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Wintriss WPC 1000, User Manual

The Wintriss WPC 1000 User Manual is an essential download for understanding and operating this innovative product. Our manual provides detailed instructions, troubleshooting tips, and helpful diagrams - all available for free download at manualshive.com. Get the most out of your Wintriss WPC 1000 with our comprehensive manual!

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1125100

WPC 1000 User Manual

iv

Table of Contents

Single-stroke Mode Test with Light Curtain(s)  . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Single Stroke Mode Test Without Light Curtain(s)  . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Anti-tiedown Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Anti-repeat Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Continuous Mode Test with Light Curtain(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Continuous Mode Test without Light Curtain(s)  . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Foot Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
One-hand Control Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
Bar Mode Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Checking Operation of the User Inputs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Chapter 4.

Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1

Responding to an Interrupted Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-3

Responding to a Brake Warning  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-3

Displaying and Clearing the Stroke Counter . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-4

Viewing the Counter Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Resetting the Counter Value to Zero. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Setting and Maintaining the Counter Preset Value  . . . . . . . . . . . . . . . . . . . . . .  4-5

Setting the Counter Preset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Disabling the Counter Preset  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Forcing the Counter Preset Value to 999999  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Operating the Press in Inch Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-7

Top-stop in Inch  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Top-stop Bypass (Top-stop in Inch Disabled)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Micro-inch  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Dead Motor Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Operating the Press in Single-stroke Mode . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-10

Single-stroke, Two-hand Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Single-stroke, One-hand Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Single-stroke, One-hand Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Single-stroke, Foot Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Operating the Press in Continuous Mode  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-15

Continuous, Two-hand Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Continuous, Foot Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Operating the Press in Bar Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-17

Multiple Operator Stations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-18

Chapter 5.  Troubleshooting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-1

Responding to WPC 1000 Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-2

Lockout Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-3

Brake Monitor Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  5-3

Brake Warning LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Stop Time Exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Summary of Contents for WPC 1000

Page 1: ...R August 2015 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 DA69447 ...

Page 2: ... any moveable two hand control used as a safety device is located at least the safety distance away from the hazardous area Install any light curtain or curtains at least the safety distance away from the hazardous area safety distance is defined in the OSHA and ANSI regulations Install other safeguarding devices as needed to ensure operator safety Follow the machine guarding requirements of OSHA ...

Page 3: ...chinery or other devices are not maintained or do not meet the applicable regulations or standards Ensure that supervisors die setters maintenance persons machine operators foremen and any others responsible for operation of the machinery have read and understood all instructions for use of the WPC 1000 clutch brake control DO NOT use touch buttons for any safeguarding use Failure to comply with t...

Page 4: ...of the WPC 1000 User Manual 1125100 This revision of the WPC 1000 user manual covers WPC 1000 software version 2 77 and higher The changes include Revised mounting dimensions for the WPC 1000 enclosure see Figure 2 4 page 2 7 ...

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...

Page 6: ... Wiring the Control Enclosure 2 6 Slide Adjust Considerations 2 7 Connecting AC Wiring 2 8 Installing a Dual Safety Valve 2 9 Installing Clutch and Counterbalance Air Pressure Switches 2 11 Installing Operator Station s 2 12 Wiring a Pre wired Operator Station 2 13 Checking Pre wired Operator Station Wiring 2 13 Making Wiring Connections 2 14 Wiring an Unwired Operator Station 2 16 Wiring a User b...

Page 7: ... Switch 2 39 Installing One hand Control 2 40 Mounting the One hand Control 2 41 Wiring One hand Control to WPC 1000 2 43 Mounting and Wiring the Bar Control Enclosure 2 45 Installing Revised Firmware in WPC 1000 2 46 Installing WPC 1000 without Enclosure 2 48 Installing the WPC 1000 Mounting Plate 2 48 Installing the Panel mount Display 2 49 Mounting the Display 2 49 Connecting the Panel mount Di...

Page 8: ...fety Distance Formula 3 22 OSHA Safety Distance Formula 3 24 Adding to Safety Distance for Blanking Windows 3 25 Setting Micro Inch 3 26 Setting Press Option Switches 3 27 Switches 1 and 2 Top stop On Angle Range 3 27 Switch 3 One hand Control and Foot Switch Settings 3 28 Enabling Light Curtain Break Mode in a One hand Control 3 28 Enabling Foot Control in a Foot Switch 3 28 Switch 4 Enabling Aut...

Page 9: ...ing and Maintaining the Counter Preset Value 4 5 Setting the Counter Preset 4 5 Disabling the Counter Preset 4 6 Forcing the Counter Preset Value to 999999 4 7 Operating the Press in Inch Mode 4 7 Top stop in Inch 4 8 Top stop Bypass Top stop in Inch Disabled 4 8 Micro inch 4 9 Dead Motor Inch 4 9 Operating the Press in Single stroke Mode 4 10 Single stroke Two hand Operation 4 10 Single stroke On...

Page 10: ...Input Failures 5 15 Top stop and Overrun Setting Faults 5 16 Overrun Limit Switch Fault 5 16 Overrun Limit Switch Test Angle Fault 5 17 Overrun Limit Switch Setting Fault 5 17 Internal Memory Failures 5 17 Resetting Ross DM2 DSV Faults 5 18 Appendix A Extracts from OSHA Regulations and ANSI Standards A 1 Extracts from OSHA Regulation 1910 217 A 1 Extracts from ANSI Standards for Presence sensing D...

Page 11: ... 2 6 Pre wired Operator Stations Showing Mute Lamp Connections 2 13 Figure 2 7 Wiring Steps to Modify Operator Station for WPC 1000 2 14 Figure 2 8 Pre wired Operator Station with Side Run Buttons Mounting Dimensions 2 15 Figure 2 9 Pre wired Operator Station with Top Run Buttons Mounting Dimensions 2 15 Figure 2 10 Unwired Operator Station Mounting Dimensions 2 16 Figure 2 11 WPC 1000 Control Boa...

Page 12: ...Gray Conductors 2 64 Figure 2 44 Strain Relief Installed on Connector Gray Conductors 2 65 Figure 3 1 WPC 1000 Displays Showing Indicator Segments 3 2 Figure 3 2 WPC 1000 Displays Showing System Initialized Int Message 3 4 Figure 3 3 WPC 1000 Displays Showing Resolver Zeroed rES Message 3 5 Figure 3 4 WPC 1000 Displays Showing Initializing Start time Limit Str Message 3 6 Figure 3 5 Setting Overru...

Page 13: ...able 2 18 WPC 1000 Control Board DSV Lockout Relay Board Wiring Connections 2 70 Table 2 19 WPC 1000 Control Board Power J103 Wiring Connections 2 70 Table 2 20 WPC 1000 Display Board Wiring Connections 2 71 Table 3 1 WPC 1000 Standard Display Default Parameters Press Running 3 2 Table 3 2 WPC 1000 Optional Counter Display Default Parameters Press Running 3 3 Table 3 3 Overrun Sensor Magnet Locati...

Page 14: ...how to run the press using WPC 1000 s Inch Single stroke and Continuous stroke selections and Two hand One hand and Foot modes Chapter 5 shows you how to respond to and correct the fault codes that appear on the display when WPC 1000 detects an error Appendix A provides OSHA regulations and ANSI standards pertaining to the use of presence sensing devices for point of operation guarding on mechanic...

Page 15: ...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 16: ...which shall 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 no...

Page 17: ...1125100 WPC 1000 User Manual xii Table of Contents ...

Page 18: ...Resolver The resolver which is mounted on the press turns one to one 1 1 with the crankshaft allowing WPC 1000 to know the exact position of the crankshaft on every stroke The resolver is similar to an electrical generator and works on the principle of inductance The resolver s two outputs vary in amplitude and phase as the resolver turns WPC 1000 translates these analog signals to a number that i...

Page 19: ...ESET SELECT MUTE INTERRUPTEDSTROKE BRAKEWARNING TOPSTOPANGLE AUTOCARRYUP ANGLE SPM 90 STOPTEST STOPTIMELIMIT MICRO INCH STOPPINGTIME STOPPINGANGLE CAM1 off on CAM2 off on WPC 1000 Wintriss Clutch Brake Control STROKESELECT O F F INCH SINGL E C O N T MODESELECT 1 H A N D 2 HAND F O O T MICROINCH O N O F F WPC 1000 Wintriss Clutch Brake Control WPCSETTINGS RESET SELECT MUTE BRAKEWARNING INTERRUPTEDS...

Page 20: ...cy Stop Switch Stops the press immediately when you push it The switch is not spring loaded so you must pull it back to its original position to clear the emergency stop F13 fault see page 5 7 Top Stop Switch Stops the press at the top of its stroke when pressed during Continuous operation Palm Time Lamp Illuminates when one Run Inch palm button is depressed turning off after the 1 2 second palm t...

Page 21: ... One hand operating mode WPC 1000 tests the Shadow inputs every time that the press is started and stopped See Installing a Light Curtain page 2 18 for more information WPC 1000 is designed to be used with a Shadow light curtain If you order WPC 1000 without a light curtain the control enclosure does not have a Mode Select switch and the unit operates only in Two hand mode The light curtain is pla...

Page 22: ...age 3 1 Figure 1 3 WPC 1000 Displays WPCSETTINGS RESET SELECT MUTE INTERRUPTEDSTROKE BRAKEWARNING TOPSTOPANGLE AUTOCARRYUP ANGLE SPM 90 STOPTEST STOPTIMELIMIT MICRO INCH STOPPINGTIME STOPPINGANGLE CAM1 off on CAM2 off on WPC 1000 Standard Display WPC 1000 Optional Counter and Crank Angle Display Digital Display Press Speed Crank Angle Error Codes Indicator Segments WPC Settings Key Switch Interrup...

Page 23: ...Indicator Segments Ten rather than eight segments are provided The two additional segments display a counter and counter preset see next item Counter and Counter Preset The counter see page 4 4 maintains a cumulative total of the number of strokes made by the press When the count total reaches the value set on the Counter Preset indicator segment see page 4 5 WPC 1000 stops the press The counter i...

Page 24: ...en you push the Run Inch palm buttons Normally in Inch the DSV is open for only as long as the Run Inch buttons are depressed The Micro inch setting specifies the length of time the DSV is open regardless of how long the Run Inch buttons are held Allowing finer adjustments than are possible in Inch Micro inch is designed to facilitate setup on high speed or short stroke presses Requires installati...

Page 25: ...erators and setup personnel to bar the press by hand for die setting and adjustment Recommended for smaller capacity presses of 65 tons or less Display Configuration Options WPC 1000 is available without an enclosure Installation instructions for panel mount and display board kit options are provided beginning on page 2 48 Auto Compensated Top Stop ACTS A feature that automatically adjusts the Top...

Page 26: ...d palm time and mute lamps Pre wired unwired version also available Dual Safety Valve DSV Available in 0 75 in 19 mm or 1 in 25 mm Ross DM2 models Air Pressure Switch 12 150 PSI Monitors clutch air supply pressure Wintriss AC Power Supply Included Input 100 240 10 Vac universal switching 50 VA 50 60 Hz Output 24 1 Vdc 200 mA maximum for customer use including Auxiliary Output Auxiliary Output capa...

Page 27: ...y Includes 6 digit counter display and preset function crank angle clock Shadow V Shadow VI Shadow VII or Shadow 8 Light Curtain Heights from 6 to 60 in scanning ranges from 23 to 65 Refer to Shadow literature for more information Firmware Muting for Shadow light curtain on the upstroke Two hand only One hand two hand or foot operation Auto compensated top stop Selector Switches Mode One hand two ...

Page 28: ...after any modification or repair of the WPC 1000 clutch brake control Lockout Tagout the press during all installation modification repair or maintenance procedures Ensure that supervisors die setters maintenance persons machine operators foremen and any others responsible for operation of the machinery have read and understood all instructions for use of the WPC 1000 clutch brake control Disconne...

Page 29: ...Chapter 3 ALL SIGNAL GROUNDS MUST BE CONNECTED THROUGH THE CONTROL BOARD Connect all signal grounds through pins on the WPC 1000 Control board READ INSTALLATION INSTRUCTIONS BEFORE STARTING INSTALLATION If you install WPC 1000 yourself read this installation chapter carefully and plan how you are going to proceed before you start drilling holes running conduit or cutting wires Make sure you are fa...

Page 30: ...lve DSV can be run in the same conduit Provide a dedicated 120V power circuit from the press control transformer to the WPC 1000 input power connection Do not power any relays or solenoids from this circuit or the auxiliary power terminals on WPC 1000 Doing so may cause erratic press shutdowns due to electrical noise Run one or two low voltage conduits for the resolver wires to the knockouts on th...

Page 31: ...witch Timing chain Resolver Air pressure switch Dual Safety Valve DSV DSV wiring Resolver overrun limit switch and air pressure switch wiring Operator station wiring 120 VAC high voltage wiring from Customer Control Transformer Wintriss Clutch brake Control Operator Station Motor Control Crankshaft ...

Page 32: ...re not on the insulation Terminating Cable Shields Perform the following steps to terminate shielded cables to the ground studs located inside the WPC 1000 enclosure near the cable s point of entry referring to Figure 2 3 page 2 6 1 Strip the cable jacket as far as the end of the conduit fitting 2 Cut the drain wire to a length that can wrap at least once around the nearest ground stud Loosen the ...

Page 33: ... at least 120 Plastic cable ties and self sticking cable clamps are provided in the accessory parts bag Use them to organize the cables and wiring inside the control enclosure Wiring the Control Enclosure WPC 1000 requires the following electrical components Motor forward auxiliary contact 24V Slide adjust monitor circuit 24V Motor stop circuit 110V if applicable Motor reverse auxiliary contact 24...

Page 34: ...ech Support NON ENCLOSURE INSTALLATION See Installing WPC 1000 without Enclosure page 2 48 for installation instructions if you are installing WPC 1000 in your own enclosure or console Figure 2 4 WPC 1000 Mounting Dimensions NOTICE 12 00 304 8 14 68 372 8 17 62 447 6 16 88 428 8 Note Allow sufficient clearance for opening door 7 27 184 5 14 28 362 7 Dimensions inches mm WPCSETTINGS RESET SELECT MU...

Page 35: ... 230 Vac wires are black and red with green or green yellow for ground 3 Run the power wires to the enclosure through flexible liquid tight conduit Because WPC 1000 is rated NEMA 12 protected against dust and oil you must use conduit of the same rating and make proper connections to ensure NEMA 12 protection ELECTRIC SHOCK OR HAZARDOUS ENERGY Disconnect main power before installation Remove all po...

Page 36: ... power terminal block insert the stripped portion of the wire and tighten the screw 6 Double check connections 7 Make all necessary conduit connections to ensure NEMA 12 protection Installing a Dual Safety Valve Figure 2 5 AC Input Wiring Connections USER SUPPLIED DUAL SAFETY VALVE NOT SUITABLE FOR SAFETY USE Ensure that your dual safety valve meets the applicable safety standards Contact the valv...

Page 37: ...end of the DSV which has three connectors altogether including one for the DSV monitor that is already INSTALL DSV CLOSE TO CLUTCH BRAKE ASSEMBLY TO REDUCE STOPPING TIME Install the dual safety valve as close as possible to the clutch brake assembly Any excess piping between the valve and the clutch brake assembly increases the Stopping Time of the press Failure to comply with these instructions w...

Page 38: ...on XSZ Make sure that you wire the Herion DSV monitor between pin 44 and a 24 Vdc output See Figure 4 at the end of the manual Installing Clutch and Counterbalance Air Pressure Switches Install and wire the clutch air pressure switch and counterbalance switch as follows 1 Install a filter regulator and lubricator in line before the air pressure switch if not already present 2 Connect shop air to t...

Page 39: ...have finished wiring you can place the Operator Station temporarily on the floor or on a cart If you are not installing a light curtain and if you are planning to use the Operator Station as a two hand safety device the Operator Station must be mounted at the correct safety distance from the nearest pinch point on the press This distance must be calculated based on the Stopping Time of your press ...

Page 40: ...amp wiring If your mute lamp wiring looks like panel E in Figure 2 7 page 2 14 i e the black wire is connected the red and white wire not connected the wiring is correct If your mute lamp wiring looks like panel A follow steps A through E in Figure 2 7 to disconnect the white and red wires and connect the black wire 4 When the mute lamp wiring is correct connect the Operator Station to WPC 1000 Fi...

Page 41: ... the Operator Station Figure 2 7 Wiring Steps to Modify Operator Station for WPC 1000 B Free the black wire Disconnect the pair of white and red wires C Connect the black wire where you just disconnected the pair of white and red wires Bend the white and red wires back on themselves Ty wrap them in place Insulate connector lug with electrical tape D E Black wire with connector lug not connected to...

Page 42: ...safety distance Refer to Figure 2 8 and Figure 2 9 above for mounting dimensions Figure 2 8 Pre wired Operator Station with Side Run Buttons Mounting Dimensions Figure 2 9 Pre wired Operator Station with Top Run Buttons Mounting Dimensions MUTE PALM TIME PRIOR ACT INTRISS W TOP STOP 5 8 148 REF 4 69 119 1 16 75 425 5 R U N I N C H R U N I N C H 5 50 139 7 21 25 539 8 Dimensions inches mm E M ERGEN...

Page 43: ...ng dimensions OPERATOR STATION MAY NOT MEET SAFETY REQUIREMENTS Ensure that the Operator Station is wired correctly Run all necessary tests to verify that each Operator Station is wired correctly and provides proper anti tie down and anti repeat protection Test procedures are provided at the end of this chapter and at the end of Chapter 3 Failure to comply with these instructions will result in de...

Page 44: ...rectly Ensure that on any non Wintriss Operator Station the Run buttons are placed so that two hands are required to push them at the same time and that buttons cannot be pushed simultaneously with one hand or with one hand and one elbow Ensure that on any non Wintriss Operator Station the Run buttons comply with the requirements specified in Table B 2 page B 2 Ensure that on any non Wintriss Oper...

Page 45: ...pport PREVENT OPERATOR FROM STANDING BETWEEN LIGHT CURTAIN AND HAZARDOUS AREA Ensure that the operator cannot position himself between the light curtain and the hazardous area Use another pair of light curtains or a mechanical barrier at knee to waist height to prevent the operator or a passerby from being trapped between the light curtain and the hazard Failure to comply with these instructions w...

Page 46: ...information at hand Light curtain manufacturer Light curtain model number WPC model i e WPC 1000 WPC 1000 firmware version number located on A or B microprocessor chip label Wiring diagram from the light curtain manufacturer s manual If your WPC 1000 does not have the firmware that allows Foot or One Hand control and or muting of a light curtain on the upstroke you can connect the light curtain s ...

Page 47: ...Ds Ribbon cable connector for Display board 1 Green 1 12 11 10 9 8 7 6 5 4 3 2 25 36 35 34 33 32 31 30 29 28 26 27 Orange 13 24 23 22 21 20 19 18 17 16 14 37 48 47 46 45 44 43 42 41 40 38 39 15 ON 8 7 6 5 4 3 2 1 High Lowspeed jumpers DS140 DS145 DS147 DS137 DS144 DS139 DS138 DS146 DS115 DS108 DS110 DS119 DS127 DS126 DS131 DS123 DS143 DS142 DS134 DS130 DS105 DS112 DS122 DS114 DS109 DS125 DS120 DS1...

Page 48: ...1000 Display board 1 Green 1 12 11 10 9 8 7 6 5 4 3 2 25 36 35 34 33 32 31 30 29 28 26 27 Orange 13 24 23 22 21 20 19 18 17 16 14 37 48 47 46 45 44 43 42 41 40 38 39 15 ON 8 7 6 5 4 3 2 1 High Lowspeed jumpers DS140 DS145 DS147 DS137 DS144 DS139 DS138 DS146 DS115 DS108 DS110 DS119 DS127 DS126 DS131 DS123 DS143 DS142 DS134 DS130 DS105 DS112 DS122 DS114 DS109 DS125 DS120 DS116 DS124 DS118 DS102 DS12...

Page 49: ... to the crankshaft Such a placement requires extreme precision If the resolver is only slightly off center its bearing will be subjected to side loads well in excess of its rated capacity and will ultimately fail Do not use flexible couplings which can be inaccurate or V belts which can also be inaccurate and will slip Do not use a flexible shaft like a speedometer cable The resolver will lag the ...

Page 50: ...gure 2 13 Resolver Mounting Dimensions It does not matter which direction the resolver turns when the press runs You adjust for the direction of rotation when you wire the unit see Wiring the Resolver next section 2 75 69 9 1 06 26 9 1 75 44 5 2 00 50 8 3 4 dia shaft 19 05 standard key Electrical connector for cable 3 62 91 9 0 34 8 6 dia holes 2 places 9 16 232 7 RESOLVER IS AT ZERO WHEN KEYWAY I...

Page 51: ...nd cut the resolver wires so they reach TB 103 then wire them to the L shaped connector referring to Table 2 17 page 2 70 and Figure 3 at the end of this manual Make sure you connect the black and yellow wires correctly based on the direction in which your resolver will rotate clockwise or counterclockwise Refer to Connecting Wires to Terminal Block Connectors page 2 5 if you need help wiring the ...

Page 52: ...owing the instructions in Re zeroing the Resolver page 3 4 Installing the Overrun Limit Switch The overrun limit sensor also called the overrun sensor enables WPC 1000 to monitor operation of the resolver and to stop the press whenever the resolver fails to work properly as can happen when the resolver drive chain breaks or slips or when the resolver is broken The overrun sensor provides a signal ...

Page 53: ... should be mounted so that it can be sensed by the switch for between 15 and 25 of the stroke The interval during which the magnet is sensed called the dwell decreases as the diameter of the rotating shaft increases see Figure 2 14 Select a shaft whose diameter will allow the sensor to detect the magnet for the required dwell Mounting the Overrun Sensor Switch The overrun sensor magnetic switch co...

Page 54: ...WPC 1000 Control board as shown in Table 2 2 and Figure 3 at the end of the manual Figure 2 15 Overrun Sensor Magnetic Switch Installation Example You can run both the resolver wires and the overrun limit sensor cable through the same conduit If you do so wait to cut the cable and wires until both the resolver and the overrun limit sensor are installed Table 2 2 Overrun Sensor Switch Wiring Connec...

Page 55: ...in death or serious injury USER INPUTS ADD DELAY TO STOPPING TIME DO NOT connect light curtains or other presence sensing devices to any user inputs The cross checked input pair 3A and 3B though control reliable is suitable only for applications such as connecting to safety switches used with interlocking barrier guards Failure to comply with these instructions will result in death or serious inju...

Page 56: ...ose After you have wired the inputs you will use be sure to bypass all the unused inputs by connecting them to 24V or ground Wiring the Lockout Relay The Lockout relay which is designed to be wired to critical press functions such as the motor starter provides an added safety feature to WPC 1000 Whenever a serious error condition occurs the Loc message will appear in the digital LED display To cle...

Page 57: ...and Aux Output 1 opens Wiring state changes and change conditions for Auxiliary Output 1 are provided in Table 2 5 Wiring connections are also shown in Table 2 16 page 2 69 and in Figure 2 at the back of the manual Aux Output 1 response to an Interrupted Stroke is controlled by option switch 8 on the WPC 1000 Control board Switch settings are shown in Table 2 6 page 2 31 Table 2 4 Lockout Relay Wi...

Page 58: ... make sure that the resolver is wired to the WPC 1000 as instructed on page 2 24 2 Locate the 7 conductor shielded resolver cable Run the cable through 1 2 in conduit from the WPC 1000 to the other control If there is a connector on one end of the cable cut it off 3 Pull the TB103 resolver connector out of its socket 4 Attach the wires to TB103 as shown in Table 2 18 page 2 70 and in Figure 3 at t...

Page 59: ...op circuits wire them between terminals 25and 26 on the Control board For Top stop circuits wire them between terminals 37 and 38 Refer to Figure 1 at the end of the manual for specific wiring schematics Use customized status code wiring see Wiring WPC 1000 User Inputs page 2 28 when the auxiliary equipment that you are connecting does not have its own self explanatory displays as are available in...

Page 60: ...To do so connect pin 156 on terminal block TB 705 on the WPC 1000 Display board to ground pin 155 See Table 2 20 page 2 71 Figure 2 16 WPC 1000 Display Board Location of Important Components Table 2 7 Micro inch Wiring Connections Display Board TB705 Pin Signal 157 Micro inch input 155 Ground TB701 TB702 J707 133 134 TB708 1 157 156 155 TB705 J706 149 148 147 146 145 144 143 142 141 1 1 1 1 Micro ...

Page 61: ...es that control the timing signals for your connected equipment These relays open and close circuits to your equipment at the crankshaft angles you program see Setting Programmable Cams page 3 33 Mounting and Wiring the Cam Output Assembly The cam output assembly can be ordered in an enclosure or as a PC board To mount and wire either option do the following Table 2 8 Remote Reset Switch Wiring Co...

Page 62: ...replace a relay simply pull the device out of its socket Before installing a relay make sure that all the pins match the socket holes so you do not bend the pins then press the relay in firmly 4 Locate the twelve conductor shielded cable that connects the WPC 1000 Control board to the cam outputs and terminate the shield at each end near the entry point to the enclosure or console see Terminating ...

Page 63: ...finished Figure 2 18 Cam Output Board Mounting Dimensions Table 2 9 WPC 1000 Control Board to Cam Output Assembly TB1 Wiring Connections Wire Color WPC 1000 Control Board Pin Signal 2 channel Cam I O Assembly TB1 Pin Signal 48 TB102 Bottom 24 Vdc 2 24 Vdc 23 TB102 Top Ground 3 Ground 34 TB101 Bottom Cam 2 6 Channel 2 33 TB101 Bottom Cam 1 7 Channel 1 Terminate drain wire to ground stud Terminate d...

Page 64: ...val set in WPC 1000 2 Plug TB2 and TB3 back into the Cam Output board TRIM UNUSED WIRES If your installation does not require all the wires in the cable to be used trim the unused wires cutting them flush with the ends of the cable jacket NON SAFETY OUTPUTS USED FOR SAFETY FUNCTIONS Use cams for non safety functions only such as convenience in automation They cannot protect personnel from a moving...

Page 65: ...s b Install a diode across each DC load such as relays solenoids and PLC inputs as shown in Figure 2 21 page 2 39 SUPPRESSORS INSTALLED ACROSS RELAY CONTACTS DO NOT install suppressors across the relay contacts in the cam output assembly If a suppressor is installed across the relay contacts and the relay fails shorted the equipment controlled by that relay will remain energized Failure to comply ...

Page 66: ... curtain Figure 2 21 Installing a Diode across a DC Load Table 2 10 Zero Cam Output Wiring Connections WPC 1000 Control Board Pin Signal AutoSet 1500 TB1 Pin Signal AutoSet 1504 TB101 Pin Signal pin 9 Zero Cam Output pin 2 Zero Cam pin 2 Zero Cam UNGUARDED HAZARDS When using a foot switch ensure that light curtains and other safeguards are properly installed and operating to protect operators Fail...

Page 67: ...C input 3 TB101 Top N O input 24 Vdc Common INSTALL SAFEGUARDS TO PREVENT ACCESS TO HAZARDOUS AREA Follow all applicable OSHA and ANSI regulations for safeguarding your press system Point of operation safeguarding is the single most important factor in the prevention of injuries Follow all applicable OSHA and ANSI regulations when installing a one hand control Ensure that proper safeguarding devic...

Page 68: ...d Control operates in Normal mode When switch 3 is set to ON One hand Control operates in Light Curtain Break mode Mounting the One hand Control To mount the One hand Control do the following 1 Shut off power to the press and to WPC 1000 2 Choose a mounting location on or near the press convenient to the operator The One hand Control should be mounted so the operator can reach it as part of normal...

Page 69: ...1125100 WPC 1000 User Manual 2 42 Installation Figure 2 22 One hand Control Switch Mounting Dimensions ...

Page 70: ...ly to the left or right 3 Knock out a hole in the bottom of the Operator Station near the existing conduit from the WPC 1000 control enclosure Figure 2 23 One hand Control Switch Base Mounting Dimensions ELECTRIC SHOCK OR HAZARDOUS ENERGY Disconnect main power before installation Remove all power to the press press control and other equipment used with the press Remove all fuses and tag out per OS...

Page 71: ...en the switch cover onto the base with the screws provided 7 Tighten all conduit connections that may have been loosened during installation 8 Close and latch the cover of the Operator Station and WPC 1000 9 Make sure that you have run all your ground wires Do not use conduit as ground Figure 2 24 Wiring Connections in One hand Control Switch Switch Cover Bottom View Table 2 12 One hand Control Wi...

Page 72: ...nnect the Bar selector switch input to pin 31 on the WPC 1000 Control board and the Bar actuator input to pin 17 as shown in Table 2 13 and Figure 1 at the end of the manual Figure 2 25 Bar Control Enclosure Mounting Dimensions Table 2 13 Bar Control Wiring Connections WPC 1000 Control Board Pin Bar Control Contacts 17 TB102 Top Bar actuator input 31 TB101 Bottom Bar selector switch input 24 Vdc C...

Page 73: ...re that the power source is off before you replace electronic components in a control Disconnect power from the machinery it is connected to before replacing electronic components This includes disconnecting power to the machine control and motor Ensure that installation is performed by qualified personnel Failure to comply with these instructions could result in death or serious injury STATIC DIS...

Page 74: ...the settings you recorded in step 1 10 Perform installation verification see page 2 65 and final checkout see page 3 35 tests CHIP INSTALLED INCORRECTLY Install each chip with the notch facing up otherwise when you power up the control the chips will be destroyed Align pins correctly with the socket before plugging chips in Failure to comply with these instructions could result in property damage ...

Page 75: ... Plate The mounting plate has a hole in each corner to facilitate mounting of the WPC 1000 Control board and related components in your enclosure or console When installing the mounting plate refer to Figure 2 26 for mounting dimensions Be sure to allow at least 1 in clearance on top bottom and both sides of the plate and above the power supply and Control board Figure 2 26 WPC 1000 Mounting Plate...

Page 76: ...osure or console Mount the display so that operators and setup personnel can easily see the readouts and reach the switches Make sure that all switches are no more than one foot 300 mm from the display 2 Cut out a hole in your enclosure or console and drill and tap twelve holes for 10 32 screws referring to Figure 2 27 3 Prop the display panel near the location where you plan to mount it You can d...

Page 77: ...structions Figure 2 27 WPC 1000 Panel Mount Display Mounting and Cutout Dimensions YOUR PANEL tapped or clearance holes for No 10 hardware 12 places allow 9 in 230 mm service loop allow at least 4 in 100 mm clearance behind panel Dimensions inches mm 0 5 12 7 2 places 6 50 165 1 10 00 254 0 9 00 228 6 7 50 190 5 6 00 152 4 0 25 6 4 2 places 0 25 6 4 2 places 4 00 101 6 4 places 8 00 203 2 0 25 6 4...

Page 78: ... of the manual for wiring connections DO NOT USE CONTINUOUS MODE ON PRESS WITHOUT PROPER GUARDING Disconnect the Continuous position on the stroke selector switch and cover the CONT label on your control if your press is not guarded properly for use in Continuous mode or you do not run your press in Continuous mode Failure to comply with these instructions will result in death or serious injury Mo...

Page 79: ...ure 2 29 page 2 53 for cutout dimensions for the display to Figure 2 28 page 2 51 for cutout dimensions for the selector switches 4 Install the four 6 32 x 5 8 studs from inside the enclosure or console 5 Mount the Display board on the four studs with the standoffs and lock nuts making sure that the LED display is at the top facing outward 6 Orient the label correctly from outside the enclosure or...

Page 80: ...lect button and the WPC 1000 Display board 11 Slide the connector at the end of the yellow wire on one arm of the Settings key switch wiring harness over the topmost terminal on the switch body of the Reset Select button as shown in Figure 2 30 page 2 54 Slide the connector at the end of the two black wires on the same arm of the wiring harness over the lower terminal on the Reset Select button sw...

Page 81: ...e selector switches 14 Wire each selector switch to the appropriate terminal block on the WPC 1000 Display board referring to Table 2 14 page 2 51 and Figure 4 at the back of the manual for wiring connections Figure 2 30 Reset Select Button Wiring Connections Table 2 15 Reset Button Settings Key Switch and Mute Lamp Wiring Connections Component Connector on WPC 1000 Display Board Reset button Sett...

Page 82: ...r at one edge see Figure 2 39 page 2 61 Follow the procedure that pertains to the type of ribbon cable you received with your order Installing the Multicolored Ribbon Cable next or Installing the Shielded Gray Ribbon Cable page 2 60 Installing the Multicolored Ribbon Cable When wiring the ribbon cable to the extra connector make sure that the orientation of the brown and tan wires at the edges of ...

Page 83: ...very 18 in see Figure 2 32 These marks occur roughly at the midpoint of 3 inch long sections of cable where the conductors are flattened for easy attachment to the connector Conductors in all other areas of the cable are twisted and cannot be attached to the connector 5 Determine the striped marking that allows you enough cable to make a comfortable connection at J706 on the WPC 1000 Display board...

Page 84: ...ctor top top down on a flat surface with its recessed side facing the display cable as shown in Figure 2 35 page 2 58 Remove the tape from the adhesive on it s grooved bottom Figure 2 33 Display Cable Jacket with Multicolored Ribbon Cable Exposed Figure 2 34 Ribbon Cable Connector Assembly Brown wire Purple wire Cable jacket 4 Ribbon cable Tan wire Connector top Connector bottom Strain relief ...

Page 85: ...with its keyed grooved side facing the recessed side of the inverted connector top slide its slotted ends down over the projections on the connector top see Figure 2 37 page 2 59 then gently bring the V connectors into contact with the ribbon cable Do not press the connector bottom into the connector top at this point Figure 2 35 Connector Top with Multicolored Ribbon Cable Conductors Figure 2 36 ...

Page 86: ...the two halves Do not use slip joint or channel lock pliers to crimp the connector halves 15 Using a sharp Xacto knife trim the extra ribbon cable protruding from the flat side of connector 16 Fold the ribbon cable over the recessed side of the connector top and with the flat side of the strain relief facing the keyed side of the connector slide the strain relief down over the slots in the ends of...

Page 87: ...le inside the WPC 1000 enclosure to reach the 34 pin connector J104 on the WPC 1000 Control board see Figure 2 11 page 2 20 and to allow for a service loop Also make sure that there is enough cable at the Display board end to reach J706 3 Plug the ribbon cable connector into J104 Figure 2 38 Strain Relief Installed on Connector Multicolored Conductors The ribbon cable connector can be plugged into...

Page 88: ...utward then with your index finger pry a hole in the base of the shield i e at the edge of the jacket and draw the conductors through the hole until the shield wires have been completely separated from the conductors 8 Remove the foil surrounding the conductors 9 Pull gently on the braided shield twisting individual wires as necessary to straighten it and create a separate conductor see Figure 2 4...

Page 89: ...e connection by gently pulling the lug and sleeve encased shield in opposite directions The plastic sleeve covering the lug should enclose part of the sleeve encasing the shield 12 Spread the ribbon cable conductors apart so they lie flat Note that one edge of the exposed cable has a red wire 13 Locate the three components of the extra connector the strain relief connector top and connector bottom...

Page 90: ...ttom and with its keyed grooved side facing the recessed side of the inverted connector top slide its slotted ends down over the projections on the connector top see Figure 2 43 page 2 64 then gently bring the V connectors into contact with the ribbon cable Do not press the connector bottom into the connector top at this point Figure 2 41 Connector Top with Gray Ribbon Cable Conductors and Shield ...

Page 91: ...e two halves Do not use slip joint or channel lock pliers to crimp the connector halves 20 Using a sharp Xacto knife trim the extra ribbon cable protruding from the flat side of connector 21 Fold the ribbon cable over the recessed side of the connector top and with the flat side of the strain relief facing the keyed side of the connector slide the strain relief down over the grooves in the ends of...

Page 92: ...lugged into the J706 connector in only one direction When inserting the plug make sure to align the key in the plug with the middle groove on the J706 connector The end of the ribbon cable connector with the red wire must be positioned at the end of J706 labelled 1 If the plug is not inserted correctly the display will not work properly PERFORM INSTALLATION VERIFICATION BEFORE OPERATING PRESS Comp...

Page 93: ...ces are mounted at least the safety distance from the hazardous area Safeguards are in place to prevent entry to the hazardous area under over or around light curtains or other safeguarding devices DISPLAY DOES NOT WORK If the WPC 1000 display does not work properly check to make sure that the display cable is connected correctly on both the Control and Display board ends referring to Installing t...

Page 94: ... of the DSV is crucial to personnel safety 1 Power down the press and press control 2 On the DSV Lockout Relay board which is installed in the lower right corner of the WPC 1000 Control board see Figure 2 11 page 2 20 remove fuse F302 or F303 F302 and F303 are the DSV fuses 3 Power up the press and press control select INCH with the Stroke Select switch and push both Run Inch buttons Observe what ...

Page 95: ... still does not move call Wintriss Tech Support Checking for Error Messages To check for error messages do the following 1 Run the press in Inch for a few strokes If the press runs normally go to the next section If a fault appears on the display look up the fault code in Chapter 5 and follow the remedy provided Once the problem is corrected press the Reset Select button and run the press again in...

Page 96: ...4 42 E stop Input 2 6 1 17 Bar Actuator Input 4 6 41 Top stop Input 2 4 7 16 Foot Switch N C Input 4 5 40 24 V 15 User Input 2 4 4 39 24 V 14 Aux 1 Output 38 Top stop String Center Loop Connection 13 Prior Act Lamp Output 37 Top stop String Drive Output TB101 I O Top TB101 I O Bottom Pin Signal LED Grp Pin Signal LED Grp 12 Ground 36 24 V 11 Mute Lamp 2 Output 5 7 35 Palm Time Lamp 10 Counter Outp...

Page 97: ... S2 Cosine Green 52 R1 drive Red 51 S3 ground Yellow 50 R2 ground Orange 49 S4 ground Brown Table 2 18 WPC 1000 Control Board DSV Lockout Relay Board Wiring Connections Terminal Block Pin Signal TB303 64 DSV A Relay 63 DSV A Relay TB302 62 DSV B Relay 61 DSV B Relay TB301 60 Lockout Relay OUT 59 Lockout Relay OUT 58 Lockout Relay IN Table 2 19 WPC 1000 Control Board Power J103 Wiring Connections T...

Page 98: ...707 Reset Button Settings Key Switch TB705 Micro inch key switch wiring 155 Gnd 156 Top stop in Inch Ground to Disable 3 2 157 WPC Input Micro inch 3 1 TB 702 Mode Select key switch wiring 146 Gnd 147 Not used 148 Foot 1 4 149 One hand 1 3 TB 701 Stroke Select key switch wiring 141 Gnd 142 Continuous 1 6 143 Single stroke 1 5 144 Inch 1 8 145 Off 1 7 ...

Page 99: ...1125100 WPC 1000 User Manual 2 72 Installation ...

Page 100: ...and anti repeat protection Failure to comply with these instructions will result in death or serious injury MORE OPERATORS THAN OPERATOR STATIONS Ensure that there are the same number of active operator stations as there are operators if the press is not equipped with properly installed and operating light curtains During setup lockout tagout the press if there are more operators than operator sta...

Page 101: ... is selected the crankshaft angle is displayed for all Stroke Select settings If you have the optional counter display Angle SPM is the default when the press is in Inch mode but the default switches to the Counter segment in Single stroke and Continuous Parameters displayed by default in the digital LED readout are shown in Table 3 2 page 3 3 Figure 3 1 WPC 1000 Displays Showing Indicator Segment...

Page 102: ... to TDC if necessary 2 Turn off power to the WPC 1000 3 Turn the WPC Settings key switch to its setting i e counterclockwise and turn power to the WPC 1000 back on When the message Int appears in the LED display see Figure 3 2 page 3 4 release the key Table 3 2 WPC 1000 Optional Counter Display Default Parameters Press Running Stroke Select Setting Parameter Shown in Digital LED Display Inch Crank...

Page 103: ...e F79 see Loss of Rotation page 5 15 There are times when you may need to initialize only the Start time Limit such as during troubleshooting see page 3 5 for instructions Resolver Zero Setting Set to zero Re zeroing the Resolver If you need to zero the resolver without re initializing the Start time and Stop time limits follow these steps 1 Verify that your press is at top dead center TDC using a...

Page 104: ...s see Initializing the System page 3 3 do the following 1 Power down WPC 1000 2 While powering WPC 1000 back up turn the WPC Settings key switch to i e clockwise and hold it there When Str appears in the LED display see Figure 3 4 page 3 6 release the key Figure 3 3 WPC 1000 Displays Showing Resolver Zeroed rES Message The Start time Limit value cannot be changed manually BRAKEWARNING INTERRUPTEDS...

Page 105: ...e you started your press do the following 1 Press the Reset Select button repeatedly until the Stopping Angle indicator segment illuminates 2 Turn the WPC Settings key switch to i e counterclockwise The Start Time in milliseconds that was measured the last time you started the press is shown in the LED display Figure 3 4 WPC 1000 Displays Showing Initializing Start time Limit Str Message BRAKEWARN...

Page 106: ... and change the Top stop On Angle setting on the WPC 1000 display do the following INCORRECT INSTALLATION OF OVERRUN LIMIT SWITCH Ensure that the overrun sensor magnet is installed at a proper location if you have Two hand Control without light curtains or light curtains with muting Proper installation of the magnet ensures that if the Top stop output relay fails a hazardous situation will not occ...

Page 107: ...ngle backward i e decreasing the on angle 2 Power down then power up the WPC 1000 to enable the new settings 3 Clear the Loc message on the WPC 1000 display by turning the Stroke Select switch to OFF then to INCH 4 With the press in Inch mode press the Reset Select button until the Top Stop Angle indicator is lit 5 Temporarily set the Top stop On Angle to 211 using the WPC Settings key switch Turn...

Page 108: ...u wish you can use the Your Settings column in the second row to record the correct mounting angle Example You calculated in step 8 that your Top stop On Angle is 284 which falls in the 271 to 300 column in Table 3 3 The correct mounting angle for the overrun sensor magnet would be 330 See Figure 3 5 page 3 10 WHEN DETERMINING TOP STOP ON ANGLE Remember that the Top stop angle has an internal dwel...

Page 109: ...you wish you can use the Your Settings column in those rows to record those settings Example You calculated in step 8 that your Top stop On Angle is 284 which falls in the 271 to 300 column in Table 3 3 The correct switch settings would be OFF for switch 1 and ON for switch 2 See Figure 3 5 13 Set option switches 1 and 2 on S101 on the WPC 1000 Control board to the positions you determined in step...

Page 110: ...view the off angle see Figure 3 6 Example If you mounted the magnet at an angle of 330 the magnetic switch might come on at say 321 and go off at 337 5 Run the press in Inch Single stroke and Continuous modes for about 4 strokes each If the press cycles in every mode without a fault go to step 6 If a fault occurs while you are cycling the press in one or more modes do the following Make sure that ...

Page 111: ...rill and tap a hole using a No 36 drill and 6 32 tap Mount the magnet plastic side up with the 6 32 brass screw provided Adjusting the Top stop Angle In addition to setting the Top stop On Angle preparatory to mounting the overrun sensor magnet see Setting the Top stop On Angle page 3 7 you can periodically adjust the Top stop angle to ensure that your press stops at top dead center Each time you ...

Page 112: ... 5 Run the press in Continuous mode by turning the Mode Select switch to CONT checking the press speed shown in the LED display If your press does not run in Continuous initiate a stroke with the Mode Select switch set to SINGLE 6 When the press reaches normal operating speed in Continuous or the Auto Carry up Angle is passed in Single stroke Top stop the press Note the crankshaft angle shown in t...

Page 113: ...on switch 7 on switch block S101 on the WPC 1000 Control board to OFF to enable changes to the Auto Carry up Angle see Switch 7 Disabling Access to Stop time Limit and Auto Carry up Angle Settings page 3 31 2 Power down then power up the WPC 1000 to enable this settings change INCORRECT AUTO CARRY UP ANGLE Ensure that the Auto Carry up Angle is correct If the operator can reach the pinch point the...

Page 114: ... the LED display The Stop time Limit is a setting used by the brake monitor to determine when the press needs to be stopped to alert the operator to the need for brake repair The Stop time Limit is factory set to 500 milliseconds Determining the Stopping Time of Your Press First you need to determine the Stopping Time of your press at Top stop To do so perform the following steps 1 Install the hea...

Page 115: ...e brake monitor to the Stopping Time stop time limit stopping time Tbm The Tbm value represents normal wear on the brake and ensures that WPC 1000 does not stop the press for small increases in Stopping Time The minimum value that you can set is 10 mS Stop time Limit Calculation Examples Example 1 Your recorded stopping time is 207 mS and your brake is old Take 10 of 207 0 10 x 207 20 7 round it u...

Page 116: ...nd enter the correct Stop time Limit when you set up your WPC 1000 Perform a 90 Stop Test any time you change the Stop time Limit of WPC 1000 See Determining the 90 Stop Time page 3 18 Base the Stop time Limit on the actual Stopping Time Recalculate the safety distance based on the new Stop time Limit and adjust or reinstall safeguarding devices according to the new safety distance see Calculating...

Page 117: ...switch to to arm the test The 90 Stop Test indicator flashes to alert you that the test has been armed The press will stop the next time the crankshaft angle reaches 90 INCORRECT SAFETY DISTANCE DUE TO INCORRECT STOP TIME Perform a 90 Stop Test any time you change the Stop time Limit of WPC 1000 Recalculate the safety distance based on the new Stop time Limit and adjust or reinstall safeguarding d...

Page 118: ...on once before starting the press The first time you run this test the display shows a value of 0 zero until the test is completed In subsequent tests the display shows the Stopping Time measured in the last test INCORRECT SAFETY DISTANCE DUE TO INCORRECT STOP TIME Perform a 90 Stop Test any time you change the Stop time Limit of WPC 1000 Recalculate the safety distance based on the new Stop time ...

Page 119: ...can cause injury PRESS MAY NOT STOP BEFORE OPERATOR REACHES PINCH POINT Calculate the safety distance according to the applicable safety regulations the instructions in this chapter and in your light curtain user manual Mount the Shadow light curtain heads at least the safety distance from the nearest pinch point or hazardous area of your press see Figure 3 9 Mount your Two hand Control at least t...

Page 120: ... presses and the formula contained in B11 1 2009 represents a new consensus on the proper installation of light curtains More variables are included in the ANSI than in the OSHA formula and the ANSI calculation is therefore more precise For complete information on OSHA regulation 1910 217 and ANSI standards B11 1 2009 and B11 19 2003 see Appendix A OSHA and ANSI formulas are explained below If you...

Page 121: ...ation or at maximum closing velocity The response time of the press control Tc which is the time it takes for the control to activate the press s brake is included in the result of the 90 stop time test run on the WPC 1000 see Determining the 90 Stop Time page 3 18 You can use the value generated by the 90 stop time test for the variables Ts Tc in the ANSI formula Response times Tr for Shadow ligh...

Page 122: ...Safety Distance for a Light Curtain Using the ANSI Formula The ANSI formula is Ds K x Ts Tc Tr Tbm Dpf The following value is a constant K 63 inches per second We will use the following values for the variables in the formula Ts Tc 0 190 sec result of the 90 stop time test Tr 0 059 sec response time of Shadow 8 with 202 in combined length including extensions Tbm 0 035 sec see Example 2 in Stop ti...

Page 123: ...ress control that activates the brake Response time of the light curtain Additional time Tbm added to the Stopping Time to compensate for brake wear The response time of the press control is included in the result of the 90 stop time test run on the WPC 1000 see Determining the 90 Stop Time page 3 18 Response times of Shadow light curtains are shown in Table 3 4 page 3 22 Calculation of the Tbm va...

Page 124: ...dding to Safety Distance for Blanking Windows When using fixed or floating blanking windows with your Shadow 8 light curtain you must add a factor to the calculated safety distance for each beam that is blanked This applies whether you use the ANSI or the OSHA formula For a one beam fixed blanking window you must add 5 38 in 136 6 mm to the calculated safety distance ANSI formula You must add 5 76...

Page 125: ...t at the factory is 100 mS To set Micro inch do the following 1 With power on to the WPC 1000 and the press in Inch mode press the Reset Select button repeatedly until the Micro inch indicator becomes lit see Figure 3 10 2 Turn the WPC Settings key switch to counterclockwise to increase the Micro inch time setting shown in the LED display or turn the key to clockwise to decrease the setting Figure...

Page 126: ...mit switch closes at the same angle on every stroke Settings for option switches 1 and 2 are shown in Table 3 5 ELECTRIC SHOCK HAZARD WHEN WORKING INSIDE THE ENCLOSURE Turn off and disconnect power from WPC 1000 and from the machinery it is connected to before making any wiring connections or settings inside the enclosure This includes power to the machine control and motor Failure to comply with ...

Page 127: ...e operator presses the switch after this window has expired the press will not start The light curtain must be broken again before the next stroke can be initiated Enabling Foot Control in a Foot Switch When the Mode Select switch is set to FOOT switch 3 controls how the Foot Switch must be activated in order to initiate and complete a stroke as shown in Table 3 7 page 3 29 Switch 3 Foot Switch se...

Page 128: ...everal Top stops to fine tune its settings If you use the ACTS feature it is critical that you set the Stop time Limit on your brake monitor correctly so that you have advance warning of the need for brake maintenance Since increases in stopping angle may be due to brake wear rather than to speed changes ACTS may increase the difficulty of detecting brake problems unless back up systems are in pla...

Page 129: ... synchronous time Switch 6 Enabling Access to Cam Settings Switch 6 controls access to settings for cam on and off angles if you have ordered the optional two channel cam output assembly See Table 3 10 page 3 31 When switch 6 is set to OFF cam on and off angles cannot be set or adjusted When switch 6 is set to ON cam on off settings can be made and changed You should only change this switch from i...

Page 130: ...F and H Errors One switch 8 function specifies whether the press takes an additional stroke before it top stops when an F or an H fault occurs after 210 as shown in Table 3 12 page 3 32 Table 3 10 Switch 6 Settings Enabling Cam Adjustments Setting Access to Cam Settings OFF Normal operation Default Access to cam settings disabled ON Access to cam settings enabled Cam on and off angles can be set a...

Page 131: ...terrupted Stroke cannot occur in Inch mode Table 3 12 Switch 8 Settings Top stop Mode for F and H Errors Setting Top stop Behavior for F and H Errors OFF Normal operation Default Press top stops on current stroke when F or H fault occurs before 210 on next stroke if error occurs after 210 ON Press top stops on current stroke at whatever angle an F or H error occurs NON SAFETY OUTPUT USED FOR SAFET...

Page 132: ...cam settings refer to Switch 6 Enabling Access to Cam Settings page 3 30 2 Power down the WPC 1000 then power the unit back up to enable the new setting If you do not cycle power the previous switch 6 setting will remain in effect 3 Turn the Stroke Select switch to INCH to put the press in Inch mode 4 Press the Reset Select button repeatedly until the Top Stop Angle segment is illuminated When opt...

Page 133: ...ings if necessary 9 Set option switch 6 back to the OFF position 10 Power down WPC 1000 then power it back up to enable the new setting If you do not cycle power the previous switch 6 setting may remain in effect Figure 3 13 WPC 1000 Displays Showing Cam Channel 1 OFF Setting Cam 1 ON 180 If you do not cycle power to the WPC 1000 after moving option switch 6 back to its default setting WPC 1000 wi...

Page 134: ...g testing Failure to comply with these instructions will result in death or serious injury INCORRECT INSTALLATION Perform the necessary checkout procedures according to the instructions in this manual Ensure that all procedures are performed by qualified personnel Failure to comply with these instructions will result in death or serious injury ELECTRIC SHOCK HAZARD WHEN WORKING INSIDE ENCLOSURE WI...

Page 135: ... Corresponding pin numbers for LEDs are shown in bold LEDs w out pin numbers are for internal connections Pins 141 157 are on display board 24 VDC 5 Logic A 5 Logic B GROUP 1 144 Inch select 145 Off select 142 Continuous select 148 Foot select 143 Single stroke select 149 One hand select Up button Reset button 3 6 4 7 8 5 1 2 GROUP 2 2 Palm switch input N O 3 Foot switch input N O 4 One hand input...

Page 136: ... for a few strokes If the press runs without displaying an error go to the next applicable test If a fault code between F80 and F89 or between H80 and H89 appears on the display this indicates a problem with the overrun limit sensor Check to make sure that you installed the overrun limit sensor see Installing the Overrun Limit Switch page 2 25 and overrun limit sensor magnet Installing the Overrun...

Page 137: ...pen Perform the following test to verify that your Shadow light curtain is installed and wired correctly and operating properly referring also to the troubleshooting information in your light curtain user manual if necessary If you have more than one light curtain on your press perform this test on each light curtain 1 Power up the light curtain 2 Check to see whether there is power to the Shadow ...

Page 138: ... V INT terminal in the transmitter see Figure 6 at end of manual Shadow VI pin 19 on auxiliary TB4 in the control see Figure 2 at end of manual Shadow VI WPC Interface Board pin 5 on TB4 see Figure 7 at end of manual If the applicable terminal does not read 0 V relative to ground check and correct the ground wiring for the unit The Light Curtain Test Mode jumper which is located in the lower right...

Page 139: ...r Station 5 Check to see whether fault code F13 appears on the LED display If F13 displays go to the next step If F13 does not display check to see whether the E stop input 1 and E stop input 2 LEDs on the WPC 1000 Control board turn off when the Emergency Stop button is pressed If the two LEDs do not turn off check the wiring of the E stop input 1 and 2 connections and correct any problems If the...

Page 140: ... 13 Press both Run Inch palm buttons on the Operator Station at the same time The ram should not move and the fault code associated with the input the counterbalance pressure switch is connected to normally F51 for User 1 Input should display If the ram does not move and the appropriate fault code appears restore the counterbalance air press the Reset Select button and go to the next step If the r...

Page 141: ...stroke or does not stop at top dead center call Wintriss Tech Support If the ram moves but does not make a complete stroke or does not stop at top dead center and an overrun limit switch fault does not display check the wiring of the palm buttons and light curtains correcting any problems then Inch the ram to the top of the stroke and repeat the test If the ram still does not make a complete strok...

Page 142: ...t field while the ram is on the downstroke Observe the action of the ram If you are using one light curtain and the ram stops immediately and the Interrupted Stroke LED flashes go to the next step If you are using two light curtains and the ram stops immediately and the Interrupted Stroke LED flashes inch the ram to the top of the stroke and repeat the test starting with step 6 by interrupting the...

Page 143: ...the test again starting with step 2 If the ram still does not make a complete stroke or does not stop at top dead center call Wintriss Tech Support If the LED display is blank or shows an error other than an overrun limit switch fault check and correct the wiring of the palm buttons and light curtains correcting any problems then run the test again starting with step 2 If the ram still does not co...

Page 144: ...cle the press through one stroke When the press top stops continue to hold down the left button and remove your hand from the right button then after a moment replace your hand on the right button and continue to hold down both buttons If the press does not initiate the stroke go to the next step If the press does initiate the stroke check the wiring of the palm buttons When the problem has been c...

Page 145: ...mode and both Run Inch buttons are pressed simultaneously To perform the test do the following 1 Set the Stroke Select switch to SINGLE 2 Press and hold down both Run Inch palm buttons until the press completes a stroke and for ten seconds after the press stops If the press makes one stroke and then top stops WPC 1000 is operating correctly Go to the next applicable test If the press cycles again ...

Page 146: ...4 If the Prior Act lamp does not turn off after eight seconds stop Do not go any further Call Wintriss Tech Support 4 Press the Prior Act button and before the indicator lamp goes out press both Run Inch palm buttons releasing them after bottom dead center on the first stroke The press should continue running If the press continues to run go to the next step If the press stops check the wiring of ...

Page 147: ...nterrupted Stroke LED should flash If the press comes to an immediate stop and the Interrupted Stroke LED flashes go to the next step If your WPC 1000 has the muting option and the ram stops as soon as it reaches the non muted i e downward portion of the stroke go to the next step If your WPC 1000 has the muting option and the ram does not stop in the non muted portion of the stroke check the wiri...

Page 148: ...on the first stroke The press should continue running If the press continues to run go to the next step If the press stops check the wiring of the palm buttons and correct any problems Run the test again If the press still stops call Wintriss Tech Support 4 Press the Emergency Stop button on the Operator Station The ram should stop immediately the F13 fault code should appear in the LED display an...

Page 149: ...referring to Figure 3 14 page 3 36 for LED locations on the WPC 1000 Control board RESET EMERGENCY STOP BUTTON AFTER USE The Emergency stop button is not spring loaded You must pull it up to its original position to reset the Emergency stop F13 fault INJURY DURING TESTING Keep all personnel away from the press during testing Be sure there is no die or other tooling in the press during testing Fail...

Page 150: ...t the Auto Carry up Angle 7 Press and hold the Foot Switch through the Auto Carry up Angle then release the Foot Switch The press should complete the stroke stopping at Top stop 8 Press and hold the Foot Switch again but release it before the Auto Carry up Angle The press should begin to cycle but stop immediately when the Foot Switch is released 9 Press and hold both Run Inch buttons The press sh...

Page 151: ...wer back up the WPC 1000 if necessary to enable the settings change The WPC 1000 is now in normal One hand Control operation the press stroking each time the One hand Control switch is depressed 4 Press the One hand Control switch and release it immediately The press should make a single stroke and stop at top dead center Verify that the Palm switch input N C LED turns off when the One hand Contro...

Page 152: ...h input LED on the WPC 1000 Control board is lit 3 Turn the press motor off 4 While the press s flywheel is still turning press and release the Operate button on the Bar Mode Control Verify that the following events occur The Dual Safety Valve should energize while the Operate button is depressed and de energize when the button is released The Bar actuator input LED should illuminate while the Ope...

Page 153: ...the press stops and the appropriate fault code displays the input is wired and operating properly Repeat the test for the other user inputs When you have checked all of the inputs go to the next step If the press does not stop and or the appropriate fault code does not display check the wiring of that input and rerun the test If the press still does not stop and or the correct fault code does not ...

Page 154: ...T label on your control s Stroke Select switch Failure to comply with these instructions will result in death or serious injury MORE OPERATORS THAN OPERATOR STATIONS Ensure that there are the same number of active operator stations as there are operators if the press is not equipped with properly installed and operating light curtains During setup lockout tagout the press if there are more operato...

Page 155: ...U TURN ON POWER TO THE PRESS Whenever you turn on power to your press the message Loc appears in the LED display see Lockout Message page 5 3 To clear this message simply turn the Stroke Select switch to OFF and then back to the previous operating mode If the Stroke Select switch is already in the OFF position when you power up turn it to the desired stroke selection to clear the Loc message Once ...

Page 156: ...hen the Emergency stop occurs WPC 1000 stays in Inch mode allowing the operator to return the press to Top stop by simultaneously pressing and holding the Run Inch palm buttons just as he does in Two hand Maintained Single stroke mode Responding to a Brake Warning The amber colored Brake Warning LED on the WPC 1000 display see Figure 1 3 page 1 5 for location illuminates whenever the Stopping Time...

Page 157: ...ent crankshaft angle is shown in the LED display Viewing the Counter Value To view the current value of the counter do the following 1 Press the Reset Select button repeatedly until the Counter indicator segment illuminates The digital display will show the current counter value as shown in Figure 4 1 The Counter segment is selected automatically when the Stroke Select key switch is turned from IN...

Page 158: ... the counter reaches the preset value WPC 1000 sends a Top stop signal to the press and displays the F15 fault code on the digital LED display see Operational Faults page 5 6 indicating that the counter preset has been reached Press the Reset Select button to clear the counter returning it to zero The counter then starts counting again from one 1 The counter preset value will remain the same until...

Page 159: ...ed turn the WPC Settings key switch to clockwise and hold it while you press the Reset Select button The LED display will show the value 0 zero 2 Release the WPC Settings key switch Figure 4 2 WPC 1000 Optional Counter Display with Counter Preset Value Shown The longer you turn and hold the key switch to or the more quickly the value changes If the number you want to enter is very large 500 000 to...

Page 160: ...e light curtain will be muted on the upstroke if WPC 1000 has the muting option If no light curtain is installed set the switch to 2 HAND If you set the switch to 1 HAND WPC 1000 defaults to Two hand mode IMPROPER SAFEGUARDING Ensure that the machine guarding system is installed and maintained according to OSHA regulation 1910 217 ANSI standards B11 1 and B11 19 and any other regulations or standa...

Page 161: ... palm buttons until the ram comes to a stop at the top of the stroke 4 To initiate another stroke release the Run Inch buttons then press and hold them until the ram again comes to rest at the Top stop position Top stop Bypass Top stop in Inch Disabled Top stop in Inch can be disabled so that the ram continues to cycle without coming to a Top stop as long as the Run Inch buttons on the Operator St...

Page 162: ...ring Micro inch page 2 32 Dead Motor Inch Dead Motor Inch is a feature that allows you to operate the press in Inch mode for a short time after the main motor is turned off using the energy stored in the flywheel Dead Motor Inch allows the press to be inched in smaller increments than is possible when the press is running and is useful during setup To activate Dead Motor Inch do the following 1 Tu...

Page 163: ...nstructions will result in death or serious injury If you are running Two hand Only firmware One hand and Foot modes are not available OPERATOR STATION WIRED INCORRECTLY Run all necessary tests to verify that each Operator Station is wired correctly and provides proper anti tie down see page 3 45 and anti repeat see page 3 46 protection Failure to comply with these instructions will result in deat...

Page 164: ...stem fault is detected or if a light curtain is blocked Single stroke One hand Operation Single stroke One hand operation can only be used with WPC 1000 systems running Two hand One hand Foot firmware equipped with a Mode Select key switch and employing a Shadow light curtain to guard the point of operation To run the press in this mode do the following 1 With the Mode Select switch set to 1 HAND ...

Page 165: ...trol Ensure that proper safeguarding devices are installed and working properly Wintriss takes no responsibility if safeguarding devices are not installed or working correctly DO NOT use WPC 1000 or a One hand Control as a safeguarding device Install and operate WPC 1000 and a One hand Control in accordance with OSHA and ANSI regulations Failure to comply with these instructions will result in dea...

Page 166: ...reak the light curtain then remove your hand and press the One hand Control button within 8 seconds if option switch 3 is set for Light Curtain Break mode The press will make a complete stroke coming to rest at Top stop If the Interrupted Stroke LED flashes press and hold the Run Inch palm buttons on the Operator Station to return the press to Top stop The Interrupted Stroke LED should turn off Th...

Page 167: ... With the Stroke Select switch set to FOOT depress the Foot Switch to initiate a stroke releasing or holding the pedal depending on the option switch 3 setting Release the Foot Switch if option switch 3 is set for Foot Trip Hold the Foot Switch through the Auto Carry up Angle if option switch 3 is set for Foot Control The ram completes the stroke coming to rest at Top stop INCORRECT INSTALLATION Y...

Page 168: ...tain is blocked during the non muted portion of the stroke IMPROPER SAFEGUARDING Ensure that the machine guarding system is installed and maintained according to OSHA regulation 1910 217 ANSI standards B11 1 and B11 19 and any other regulations or standards that apply Ensure that guarding is properly installed to prevent access to the machine over under or around any guarding device Failure to com...

Page 169: ...will stop if one of the following events occurs You press the Top Stop button You press the Emergency Stop Reset button A system fault is detected The light curtain is blocked during the non muted portion of the stroke INCORRECT INSTALLATION You must install a Shadow light curtain correctly and connect it to WPC 1000 properly in order to run the press in Continuous Foot mode Failure to comply with...

Page 170: ...ar Control enclosure 6 Bar the press using a spring loaded bar 7 If an F26 error appears in the display press the Reset Select button to clear it and continue with the barring operation INJURY WHEN USING BAR MODE Keep all personnel away from the press while it is being barred Use a spring loaded turnover bar when you bar the press Failure to comply with these instructions will result in death or s...

Page 171: ... or the press will not start In addition all Operator Stations must contain a Two hand Control module to provide the required 1 2 second palm or synchronous time HAZARDS EXPOSED BY NON WORKING OPERATOR STATION Safeguard the point of operation exposed by the non working Operator Station when using multiple operator stations The exposed area near a disabled Operator Station must be properly guarded ...

Page 172: ...re to comply with these instructions will result in death or serious injury IMPROPER SAFETY RELAY REPAIR If a relay fuses DO NOT reset the WPC 1000 to restart the machine Remove the WPC 1000 from operation immediately and replace the DSV Lockout relay board before operating the press again Failure to comply with these instructions will result in death or serious injury ALL SIGNAL GROUNDS MUST BE C...

Page 173: ... the problem that caused the fault 2 Clear the fault code or message on the WPC 1000 display by doing one of the following To clear F and H faults press the Reset Select button on the display or if one is installed a Remote Reset switch To clear E faults power down the WPC 1000 then power the unit back up Figure 5 1 WPC 1000 Displays Showing Fault Code Table 5 1 Fault Codes Significance of Initial...

Page 174: ...n of this LED often means that the brake is wearing and or defective To respond to this error do the following 1 Contact your maintenance crew immediately and have them investigate the condition of the brake 2 If the brake checks out your Stop time Limit is too tight not allowing for normal wear Set a new Stop time Limit following the instructions in Running Brake Monitor Tests and Making Settings...

Page 175: ...20 Failure to comply with these instructions will result in death or serious injury PRESS MALFUNCTION Correct or repair any press malfunction or wiring error before restarting the press Failure to comply with these instructions will result in death or serious injury Figure 5 3 WPC 1000 Display Showing Stopping Time Fault BRAKE WARNING The Brake Warning LED alerts you when the Stopping Time of the ...

Page 176: ...a fault by following the suggested remedy contact Wintriss Tech Support for assistance Resolver Faults Problem The press is running faster than 1000 SPM the resolver has failed or the wiring in the resolver circuit to WPC 1000 is loose or bad Remedy If WPC 1000 s rated press speed is exceeded reduce the speed If press speed is not the problem check the resolver wiring for shorts breaks or loose co...

Page 177: ...0 to 30 Remedy Re zero the resolver at top dead center see Re zeroing the Resolver page 3 4 Operational Faults Problem The main motor has been turned off Remedy Turn the motor back on clearing the Loc message first if the motor was deactivated during Lockout see page 5 3 If the motor won t turn on you may need to replace the Forward contact blocks on the starter with new unused ones F04 or F05 E07...

Page 178: ...to the user manual for that control to check for a specific error condition and correct the error Problem The Prior Act button on the Operator Station was depressed i e switch was open after initiation of the stroke Remedy Press Reset Select If the problem persists check the wiring from the Operator Station to WPC 1000 If necessary Contact Wintriss Tech Support Problem The preset on the optional c...

Page 179: ...d correct the condition that the inputs are monitoring see Table 5 2 page 5 12 Problem You are attempting to run the main motor in reverse without selecting Two hand Inch mode Remedy Switch to Two hand Inch mode then run the motor in reverse Problem The N O inputs from the Run Inch palm buttons on the Operator Station do not turn off i e open when they should Remedy Check to make sure that the pal...

Page 180: ...mine the correct operating mode for your stroke selection Problem Both Run Inch palm buttons on the Operator Station were pressed in One hand mode Remedy Press only one Run Inch palm button when running the press in One hand mode Problem The flywheel turned faster than 6 SPM while the press was in Bar mode creating a potentially unsafe barring condition Remedy After clearing the error bar the pres...

Page 181: ...art request received from second processor F33 Incorrect reply to Mode Change message received from second processor F34 No reply to Mode Change message received from second processor F35 Incorrect reply to Power up message received from second processor F36 No reply to Reset Error message received from second processor F37 No reply to Compare Input Buffers message received from second processor H...

Page 182: ... rebuild the valve if necessary F48 Check to see whether the air pressure is turned off or set too low and correct if necessary If the error persists after you reset the unit contact Wintriss Tech Support Customized Status Codes Problem A failure has occurred in an auxiliary press function e g lubrication system wired to WPC 1000 user input 1 or 2 see Table 5 2 Remedy Diagnose and correct the cond...

Page 183: ...ort Problem The light curtain was obstructed during the stroke Remedy Remove the obstruction Problem A light curtain is connected with Two hand Only firmware installed in WPC 1000 Remedy Remove the Two hand Only firmware and install a firmware version intended for use with a light curtain referring to Installing Revised Firmware in WPC 1000 page 2 46 Contact Wintriss Tech Support for help in selec...

Page 184: ...f the error persists after you reset the unit contact Wintriss Tech Support for assistance or replacement of the driver Top stop Circuit Driver Failure Problem The Top stop input circuit driver has failed or is about to fail Remedy Check Top stop circuit wiring and correct any problems If the error persists after you reset the unit contact Wintriss Tech Support for assistance or replacement of the...

Page 185: ...es DO NOT reset the WPC 1000 to restart the machine Remove the WPC 1000 from operation immediately and replace the DSV Lockout relay board before operating the press again Failure to comply with these instructions will result in death or serious injury F70 DSV relay driver A was not off at start of stroke F71 DSV relay drivers A and B did not turn on properly or have shorted F72 or H72 DSV Control...

Page 186: ...ay be bad resulting in no movement of the crankshaft and resolver even though the DSV is energized In addition an internal WPC 1000 problem could have occurred Remedy Check the Start time Limit setting and re initialize if necessary see Initializing Only the Start time Limit page 3 5 Check the resolver and resolver drive and replace the resolver if necessary Check the clutch and repair if necessar...

Page 187: ... closes only once per stroke referring to Installing the Overrun Sensor Magnet page 3 7 and the LED map on page 3 36 Check to make sure that the switch is installed correctly referring to Installing the Overrun Limit Switch page 2 25 and that the magnet is installed at the correct angle Also check to make sure that the magnet is attached using a brass or other non ferrous screw Check the diameter ...

Page 188: ...t the magnet on a shaft with a smaller diameter Check installation of the overrun sensor and magnet and wiring of the overrun sensor referring to Installing the Overrun Limit Switch page 2 25 and Mounting the Overrun Sensor Magnet page 3 11 Overrun Limit Switch Setting Fault Problem The angle range e g 271 to 300 within which the Top stop On Angle must fall have not been set correctly on option sw...

Page 189: ...ear on the WPC 1000 display To clear the fault and reset the DSV press Reset Select and turn the Stroke Select key switch to OFF then to one of the other operating modes see page 5 11 If you have trouble resetting the DSV the problem may be that both poppets are faulted requiring more air for a reset than can be supplied by the system In this case try resetting the unit with the muffler port obstr...

Page 190: ...ed upon for use in any specific application The material is provided with PMA s permission for informational purposes only Refer to the most recent versions of OSHA documents To obtain copies of OSHA regulations write to OSHA s Office of Information and Consumer Affairs 200 Constitution Avenue NW Room N3647 Washington DC 20210 Tel 202 219 8151 fax 202 219 5986 REFER TO CURRENT REVISIONS OF OSHA AN...

Page 191: ...of operation Presence sensing device c 3 i a Refers to the functional requirement of a presence sensing device which prevents and or stops normal stroking of the press OSHA 1910 217 c 3 iii iii A presence sensing point of operation device shall protect the operator as provided in paragraph c 3 i a of this section and shall be interlocked into the control circuit to prevent or stop slide motion if ...

Page 192: ...me increase must be accommodated due to braking system deterioration a percentage factor must be added to the measured time to obtain the factor for use in the equation for determining safety distance A percentage factor of 20 is recommended for presses with new brakes or brakes of good condition For older brakes a 10 factor is recommended Example Measured stopping time 0 190 seconds Time factor 1...

Page 193: ...s auxiliary equipment and safeguards are in safe operating condition and adjustment The employer shall maintain records of these inspections and the maintenance work performed Records of clutch and brake will be weekly Other inspections are periodic subject to time factor determined by employer ii Each press shall be inspected and tested no less than weekly to determine the condition of the clutch...

Page 194: ...accepted standards under the designation American National Standards The standards reflect a national consensus of manufacturers consumers scientific technical and professional organizations and governmental agencies Shown below are extracts of standards requirements and explanatory information from ANSI B11 1 2009 and B11 19 2003 for presence sensing devices light curtains and Two hand controls C...

Page 195: ...sponse time of the control system and the time it takes hazardous motion to stop The following formula should be used when calculating the safety distance Ds Ds K Ts Tc Tbm Where K 63 inches second hand speed constant Ts the stop time of the press measured from the final de energized control element usually the air valve Tc the response time of the control Tbm the additional time allowed by the st...

Page 196: ...evice should be located or adjusted so that the device always responds to the intrusion at or prior to the safety distance Ds Also care should be taken when installing the device so that it does not detect false signals from other devices or equipment in the area The presence sensing device cannot protect against a catastrophic failure of the press which causes unintended cycling action See Annex ...

Page 197: ...ns or which incorporate fixed blanking or floating blanking features shall be designed so that the adjustments or features are capable of supervisory control by the user E8 6 3 10 Typically these adjustments or controls are key operated or located under lockable covers 8 6 3 11 The device shall be provided with a means that visibly indicates when it is functioning properly E8 6 3 11 Red and green ...

Page 198: ...evice to the press control shall conform to the requirements of 6 11 and 8 8 8 6 3 15 The sensitivity of the device to intrusion shall not be adversely affected by changing conditions around the press 8 6 3 16 The effective sensing field of the device shall be located at distance from the nearest point of operation hazard so that individuals cannot reach into the point of operation with a hand or ...

Page 199: ...e monitor 6 12 NOTE No increase in safety distance is required for fixed blanking applications if the blanked area is entirely occupied by the material or fixtures In some instances the use of blanking does not allow efficient production of certain piece parts Horizontal placement of the sensing field so that it detects that operator s waist area may present a solution In this application the oper...

Page 200: ... or object sensitivity is greater than the value used to calculate the safety distance E8 6 3 18 Examples of ambient light are associated with windows light fixtures skylights bay doors or die lights 8 6 3 19 All areas of entry to the point of operation not protected by the presence sensing device shall be otherwise safeguarded E8 6 3 19 Usually the electro optical presence sensing devise is used ...

Page 201: ... obstruction with a diameter of 25 mm 1 inch to pass undetected at certain points in the field 8 3 1 3 The device shall not fail to change its output state if not muted when it detects the presence of an individual E8 3 1 3 Muting may be accomplished by the device its interface auxiliary controls or the machine control system When the device provides the muting its output may or may not change sta...

Page 202: ...F and area scanning presence sensing safeguarding devices shall be designed and constructed to meet the requirements of 6 1 8 3 1 10 The area scanning device shall provide a means or operating mode to verify the size shape and detection capabilities of the detection area or zone Information shall be provided by the area scanning device supplier to identify the a maximum safeguarding range b minimu...

Page 203: ... with the device to prevent the individual from exposure to the hazard When an individual can pass through the sensing field see the requirements of 8 3 2 3 The electro optical presence sensing device may fail to detect an individual s presence due to reflective workpieces or objects in the vicinity of the device Care should be used to ensure that these reflections do not render the device ineffec...

Page 204: ... devices have sensing fields that can vary due to antenna e design effects of adjacent machinery and equipment field sensitivity adjustments and environmental factors such as humidity or temperature Before the machine is used for production purposes the RF device should be checked to ensure that the effective field protects individuals at the safety distance 8 3 2 3 The presence sensing device sha...

Page 205: ...roduction The intention of a manual reset is to encourage the diagnosis of a failed component subassembly device or module A second failure may occur during the diagnostic or troubleshooting process negating the safety function s Additional safeguarding should be used to protect individuals during this process See the definition for control reliability and Annex C for further information If the ma...

Page 206: ...ect the performance of the device 8 3 2 8 The total tolerance in the range measurement of an area scanning device shall be included in determining the distance from the nearest recognized hazard to the detection area or zone This detection area shall be identified and tested to ensure that the device is able to detect individuals entering the detection area The effective sensing field shall be ver...

Page 207: ...1125100 WPC 1000 User Manual A 18 Extracts from OSHA and ANSI ...

Page 208: ...t the Operator Station meets the requirements of all applicable safety regulations Ensure that the Operator Station is wired correctly Ensure that on any non Wintriss Operator Station the Run buttons are placed so that two hands are required to push them at the same time and that buttons cannot be pushed simultaneously with one hand or with one hand and one elbow Ensure that on any non Wintriss Op...

Page 209: ...ations page 330 Table B 2 Specifications for Operator Station Switches Switch Specifications Run NEMA 12 or 13 UL rated 1 NC 1 N0 single contact block with transfer style contacts One contact bar moves from N C contacts to the N O contacts to ensure that the N C and N O contacts cannot be closed simultaneously Allen Bradley AB S 800T D1JA Square D 9001KR25GH13 or equivalent Must be guarded against...

Page 210: ...er underneath the DSV Lockout Relay board on the old board see Figure C 1 below Old boards have assembly number D4315202 new boards have assembly number 4332701 Figure C 1 Old WPC 1000 Control Board with DSV Lockout Relay Board Location of Important Components NOTICE GROUP 2 GROUP 1 GROUP 4 GROUP 3 GROUP 5 GROUP 6 TB101 TB102 DS101 J101 LO SPEED U125 FIRM WARE CHIP B J102 DS132 TB103 RESOLVER DISP...

Page 211: ... compatible with both old and new control boards Firmware versions lower than V 2 77 only work with the old board If you install a new board in WPC 1000 systems running firmware earlier than V2 77 you will get an F35 error Table C 1 Differences between New and Old Control Boards Component New Board Old Board Light Curtain Test Mode jumper J107 Located beneath DSV Lockout Relay board see Figure 2 1...

Page 212: ...tion for bottom dead center brake monitor A WPC 1000 feature that checks for brake wear calculated safety distance See safety distance cam channels Relays that open and close on signals from the programmable cam switch to turn auxiliary equipment on and off at specified crankshaft angles concurrent time The length of time within which each pair of palm switches on all Operator Stations connected t...

Page 213: ...ormula for calculating the safety distance The hand speed constant is the distance one can theoretically move one s hand and arm in one second OSHA recommends a hand speed constant of 63 inches per second interrupted stroke A condition that occurs when the press has been Emergency stopped before the completion of the stroke by either the operator or an automatic device for personnel or equipment p...

Page 214: ...mounted on the press to check the accuracy of the crankshaft angle maintained by the resolver The overrun limit switch consists of a magnet which is mounted on the crankshaft or other shaft and a stationary magnetic switch which is mounted just above the magnet so that it detects the magnetic field on every stroke The magnetic switch is also called an overrun sensor WPC 1000 checks the resolver cr...

Page 215: ...light curtains two hand controls and type B movable barriers to be mounted to assure the safety of the operator The safety distance is calculated using a precise formula set by OSHA regulations and or ANSI standards The formula uses the results of the ninety degree 90 stop time test start time The amount of time it takes the resolver to start turning after the Dual Safety Valve DSV is energized st...

Page 216: ... the press at the top of its current stroke 0 A top stop can be initiated manually by the operator or automatically by WPC 1000 or other devices zero cam A closure to ground signal that turns on at approximately 270 and turns off at 30 Zero cam can be used with AutoSet load monitors to zero or clear the current tonnage reading Zero cam is also used with RamPAC to check counterbalance air pressure ...

Page 217: ...1125100 WPC 1000 User Manual G 6 Glossary ...

Page 218: ...switch concurrent time setting for multiple op stations 3 30 continuous mode operating the press in continuous foot 4 16 operating the press in continuous two hand 4 15 testing with light curtain s 3 47 testing without light curtain s 3 49 control enclosure See enclosure WPC 1000 controls Wintriss connecting to WPC 1000 2 32 counter disabling counter preset 4 6 resetting counter preset to 999999 4...

Page 219: ...press in top stop in inch 4 8 indicator segment LEDs location 1 5 inputs user See user inputs interlocks See user inputs interrupted stroke location of interrupted stroke LED 1 6 responding to 4 3 setting auxiliary output 1 response to 3 32 J jumper settings Shadow VII and Shadow 8 2 19 L LEDs brake warning LED 4 3 digital readout 1 4 indicator segments 1 5 interrupted stroke LED 4 3 LED indicator...

Page 220: ...or switch 2 27 P palm time setting for one operator station 3 30 panel mount WPC 1000 installing display cable 2 55 installing selector switches 2 51 mounting in enclosure or console 2 49 PC boards location of components WPC 1000 control board old version C 1 WPC 1000 control board with relay board 2 20 WPC 1000 control board without relay board 2 21 WPC 1000 display board 2 33 power supply requir...

Page 221: ... tests checkout 3 35 installation verification 2 65 ninety degree 90 stop time 3 18 top stop on angle adjusting 3 12 determining 3 7 setting 3 7 3 27 top stop button operator station location 1 3 testing top stop circuit 3 37 top stop bypass operating the press in 4 8 top stop in inch disabling 2 33 operating the press in 4 8 top stop mode for F and H errors setting 3 31 two hand mode operating th...

Page 222: ... 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 V Safety Light Curtain DA71433 DA71449 Shadow VI Safety Light Curtain DA71422 DA71445 Shadow VII Safety Light Curtain ...

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