoSetPAC detects a tonnage fault Wintriss recommends you connect AutoSetPAC to the top stop rather than to the E stop circuit of your press to prevent the press from sticking on the bottom if an overload occurs Top stop circuits are active only in Continuous automatic operations on most press controls If overload protection is required during Inch or Sin...

Page 37: ... 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 115V K101 Rx Tx XU106 5V DS111 DS112 12V 12V F102 1 4 AMP 250VAC 4 AMP 250VAC TB105 TB106 6 5 4 3 2 1 DS108 DS104 DS105 MODE S110 P102 Power and stop circuit connector Strain link connectors Communications connector Gain adjustment potentiometer High low gain jumper Connector for zero cam and osci...

Page 38: ...EAR 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 115V K101 Rx Tx XU106 5V DS111 DS112 12V 12V F102 1 4 AMP 250VAC 4 AMP 250VAC TB105 TB108 TB107 TB106 6 5 4 3 2 1 DS108 DS104 DS105 MODE S110 P102 Power and stop circuit connector High low gain jumper Gain adjustment potentiometer Communications connector Connector for zer...

Page 39: ...he wire into the hole and tighten the screw to pin the wire in place Figure 2 8 AC Power Connections 6 Remove the connector from terminal block TB103 at the top right of the AutoSetPAC processor board and connect the remaining AC wires as shown in Figure 2 8 and Table 2 1 page 40 NOTICE A ground wire is attached from pin 4 on the TB103 connector to a case lug as shown in Figure 2 8 It is recommend...

Page 40: ...AutoSetPAC 24 VDC Power Wiring Connections TB109 Pin Label Wire Color 1 24 RED 2 GND WHITE Table 2 3 AutoSetPAC 24 VDC Stop Circuit Wiring Connections TB103 Pin Label Wire Color 3 STOP N A 4 STOP N A 7 Connect the press control stop circuit wires to the TB103 connector as shown in Table 2 1 Either wire can be connected to either pin NOTICE WIRING FOR WINTRISS CLUTCH BRAKE CONTROL If you are wiring...

Page 41: ...stent with your press s electrical prints ELECTRIC SHOCK HAZARD Do not connect AC wires to the power source until all other installation procedures have been completed Failure to comply with these instructions could result in death or serious injury Installing Strain Links Two AutoSetPAC 2 Channel or four AutoSetPAC 4 Channel differential strain links are provided with your AutoSetPAC load analyze...

Page 42: ...ure compression see Figure 2 10 The rear mounting option is often preferred because the strain links are away from the work area On straight side presses strain links are typically mounted on both front and rear they measure tension or stretching of the frame On 2 channel AutoSetPACs strain links are mounted diagonally for example one on the left front one on the right rear see Figure 2 11 On 4 ch...

Page 43: ...cult or impossible to zero Irregular surfaces also cause inaccurate tonnage readings Use caution when determining an appropriate location for each strain link Do not mount any strain link on the press column above or below a hole 1 in diameter or larger Avoid mounting strain links inside the die area where they will be subjected to harsh chemicals If necessary use a cover to protect strain links F...

Page 44: ...a 5 mm drill bit drill the hole 12 mm deep and tap with an M6X1 thread NOTICE 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 angled 3 Mount the drill jig supplied with the strain links see Figure 2 12 for mounting dimensions first aligning the large hole in the jig with the mounting hole you have just ...

Page 45: ...oles Drill the holes 1 2 deep using a No 7 drill bit 5 Remove the drill jig and tap the three holes Bottom tap for a 1 4 x 20 thread 6 Mount the strain link loosely on the press using the four shorter mounting screws NOTICE STRAIN LINKS SHOULD BE MOUNTED LOOSELY Do not tighten the screws on the strain links The strain links are tightened down during the strain link zeroing procedure see Zeroing St...

Page 46: ...ock Connector Strain Link Connections AutoSetPAC 2 Channel Strain Link Connections AutoSetPAC 4 Channel TB105 Left Left Rear TB106 Right Right Rear TB107 Not used Left Front TB108 Not used Right Front 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 connecto...

Page 47: ...ing Connections TB105 TB108 Compression Pin Wire Color Function 1 Unused 2 White Input 3 Green Input 4 Black Ground 5 Red Exc Shield should be connected to ground stud on enclosure nearest entry of strain link wiring 6 When you have finished wiring the connector plug it back into the terminal block from which you removed it The connector goes in only one way Double check connections 7 Wire the rem...

Page 48: ...m window The zero cam ensures that AutoSetPAC records press tonnage occurring near the bottom of the stroke and not tonnage events associated with the beginning or end of the stroke The zero cam window also enables AutoSetPAC to determine what proportion of the tonnage recorded on each stroke is being produced by expansion of the press frame as the press heats up during the day and to correct the ...

Page 49: ...AC 4 Channel board see Figure 2 7 CAUTION DO NOT combine low and high voltage wiring in the same conduit Failure to comply with these instructions could result in property damage 2 Run the single conductor zero cam wiring through flexible liquid tight low voltage conduit from SmartPAC to AutoSetPAC If you have SmartPAC and AutoSetPAC enclosures they are rated NEMA 12 protected against dust and oil...

Page 50: ...TB6 Pin Signal SmartPAC 2 TB103 Pin Signal BLK 1 SHLD 1 SHLD 240 GRD 240 GRD ORG 2 TXD 2 TXD 241 RXD2 241 RXD2 BRN 3 TXD 3 TXD 242 RXD2 242 RXD2 RED 4 RXD 4 RXD 243 TXD2 243 TXD2 GRN 5 RXD 5 RXD 244 TXD2 244 TXD2 120 VAC Figure 1 or 8 Figure 2 or 9 Figure 8 or 9 Figure 1 or 2 24 VDC Figure 7 or 12 Figure 6 or 11 Figure 11 or 12 Figure 6 or 7 2 Run the five conductor shielded communications cable t...

Page 51: ...each strain link is 3 907 Vdc For example for an AutoSetPAC 4 Channel 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 these steps to connect an oscilloscope 1 Locate terminal block TB101B 120 VAC AutoSetPAC 2 Channel or TB101 A 120 VAC AutoSetPAC 4 Channel on the AutoSetPAC processor board referring to Figure 2 6 ...

Page 52: ... Block Pin Label 2 Channel TB101 1 Channel 1 Left Rear 2 Channel 2 Right Rear 3 no connection 4 no connection 5 Ground 4 Channel TB101 1 Channel 1 Left Rear 2 Channel 2 Right Rear 3 Channel 3 Left Front 4 Channel 4 Right Front 5 Ground Refer to Connecting AC and Stop Circuit Wiring page 36 if you need help connecting the wires to the terminals Make sure not to wire the connector backwards 4 Plug t...

Page 53: ... time limits on the Set Brake Monitor screen in Initialization mode Also record the cam channel names shown on the Cam Channel Name Menu in Initialization before changing the firmware Refer to your SmartPAC manual for assistance 3 Power down SmartPAC 4 Replace the SmartPAC firmware if necessary referring to the SmartPAC user manual If you have a panel mount do not replace the firmware or character...

Page 54: ...u recorded in step 2 Refer to your SmartPAC user manual 9 When you are finished proceed with initialization and calibration of your AutoSetPAC 10 Return the obsolete SmartPAC firmware board to Wintriss When you are ready to make parts go to Program mode see Chapter 4 and enter setpoint percentages and a sample period setting for each tool that was programmed previously Connecting an AutoSet to Sma...

Page 55: ...eath the power transformer T101 at the top of the AutoSet processor board see board drawings in AutoSet user manual 5 Note that the semi circular notch on the firmware chip faces to the left When replacing the chip make sure that the notch on the new chip also faces to the left 6 If you have not installed a zero cam switch and wired a zero cam input to your AutoSet wire the SmartPAC zero cam outpu...

Page 56: ...irmware 2 If you must replace SmartPAC firmware be sure to record the settings for start and stop time limits on the Set Brake Monitor screen in Initialization mode Also record the cam channel names shown on the Cam Channel Name Menu in Initialization before changing the firmware Refer to your SmartPAC manual for assistance 3 Perform steps 3 through 6 in Connecting a New AutoSetPAC to Original Sma...

Page 57: ...channel names select SELECT CAM NAMES you recorded in step 2 Refer to your SmartPAC user manual if necessary 9 Select TONNAGE MONITOR on the Main Initialization Menu to display the Tonnage Monitor Initialization Menu 10 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 11 Se...

Page 58: ...side the enclosure s All power to the press press control and other equipment used with the press must be off when you work inside the enclosure Remove all fuses and tag out per OSHA 1910 147 Control of Hazardous Energy Lockout Tagout Ensure that this procedure is performed by qualified personnel Failure to comply with these instructions could result in death or serious injury NOTICE YOU MAY ALSO ...

Page 59: ...lign pins correctly with the socket before plugging chip in Failure to comply with these instructions could result in property damage 6 Plug the chip into its socket inserting the left row of pins first then aligning the right row of pins over the socket and pushing them in Make sure that the notch in the chip faces left and that all of the pins are in the socket NOTICE If the two rows of pins are...

Page 60: ...splays contact Wintriss Tech Support 8 Access the List of Installed Options screen in SmartPAC Initialization referring to your SmartPAC manual if necessary AutoSetPAC should be displayed in the options list along with its new firmware version number for example V2 00 9 If AutoSetPAC appears in the list you have completed installation of your new firmware successfully 10 If AutoSetPAC is not in th...

Page 61: ...bration Kit 77 Setting Up and Adjusting the Calibration Kit 77 Applying Full scale Tonnage to the Calibration Kit 84 Setting Full scale Tonnage on Your AutoSetPAC 85 Adjusting AutoSetPAC To Read the Correct Tonnage 87 Checking Linearity 91 Final Checkout 92 NOTICE SmartPAC refers to original SmartPAC SmartPAC 2 and SmartPAC PRO unless otherwise indicated NOTICE REFER TO YOUR SMARTPAC USER MANUAL I...

Page 62: ...and 7 settings are shown in Table 3 1 Figure 3 1 Switch Block S101 Default Settings Shown Table 3 1 Switch Block S101 Settings S101 Switch Number Setting 1 Unused 2 Unused 3 Unused 4 Unused 5 Unused 6 OFF Default Identifies an AutoSetPAC as a single unit connected to SmartPAC or as the first of two connected AutoSetPACs If a second AutoSetPAC is connected switch 6 on that unit must be set to ON ON...

Page 63: ...ting modes with the Program Run key make sure that SmartPAC is displaying the top level screen in the current mode i e Main Program Menu or Main Run Menu To return to the top level menu press RESET or EXIT repeatedly To access the Initialization Menu on original SmartPAC SmartPAC 2 or SmartPAC PRO do the following Access Original SmartPAC or SmartPAC 2 Initialization Menu 1 Turn the Program Run ke...

Page 64: ...1101600 AutoSetPAC User Manual 64 Chapter 3 Initialization and Calibration Figure 3 2 SmartPAC 2 Main Initialization Menu Figure 3 3 SmartPAC PRO Initialization Menu ...

Page 65: ...meters page 68 Setting Reverse Setpoint of Press Capacity page 68 Instructions for setting press capacity are provided in Setting Full scale Tonnage on Your AutoSetPAC page 85 To make calibration settings refer to Adjusting AutoSetPAC To Read the Correct Tonnage page 87 Initializing Parameters Before making Initialization settings you must initialize AutoSetPAC This action clears all current Initi...

Page 66: ...enu allows you to change the default names for AutoSetPAC s strain link channels If you have an AutoSetPAC 2 Channel load analyzer two input names can be set If you have an AutoSetPAC 4 Channel unit you can set four input names To change the Input Name defaults do the following 1 Select SET INPUT NAMES to display the Load Monitor Input Name Menu see Figure 3 6 page 67 Default input names are as fo...

Page 67: ... the directions in the window to key in the name you want The name can be any combination of alphabetic characters numbers and symbols To key in letters use the Up Down Left and or Right cursor keys to highlight each letter then press ENTER to select it To key in numbers press the desired selection on the numeric keypad and press ENTER To clear an entry press the CLEAR key To accept your selection...

Page 68: ... a Setup Mode circuit in SmartPAC see Chapter 2 in your SmartPAC user manual No special wiring is required if your AutoSetPAC is being used with SmartPAC integrated with WPC 2000 The high setpoint does not appear on this screen because the high setpoint cannot be disabled To enable or disable one of these items do the following 1 Press ENTER with the cursor resting in the desired field until the s...

Page 69: ...de Actions You can prevent unauthorized personnel from recalculating setpoints or making adjustments to setpoint percentages in Run mode To do so you lock out these capabilities from Run mode on the Security Access Menu and remove the Program Run key when SmartPAC is switched to Run mode When setpoint recalculation and adjustment capabilities are locked out of Run mode they are still functional in...

Page 70: ...setpoints 3 When the setting you want is displayed press RESET You are returned to the Main Initialization Menu NOTICE LOCKING OUT OTHER FUNCTIONS Refer to Chapter 4 in the SmartPAC user manual for information on locking out other functions on the Security Access Menu NOTICE LOCKING RESET MODE If you want to prevent tonnage faults and other errors from being reset in Run mode you can set the RESET...

Page 71: ... Initialization Menu see Figure 3 2 to display the Diagnostic Menu Figure 3 10 COMMUNICATIONS Item on Diagnostic Menu in Initialization Mode 2 Select COMMUNICATIONS on the Diagnostic Menu to display the Communication Data Viewer screen shown in Figure 3 11 Figure 3 11 Communication Data Viewer Screen 3 Press the F1 function key on the Communication Data Viewer screen to change the F1 label from Co...

Page 72: ...oopback test contact Wintriss Tech Support Calibrating AutoSetPAC This section shows you how to calibrate an AutoSetPAC load analyzer so that it displays an accurate reading of the tonnage applied by the press You learn how to do the following 1 Adjust each strain link until it provides a zero signal with no load on the press following the instructions in Zeroing Strain Links page 73 2 Using a sep...

Page 73: ...SetPAC processor board as described in Installing Strain Links page 41 Then to set the strain links to read zero 0 at no load do the following 1 Move the press ram to top dead center 2 Apply power to SmartPAC 3 Turn the Program Run key to PROG then press the 1 and CLEAR keys simultaneously and hold down a few seconds until the Main Initialization Menu see Figure 3 2 appears 4 Select the TONNAGE WA...

Page 74: ...screw is located on the strain link circuit board as shown in Figure 3 14 NOTICE The potentiometer adjustment screw is accessible through a hole in the cover on strain links with a Hirschman connector part no 9641801 standard or 9685105 metric Newer versions of other strain links part nos 9641601 9641602 9641603 and 9641604 standard or 9685101 9685102 9685103 and 9685104 metric may also provide an...

Page 75: ...re 2 10 page 43 NOTICE If you cannot use the Zero Offsets display to zero the strain links i e display is too far away or is obstructed perform the Using a Voltmeter to Zero Strain Links procedure page 76 NOTICE If you cannot get the Zero Offsets display to read in the 5 range make sure strain link wiring connections are tight and the connector is firmly seated If loose connections are not the pro...

Page 76: ...generating an Offsets Error message on the Current Zero Offsets display When no strain link is generating an Offsets Error message proceed with zeroing the strain links that remain 18 When all the strain links have been zeroed press RESET or EXIT repeatedly to return to the SmartPAC Main Initialization Menu Using a Voltmeter to Zero Strain Links Perform the following procedure if the AutoSetPAC Ze...

Page 77: ... calibration kit to display the correct tonnage applied to the load cells perform the following steps referring to Figure 3 15 page 79 or Figure 3 16 page 80 for location of components on old and new style AutoSet processor boards If your AutoSet calibration kit has the current version 2 0 processor board installed refer to Figure 3 17 page 81 1 Open the cover of the AutoSet 2 Channel calibration ...

Page 78: ...he power supply which helps to prevent shock when personnel are working inside the enclosure with the power on If you remove this cover to connect 115 or 230 Vac wires make sure to replace the cover before applying power The power supply is located at the top center of the processor board Failure to comply with these instructions could result in death or serious injury 4 Plug in the AutoSet calibr...

Page 79: ...AutoSetPAC User Manual 1101600 Chapter 3 Initialization and Calibration 79 Figure 3 15 AutoSet 2 Channel Calibration Kit Processor Board Old Style ...

Page 80: ...1101600 AutoSetPAC User Manual 80 Chapter 3 Initialization and Calibration Figure 3 16 AutoSet 2 Channel Calibration Kit Processor Board New Style ...

Page 81: ...displays should show 0 s or other numbers The Setpoint displays should show either numbers dashes or the message HI or LO 6 If the displays are not active turn off power to the AutoSet Re check the connections for power and strain links Make sure that the voltage selector switch S7 in Figure 3 15 S10 in Figure 3 16 is set correctly either 115V or 230V and switch S3 Figure 3 15 or S2 Figure 3 16 is...

Page 82: ... 0 Figure 3 18 Tonnage Dial Indicators Old style Board Left New style Board Right 9 Set the Tonnage dial indicators to twice the full scale tonnage of one load cell NOTICE Even if you are using two load cells for calibration you still set the Tonnage dial indicators to twice the full scale tonnage of one load cell For tonnages greater than 999 i e with more than three digits set the dials to one t...

Page 83: ...n you want referring to Figure 3 19 and Table 3 3 11 Power down the AutoSet calibration kit then back up to reset the unit and activate your tonnage and decimal point settings 12 Move the lever on the three position switch labelled S3 on old style boards see Figure 3 15 or S2 on new style boards see Figure 3 16 to the ZERO SET position and check the channel Load LED displays on the AutoSet front p...

Page 84: ...on unit by pressing the RESET button AutoSet 2 Channel or turning the DISPLAY switch to RESET AutoSet 2 Channel Plus and holding for at least two seconds Setting both percent tolerance selector dials to zero 0 disables AutoSet s automatic setpoint function NOTICE Setpoints LED displays will show numeric readings after the unit is reset Ignore these readings Only the Load LED displays are used in c...

Page 85: ...ain 7 Repeat step 6 until the readout on your calibration unit indicates that contact on the load cell s is being made at BDC 8 Continue to cycle the press and adjust the ram downward locking the shut height after each adjustment until the Load LED displays on your calibration unit show the tonnage you determined in step 4 9 If you are using two load cells make sure both Load LED readouts display ...

Page 86: ...ry Window Displayed 3 Key in a value maximum is 3000 tons following the directions in the window and press ENTER You are returned to the Tonnage Waveform Initialization Menu AutoSetPAC tonnage display formats are shown in Table 3 4 Table 3 4 AutoSetPAC 2 Channel and 4 Channel Tonnage Display Formats Tonnage Range AutoSetPAC 2 Channel Tonnage Range AutoSetPAC 4 Channel Channel Load Display Format 2...

Page 87: ...1 Select CALIBRATION on the Tonnage Waveform Initialization Menu to display the Calibration screen see Figure 3 22 Figure 3 22 Calibration Screen 2 Familiarize yourself with the gain adjustment potentiometers and high low gain jumpers to the left of the strain link inputs at the bottom of the AutoSetPAC processor board see Figure 2 6 or Figure 2 7 Table 3 5 shows the processor board labels that id...

Page 88: ... are amplified to make tonnage readings on your AutoSetPAC match tonnage readings on the calibration unit You adjust each potentiometer by turning the small screw in its lower right corner see Figure 3 23 which shows the potentiometer and jumper for the Left Rear strain link input The potentiometer screw has a 12 turn limit Jumpers control the portion of the range within which strain link signals ...

Page 89: ...ink channels on your AutoSetPAC Table 3 6 shows the ratio of each Load reading on a calibrated AutoSet to each calibration unit display Ratios may be 1 1 1 2 or 1 4 Table 3 6 AutoSetPAC Load Readings Ratio of Calibration Unit Readings No of Load Cells No of Active Displays on Cal Unit AutoSetPAC 2 Channel Displays 2 Ratio of Cal Unit AutoSetPAC 4 Channel Displays 4 Ratio of Cal Unit 1 1 1 2 of cal...

Page 90: ...AC Remove the jumper from the two lower pins and place it over the two upper pins see Figure 3 23 Power up SmartPAC Cycle the press to display a tonnage reading NOTICE When you cycle the press after repositioning a jumper a fault message may display on the Calibration screen indicating that tonnage is now over 120 of full scale To clear this error press RESET When the error is cleared the reading ...

Page 91: ...cord the calfactor and high low gain jumper setting for each strain link channel two pairs of settings for AutoSetPAC 2 Channel four pairs of settings for AutoSetPAC 4 Channel 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 in this chapter Simply access the Calibration screen in SmartPAC Cal...

Page 92: ...on procedures have been completed and before you run the press Final Checkout ensures that AutoSetPAC will stop the press properly during a tonnage fault To perform final checkout follow these steps 1 Install a test tool on your press 2 On the Tonnage Monitor Programming Menu set the REPEATABILITY item to 1 referring to Making Tonnage Monitor Settings page 98 3 Run a few parts The 1 repeatability ...

Page 93: ... Monitor Settings 99 Copying Tonnage Monitor Settings 100 Changing Tonnage Monitor Settings 101 Viewing and Adjusting Setpoints 101 High Setpoint Limits 102 Low Setpoint Limits 103 Repeatability Setpoint Limits 103 Recalculating Setpoints 104 NOTICE SmartPAC refers to original SmartPAC SmartPAC 2 and SmartPAC PRO unless otherwise indicated NOTICE REFER TO SMARTPAC USER MANUAL Instructions for crea...

Page 94: ...using the following formula Low setpoint Highest measured load highest measured load x low setpoint percentage Repeatability setpoint percentage is the percentage of the reference tonnage at which AutoSetPAC establishes repeatability setpoints It is calculated as follows Repeatability setpoint Highest measured load x repeatability setpoint percentage AutoSetPAC samples the load at each strain link...

Page 95: ...AutoSetPAC 4 Channel AutoSetPAC calculates setpoints whenever you perform the Recalculate Setpoints function see Recalculating Setpoints page 104 or page 114 or load a tool with a new high setpoint low setpoint or repeatability setpoint percentage Setpoints are displayed after the sample period is completed AutoSetPAC calculates new reverse setpoints whenever the reverse setpoint percentage or ful...

Page 96: ...ing the Tonnage Monitor Programming Menu The Tonnage Monitor Programming Menu is the screen on which you make settings for setpoint percentages sample period and startup counter if enabled To access this screen do the following NOTICE When switching between operating modes with the Program Run key make sure that SmartPAC is displaying the top level screen in the current mode i e Main Program Menu ...

Page 97: ... Mode 97 Figure 4 3 Tool Manager Screen 3 Highlight the tool you wish to Program and press F4 Edit Tool The Tool Program Menu displays see Figure 4 4 Figure 4 4 Tool Programming Menu 4 Select TONNAGE WAVEFORM The Tonnage Monitor Programming Menu see Figure 4 5 displays ...

Page 98: ...TER to display the Numeric Entry window 3 Key in the value you want following the directions in the window and press ENTER The window disappears and the value you keyed in is displayed in the HIGH PERCENTAGE field AutoSetPAC will stop the press if tonnage exceeds 120 of press capacity even if the high low and or repeatability setpoints have been disabled 4 Move the cursor to the next field 5 Perfo...

Page 99: ...cts tonnage information for calculating setpoints As a general rule set the sample period to approximately 1 4 to 1 2 of the operating speed SPM of the press For single stroke operations set the sample period to 1 stroke STARTUP COUNTER The number of strokes after press startup during which AutoSetPAC disables high low and repeatability setpoints This setting allows high speed presses to reach a n...

Page 100: ...ol with the desired tool selected Copying Tonnage Monitor Settings Once you have established high low and repeatability setpoint percentages you can use these settings for all other dies you run on the press using the Copy Tool function on the Tool Manager screen To copy one tool to another do the following 1 On the Tool Manager screen see Figure 4 3 select the tool you want to copy and press the ...

Page 101: ...desired to prevent unnecessary faults and press shutdowns You may want to change setpoints when a tool runs at a much higher or much lower speed than a previous die or generates a very different load To program a tool with new settings perform the Making Tonnage Monitor Settings procedure page 98 Viewing and Adjusting Setpoints If the capability to adjust setpoints has been locked out from Run mod...

Page 102: ...y pressing the F2 High Setpoint function key The High Setpoint Limits display shows the current high setpoint percentage the most recently calculated high tonnage setpoints for each strain link using the displayed percentage and the actual tonnage recorded for each strain link Actual tonnages are updated on each stroke To adjust the high setpoint percentage up or down press the Up Arrow or Down Ar...

Page 103: ... setpoint values for each strain link are updated allowing you to see the results of your adjustments and to compare them with actual tonnage values To recalculate setpoints based on your changes refer to Recalculating Setpoints page 104 Repeatability Setpoint Limits To display repeatability setpoint values see Figure 4 11 press the F4 Rep Setpoint function key The Repeatability Setpoint Limits di...

Page 104: ...ts capability from Run mode you can recalculate setpoints on the Main Program Menu see Figure 4 2 page 96 You should always recalculate setpoints when you use the COPY TOOL function to create a new tool number The copied tool will have the same percentages and the same setpoints as the original tool If you create a new tool not copying from an existing one you do not have to recalculate setpoints ...

Page 105: ...firm that you want to recalculate setpoints The message SETPOINTS WILL BE RECALCULATED displays briefly on top of the warning message and you are returned to the Main Program Menu Setpoints are recalculated the next time you run the press and will appear on the appropriate Adjust Setpoints display e g High Setpoint Limits Low Setpoint Limits etc the next time you access it ...

Page 106: ...1101600 AutoSetPAC User Manual 106 Chapter 4 Using AutoSetPAC in Program Mode ...

Page 107: ... Setpoints 114 Viewing Tonnage History 115 Viewing Tonnage History for a Selected Strain Link Input 115 Viewing History for the Total Strain Link Tonnage 118 Clearing Tonnage History 119 Recalculating Setpoints 119 Viewing Reverse Tonnage 120 Loading a New Tool 121 NOTICE SmartPAC refers to original SmartPAC SmartPAC 2 and SmartPAC PRO unless otherwise indicated NOTICE REFER TO SMARTPAC USER MANUA...

Page 108: ...e turn the Program Run key to the RUN position A screen like the one shown in Figure 5 1 will display Figure 5 1 SmartPAC Main Run Menu 2 The items displayed on the Main Run Menu depend on installed options and security access settings For example the LOAD NEW TOOL item does not appear on the Run menu if the LOAD TOOL item on the Security Access Menu in Initialization mode has been set to PROGRAM ...

Page 109: ...an View screen displays the current tonnage at each strain link as a colored column filling some fraction of a graduated rectangular container The total height or volume of the container represents 120 of press capacity so the height or volume of the colored column provides a good idea of the ratio of current tonnage to full scale capacity The color of the column indicates the proximity of the ton...

Page 110: ...h function key to go to the Tonnage Bargraph View screen see next section Press the F8 Return to Main Menu function key to return to the Main Run Menu Press RESET to return to the Tonnage Monitor Run Menu Displaying Tonnage in Bargraph View When you select SHOW BARGRAPHS on the Tonnage Monitor Run Menu the screen shown in Figure 5 4 displays Figure 5 4 Tonnage Bargraph View Screen The Tonnage Barg...

Page 111: ...shrink as setpoints are calculated You can rescale the graph and expand the bars by pressing the F5 Rescale the Graph function key To exit from the Tonnage Bargraph View screen do one of the following Press the F6 Go to Reverse Plan View function key to go to the Reverse Tonnage Plan View screen see Viewing Reverse Tonnage page 120 Press the F7 Go to Plan View function key to go to the Tonnage Pla...

Page 112: ...nd the actual tonnage recorded for each strain link Actual tonnages are updated on each stroke To adjust the high setpoint percentage up or down press the Up Arrow or Down Arrow cursor key Each keystroke increases or decreases the displayed value by 1 percent As you adjust the high setpoint percentage the high tonnage setpoint values for each strain link are updated allowing you to see the results...

Page 113: ...bility setpoint percentage the most recently calculated repeatability setpoints for each strain link using the displayed percentage and the actual stroke to stroke tonnage variation recorded for each strain link The tonnage variation reading is the highest stroke to stroke tonnage variance recorded during the last n number of strokes where n is the length of the sample period For example if the sa...

Page 114: ... Period Display To adjust the sample period value up or down press the Up Arrow or Down Arrow cursor key Each keystroke increases or decreases the displayed value by 1 stroke The sample period value is adjustable from 1 to 100 strokes To recalculate setpoints based on your change s refer to Recalculating Setpoints next Recalculating Setpoints NOTICE If the RECALCULATE SETPOINTS function has been l...

Page 115: ... History Menu The Tonnage History Menu gives you access to screens that provide tonnage history for each strain link input first four menu items and for the strain link total last menu item Viewing Tonnage History for a Selected Strain Link Input To view tonnage history for a selected strain link input select that input on the Tonnage History Menu A screen like the one shown in Figure 5 11 display...

Page 116: ...1101600 AutoSetPAC User Manual 116 Chapter 5 Using AutoSetPAC in Run Mode Figure 5 11 Tonnage History Display for Left Rear Input 1 ...

Page 117: ...S The number of high setpoint faults recorded during the data collection period This value in conjunction with the LOW FAULT and REP FAULT items see below helps to determine the problem dies LOW FAULTS The number of low setpoint faults recorded during the data collection period This value in conjunction with the HIGH OVERLOAD see above and REP FAULT see below items helps to determine the problem d...

Page 118: ...onnage History Information for Total Tonnage Field Description OF HITS The period of time measured in number of strokes during which AutoSetPAC has collected the displayed historical data HIGHEST LOAD The highest tonnage recorded during the data collection period This value is useful in cases of catastrophic damage or when you need to determine whether tooling components failed due to overload or ...

Page 119: ...R key To cancel this action press RESET Press RESET to return to the Tonnage Monitor Run Menu Recalculating Setpoints NOTICE If the RECALCULATE SETPOINTS function has been locked out of Run mode see Locking Run Mode Actions page 69 that item does not appear on the Tonnage Monitor Run Menu When you select RECALCULATE SETPOINTS on the Tonnage Monitor Run Menu the warning message shown in Figure 5 14...

Page 120: ...tely corrected the problem Failure to do so may result in damage to the press and tooling Failure to comply with these instructions could result in property damage Viewing Reverse Tonnage When you select SHOW REVERSE TONNAGE on the Tonnage Monitor Run Menu the screen shown in Figure 5 15 displays Figure 5 15 Reverse Tonnage Plan View Screen The Reverse Tonnage Plan View screen displays the reverse...

Page 121: ...un Menu However a tool number cannot be loaded while the press is running To load a new tool perform the following steps NOTICE If you attempt to load a tool while the press is running a message will display indicating that the press must be stopped before a tool number can be loaded 1 Select LOAD NEW TOOL on the Main Run Menu The Tool Manager screen displays Figure 5 16 Tool Manager Screen 2 High...

Page 122: ...1101600 AutoSetPAC User Manual 122 Chapter 5 Using AutoSetPAC in Run Mode Figure 5 18 Tool Loading Message ...

Page 123: ...w No Tonnage 4 Channel Units 128 NOTICE SmartPAC refers to original SmartPAC SmartPAC 2 and SmartPAC PRO unless otherwise indicated Responding to AutoSetPAC Faults When a setpoint is exceeded or there is an offset error on one or more strain links AutoSetPAC opens the output relay and stops the press simultaneously displaying a fault message on top of the SmartPAC Main Run Menu see Figure 6 1 in w...

Page 124: ...isance stop or was caused by an actual press or die malfunction A nuisance stop occurs when setpoints are so tight that small normal variations in tonnage cause AutoSetPAC to shut down the press If the fault was caused by a nuisance stop you need to adjust the offending setpoint so that it is higher or in the case of a low setpoint lower than normal tonnage fluctuations You may also need to length...

Page 125: ...s from sticking on the bottom if an overload occurs Remember that top stop circuits are active only in Continuous automatic operations on most press controls If overload protection is required during Inch or Single stroke mode you may have to install an additional relay so that AutoSetPAC will stop the press Refer to Chapter 2 for more information Setpoint Faults This section shows you how to resp...

Page 126: ...gn objects e g wrench in the die Electrical noise in the strain link cables which can cause false signals If only one input is overloaded try moving the tooling die away from that input to distribute the load more evenly Offset Errors AutoSetPAC displays an offset error when one or more strain links transmit a signal that is either too high or too low for the load analyzer to interpret accurately ...

Page 127: ...and all strain link connectors TB105 and TB106 on 2 channel AutoSetPACs TB105 TB106 TB107 and TB108 on 4 channel units from the AutoSetPAC board c Power the SmartPAC and AutoSetPAC back up and see if communications is resumed i e the TONNAGE WAVEFORM menu item displays d If SmartPAC and AutoSetPAC are now communicating properly perform the following steps in sequence to isolate the specific wiring...

Page 128: ...he calibration was done properly Check to see if the calfactors are correct Make sure that the calfactors you set are the same as the ones you wrote down during the calibration Refer to Chapter 3 If you have an existing installation 4 Check for a stretched or broken tie rod on straight side presses Tonnage Display s Shows No Tonnage 1 Check to make sure that the zero cam signal from SmartPAC to Au...

Page 129: ...ess shutdown initiated by AutoSetPAC because setpoints have been set too close to normal tonnage values or normal tonnage variations As a result setpoints are regularly exceeded causing unnecessary press shutdowns reference tonnage The highest tonnage measured by AutoSetPAC during the sample period repeatability setpoint The limit in tonnage variation from one stroke to the next above which AutoSe...

Page 130: ...startup counter is used primarily to allow high speed presses to come up to speed before AutoSetPAC begins to monitor tonnage It is also used to allow press tonnage to stabilize before calculating setpoints tonnage fault A press shutdown initiated by AutoSetPAC because tonnage has fluctuated enough to exceed the high low repeatability or reverse setpoint A fault may be caused by a stuck part signi...

Page 131: ...ew 58 full scale tonnage applying to load cells 84 setting in AutoSetPAC 85 setting on AutoSet calibration kit 82 G gain potentiometers adjusting in AutoSetPAC 89 setting on AutoSet 2 Channel calibration kit 84 H high setpoints adjusting in Run mode 112 viewing in Run mode 110 112 viewing adjusting in Program mode 102 high low gain jumper changing the setting in AutoSetPAC 90 I initializing AutoSe...

Page 132: ...point percentages 99 recalculating in Program mode 104 recalculating in Run mode 114 119 viewing in Program mode 101 viewing in Run mode 110 112 setup mode enabling disabling 68 shield cable terminating 46 51 SmartPAC connecting an AutoSet to 54 SmartPAC PRO front panel 23 specifications 27 startup counter enabling disabling 68 setting number of strokes 99 stop circuits wiring 36 strain links chan...

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