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Wintriss wpc 2000, User Manual

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WPC 2000 User Manual

1128500

Table of Contents

vii

Figure 2-12. WPC 2000 Main Processor Board (Right or Center Configuration): Location of

Important Components .................................................................................................2-23

Figure 2-13. WPC 2000 Main Processor Board (Left Configuration): Location of Important

Components ..................................................................................................................2-24

Figure 2-14. Overrun Sensor Magnet Placement: Dwell as a Function of Shaft Diameter ..............2-26
Figure 2-15. Overrun Sensor Magnetic Switch: Installation Example  .............................................2-27
Figure 2-16. WPC 2000 Display Board: Location of Important Components  .................................2-34
Figure 2-17. Cam Output Enclosure: Mounting Dimensions  ...........................................................2-37
Figure 2-18. Cam Output Board: Mounting Dimensions  .................................................................2-37
Figure 2-19. Connectors TB2 through TB5 on Cam Output Board  .................................................2-39
Figure 2-20. Installing a Suppressor across an AC Load ..................................................................2-40
Figure 2-21. Installing a Diode across a DC Load ............................................................................2-40
Figure 2-22. “Set Cams” Switch (S701) Positions  ...........................................................................2-41
Figure 2-23. One-hand Control Switch: Mounting Dimensions .......................................................2-44
Figure 2-24. One-hand Control Switch Base: Mounting Dimensions  ..............................................2-45
Figure 2-25. Wiring Connections in One-hand Control Switch (Switch Cover, Bottom View)  ......2-46
Figure 2-26. Bar Control Enclosure: Mounting Dimensions ............................................................2-47
Figure 2-27. WPC 2000 Mounting Plate: Mounting Dimensions  ....................................................2-52
Figure 2-28. WPC 2000 Panel Mount Display: Mounting and Cutout Dimensions  ........................2-53
Figure 2-29. Selector Switch: Cutout Dimensions  ...........................................................................2-55
Figure 2-30. WPC 2000 Display Board Kit: Mounting and Cutout Dimensions  .............................2-56
Figure 2-31. Reset/Select Button Wiring Connections .....................................................................2-57
Figure 3-1. WPC 2000 Display Showing Indicator Segments  .........................................................3-2
Figure 3-2. WPC 2000 Display Showing “System Initialized” (“Int”) Message  .............................3-3
Figure 3-3. WPC 2000 Display Showing “Resolver Zeroed” (“rES”) Message  ..............................3-4
Figure 3-4. WPC 2000 Display Showing “Initializing Start-time Limit” (“Str”) Message ..............3-5
Figure 3-5. Setting Overrun Timing: Example  .................................................................................3-9
Figure 3-6. WPC 2000 Display Showing Overrun Sensor “On” Angle  .........................................3-10
Figure 3-7. WPC 2000 Display Showing Stop-time Limit Value  ..................................................3-16
Figure 3-8. WPC 2000 Display Showing Results of 90° Stop-time Test  .......................................3-17
Figure 3-9. Safety Distance: Distance between Pinch Point and Light Curtain  .............................3-20
Figure 3-10. WPC 2000 Display Showing Micro-inch Time Setting ...............................................3-25
Figure 3-11. S101 Option Switch OFF and ON Settings ..................................................................3-26
Figure 3-12. Cam Channel Settings Display: Cam 1 ON Angle (270°) Shown  ...............................3-34
Figure 3-13. Cam Channel Settings Display: Cam 1 OFF Setting (325°) Shown ............................3-35
Figure 3-14. WPC 2000 LED Indicator Map (Center- or Right-mounted Board) ............................3-37
Figure 3-15. WPC 2000 LED Indicator Map (Left-mounted Board)  ...............................................3-38
Figure 3-16. WPC 2000 Display Board LED Indicator Map  ...........................................................3-39
Figure 4-1. WPC 2000 Display with “Stopping Angle” Value Shown  ............................................4-4
Figure 4-2. WPC 2000 Display with “Counter” Value Shown  ........................................................4-5
Figure 4-3. WPC 2000 Display with “Counter Preset” Value Shown ..............................................4-7
Figure 5-1. WPC 2000 Display Showing Fault Code .......................................................................5-2
Figure 5-2. WPC 2000 Display Showing Lockout Message  ............................................................5-3
Figure 5-3. WPC 2000 Display Showing Stopping Time Fault  .......................................................5-4
Figure 5-4. Ross DM2 DSV Showing Reset Button .......................................................................5-22
Figure C-1. Option 1 Board Installed on WPC 2000 Main Processor Board ................................... C-4
Figure C-2. WPC 2000 Option 1 Board  ........................................................................................... C-5
Figure C-3. WPC 2000 Option 1 Board: LED Map  ......................................................................... C-7

Summary of Contents for wpc 2000

Page 1: ... November 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 DA70481 ...

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 2000 clutch brake control DO NOT use touch buttons for any safeguarding use Failure to comply with t...

Page 4: ...on P of the WPC 2000 User Manual 1128500 This revision of the WPC 2000 user manual covers WPC 2000 software version 6 00 and higher The changes include Revised mounting dimensions for the WPC 2000 enclosure see 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: ...nnecting AC Wiring 2 8 Installing a Dual Safety Valve 2 9 Installing Air Pressure Switches 2 11 Installing a Clutch Air Pressure Switch 2 11 Installing a Counterbalance Air Pressure Switch 2 12 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 15 Wiring an Unwired Operator Station 2 16 Wiring a Us...

Page 7: ... Board 2 41 Setting Switch 1 on S102 on the Main Processor Board 2 41 Wiring a Remote Switch 2 41 Wiring Zero Cam Output to AutoSet 2 42 Wiring a Foot Switch 2 42 Installing a One hand Control 2 43 Mounting a One hand Control 2 44 Wiring a One hand Control to WPC 2000 2 45 Mounting and Wiring the Bar Control Enclosure 2 47 Wiring Automatic Single stroke 2 48 Wiring Automatic Continuous On demand 2...

Page 8: ...ng the Safety Distance 3 19 ANSI and OSHA Safety Distance Formulas 3 20 ANSI Safety Distance Formula 3 21 OSHA Safety Distance Formula 3 23 Adding to Safety Distance for Blanking Windows 3 24 Setting Micro Inch 3 25 Setting Press Option Switches 3 26 Making Settings on Switch Block S101 3 26 Switches 1 and 2 Top stop On Angle Range 3 26 Switch 3 One hand Control and Foot Switch Settings 3 27 Switc...

Page 9: ... Clearing the Stroke Counter 4 5 Viewing the Counter Value 4 5 Resetting the Counter Value to Zero 4 6 Setting and Maintaining the Counter Preset Value 4 6 Setting the Counter Preset 4 6 Disabling the Counter Preset 4 7 Forcing the Counter Preset Value to 999999 4 8 Operating the Press in Inch Mode 4 8 Top stop in Inch 4 9 Top stop Bypass Top stop in Inch Disabled 4 9 Micro inch 4 10 Dead Motor In...

Page 10: ...e and Lockout Relay Failures 5 16 Loss of Rotation 5 17 Internal Timing Input Failures 5 18 Top stop and Overrun Setting Faults 5 18 Overrun Limit Switch Fault 5 18 Overrun Limit Switch Test Angle Fault 5 19 Overrun Limit Switch Setting Fault 5 19 Internal Memory Failures 5 20 Resetting Ross DM2 DSV Faults 5 20 Appendix A Extracts from OSHA Regulations and ANSI Standards A 1 Extracts from OSHA Reg...

Page 11: ...Wiring Figure 16 WPC 2000 and Shadow VII DIN Control Wiring Figure 17 WPC 2000 Ross DM2 DSV Wiring Figure 18 WPC 2000 and Shadow 8 Control Box Wiring Figure 19 WPC 2000 and Shadow 8 Wiring Figure 20 WPC 2000 Plus Option 1 User Input External Wiring List of Figures Figure 1 1 WPC 2000 Control Enclosure and Display 1 2 Figure 1 2 Operator Station Components Side mounted Run Inch Palm Buttons 1 3 Fig...

Page 12: ...gure 3 1 WPC 2000 Display Showing Indicator Segments 3 2 Figure 3 2 WPC 2000 Display Showing System Initialized Int Message 3 3 Figure 3 3 WPC 2000 Display Showing Resolver Zeroed rES Message 3 4 Figure 3 4 WPC 2000 Display Showing Initializing Start time Limit Str Message 3 5 Figure 3 5 Setting Overrun Timing Example 3 9 Figure 3 6 WPC 2000 Display Showing Overrun Sensor On Angle 3 10 Figure 3 7 ...

Page 13: ... Board Wiring 2 63 Table 2 21 Resolver TB 106 Wiring 2 63 Table 2 22 Cam Outputs TB 109 Wiring 2 63 Table 2 23 Display Board Wiring 2 63 Table 2 24 AC Power Wiring 2 63 Table 3 1 WPC 2000 Display Default Parameters Press Running 3 2 Table 3 2 Overrun Sensor Magnet Location and Option Switch Settings 3 8 Table 3 3 Shadow Light Curtain Response Time and Object Sensitivity 3 21 Table 3 4 Switches 1 a...

Page 14: ...User Manual 1128500 Table of Contents ix Table C 2 WPC 2000 Option 1 Board Wiring Connections TB601 C 6 Table C 3 WPC 2000 Option 1 Board Wiring Connections TB602 C 6 Table C 4 WPC 2000 Option 1 Fault Codes C 8 ...

Page 15: ...ter 4 shows you how to run the press using WPC 2000 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 2000 detects an error Appendix A provides OSHA regulations and ANSI standards pertaining to the use of presence sensing devices for point of operation guar...

Page 16: ...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 17: ... 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 n...

Page 18: ...ch is mounted on the press turns one to one 1 1 with the crankshaft allowing WPC 2000 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 2000 translates these analog signals to a number that indicates the position of ...

Page 19: ...T SELECT BRAKEWARNING INTERRUPTEDSTROKE TOPSTOPANGLE AUTOCARRYUP STOPTIMELIMIT MICRO INCH STOPPINGTIME STOPPINGANGLE 90 STOPTEST COUNTER COUNTERPRESET ANGLE SPM Digital LED Display Counter Press Speed Error Codes Crank Angle Crank angle Clock Reset Select Button Indicator Segments WPC Settings Key Switch Interrupted Stroke LED Brake Warning LED camonangle camoffangle MUTE WPC 2000 Wintriss Clutch ...

Page 20: ...lso used in Automatic Single stroke operation see page 4 16 Emergency 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 In...

Page 21: ...C 2000 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 placed between the Operator Station and the die space Shadow s mounting bracket design allows plenty of room for adjustment WPC 2000 Display The WPC 2000 display provides the following features see Figure 1 1 Digital LED Display A highly visible s...

Page 22: ...flashes and WPC 2000 switches to Two hand Maintained Single stroke mode If WPC 2000 was set to Inch mode the press stays in Inch mode To clear the Interrupted Stroke the operator pushes both Run Inch buttons simultaneously and holds them until the press reaches the top of the stroke At this point the Interrupted Stroke LED turns off and WPC 2000 automatically reverts to the original operating mode...

Page 23: ...s the processor A or B that detected the problem Underlying causes and remedies for each fault code are provided in Chapter 5 Lockout Selected error codes that are associated with serious error conditions generate the lockout message Loc which displays in the digital LED readout when the error has been reset The lockout function provides an added safety feature to WPC 2000 forcing the operator to ...

Page 24: ... a feed or transfer to be stopped or prevented from starting when an E stop button is pressed a light curtain is interrupted or a cross checked input is open If your WPC 2000 has Shadow light curtain muting firmware you can prevent the auxiliary E stop relays from issuing a Stop command if the light curtain is interrupted during the muted portion of the stroke by setting option switch 2 on switch ...

Page 25: ... in 19 mm keyed shaft Rated shaft loading 200 lb axial 200 lb radial Operator Station NEMA 12 Includes two palm buttons Top stop Emergency stop and Prior Act buttons and 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 ...

Page 26: ... g feed transfer etc which can be stopped or prevented from starting if any E stop button is depressed any light curtain is interrupted or any cross checked inputs are open Speed 7 500 SPM 500 2000 SPM optional Displays Six digit LED Displays press speed crankshaft angle presettable counter 90 stop time test result stopping time stopping angle top stop angle auto carry up angle stop time limit and...

Page 27: ...5 x 88 4 mm shock mounted Relay SPDT 0 3A resistive at 240V standard DC Solid State SPST 2A at 5 60 Vdc optional AC Solid State SPST 1A at 70 250 Vac optional Foot Switch Safety switch for foot actuation 1 hand 2 hand foot firmware required One hand Control Control for one hand actuation 1 hand 2 hand foot firmware required Counterbalance Air Pressure Switch 12 150 PSI Monitors counterbalance air ...

Page 28: ...after any modification or repair of the WPC 2000 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 2000 clutch brake control Disconne...

Page 29: ...er 3 ALL SIGNAL GROUNDS MUST BE CONNECTED THROUGH MAIN PROCESSOR BOARD Connect all signal grounds through pins on the WPC 2000 Main Processor board READ INSTALLATION INSTRUCTIONS BEFORE STARTING INSTALLATION If you install WPC 2000 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 a...

Page 30: ...y Valve DSV can be run in the same conduit Provide a dedicated 120V power circuit from the press control transformer to the WPC 2000 input power connection Do not power any relays or solenoids from this circuit or the auxiliary power terminals on WPC 2000 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 o...

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 2000 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: ...ol enclosure door 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 2000 requires the following electrical components Motor forward auxiliary contact 24V Slide adjust monitor circuit 24V Motor stop circuit 110V if applicable Motor reverse aux...

Page 34: ...stop circuit or a user interlock to stop the press as soon as the ram adjust switches on For help in determining how to connect this wiring call Wintriss Tech Support NON ENCLOSURE INSTALLATION See Installing WPC 2000 without Enclosure page 2 51 for installation instructions if you are installing WPC 2000 in your own enclosure or console Figure 2 4 WPC 2000 Enclosure Mounting Dimensions NOTICE 12 ...

Page 35: ...gure 2 5 No 16 wire No 14 if local codes require it is recommended for these circuits with a minimum 75 C temperature rating 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 OSHA 1910 147 Control of Hazardous Energy Lockout Tagout Ensure that installation...

Page 36: ...he black wire to the LINE terminal and the white wire to NEUT For 230 Vac connect the black wire to the LINE terminal and the red wire to NEUT Strip the wire 1 4 in from the end Loosen the screw in the input 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...

Page 37: ...onnector at this end of the DSV The other two connectors are installed on the two valve solenoids at the other end of the DSV which has three connectors altogether including one for the DSV monitor that is already installed You wire the Reset solenoid and valve solenoid connectors to WPC 2000 as shown in Figure 17 DSV MUFFLER CLOGGING OR LOOSENING Clean the DSV muffler periodically A clogged muffl...

Page 38: ...ling Air Pressure Switches Your WPC 2000 requires switches to monitor clutch air pressure and counterbalance air pressure if there is a counterbalance Installing a Clutch Air Pressure Switch Install and wire the clutch air pressure switch as follows 1 Install a filter regulator and lubricator in line before the clutch air pressure switch if they are not already present 2 Connect shop air to the cl...

Page 39: ...y mounted until you have calculated the correct safety distance see Calculating the Safety Distance page 3 19 and performed the applicable verification see page 2 58 and checkout see page 3 35 tests When you 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...

Page 40: ...ng to the mute lamp inside the Operator Station and modify if necessary according to the instructions below Operator stations shipped as part of WPC 2000 systems should not need modification 1 Find the mute lamp on the Operator Station as shown in Figure 2 6 2 Open the Operator Station and locate the mute lamp connections on the underside of the cover Figure 2 6 Pre wired Operator Stations Showing...

Page 41: ... wiring is correct connect the Operator Station to WPC 2000 Figure 2 7 Wiring Steps to Modify Operator Station for WPC 2000 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 wi...

Page 42: ...ation box 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 C Y S T O P 6 06 154 0 MUTE PALM TIME PRIOR ACT INTRISS W TOP STOP 16 ...

Page 43: ...s manual Before using your press be sure to check the wiring carefully run all the applicable verification and checkout tests and calculate the safety distance You can then mount the Operator Station in a permanent location referring to Figure 2 10 for mounting dimensions OPERATOR STATION MAY NOT MEET SAFETY REQUIREMENTS Ensure that the Operator Station is wired correctly Run all necessary tests t...

Page 44: ...d 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 Operator Station the Run buttons comply with the requirements specified in Table B 2 page B 2 Ensure that on any non Wintriss...

Page 45: ...arded by mechanical barriers To determine the Stopping Time of the press refer to page 3 14 To calculate the correct safety distance see page 3 19 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 ...

Page 46: ...w VII or Shadow 8 light curtains on your press you must set jumpers JP121 JP124 on the WPC 2000 Main Processor board see Figure 2 12 page 2 23 or Figure 2 13 page 2 24 to the positions shown in Table 2 1 Wiring diagrams are provided in figures 15 Shadow VII control box 16 Shadow VII DIN controller 18 Shadow 8 optional control and 19 Shadow 8 wired directly to WPC 2000 at the back of the manual Ins...

Page 47: ...compensate for slack or stretch The drive method you choose must also allow for adjustment of the resolver to its zero position at top dead center All sprockets must be keyed or pinned The resolver shaft has a standard key Wintriss Controls Group stocks a spring loaded base with a hole pattern to match the resolver When designing the drive for the resolver observe the following precautions Do not ...

Page 48: ... a speedometer cable The resolver will lag the crankshaft because of the twisting of the shaft on start up When the crankshaft stops the resolver will turn past the true stopping point and snap backward Mounting the Resolver To mount the resolver perform the following steps Figure 2 11 Resolver Mounting Dimensions 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 ...

Page 49: ...ockwise when the press runs 5 Measure and cut the resolver wires so they reach TB 106 then wire them to the L shaped connector referring to Table 2 21 page 2 63 and Figure 2 at the end of the 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 50: ...essor LED DS149 Light curtain B output type jumper JP121 Light curtain A test mode jumper JP124 5V B processor LED DS151 Option switches S101 Option switches S102 Green Orange Green Green Green Orange TB102 Green Orange LO HI INT EXT PNP NPN RAM chip U102 A pro cessor chip U111 ON 8 7 6 5 4 3 2 1 ON 8 7 6 5 4 3 2 1 B pro cessor chip U134 INT EXT PNP NPN LED 1 45 2 3 4 5 6 7 8 9 10 46 47 48 49 50 5...

Page 51: ...essor LED DS149 Light curtain B output type jumper JP121 Light curtain A test mode jumper JP124 5V B processor LED DS151 Option switches S101 Option switches S102 Green Orange Green Green Green Orange TB102 Green Orange LO HI INT EXT PNP NPN RAM chip U102 A pro cessor chip U111 ON 8 7 6 5 4 3 2 1 ON 8 7 6 5 4 3 2 1 B pro cessor chip U134 INT EXT PNP NPN LED 1 45 2 3 4 5 6 7 8 9 10 46 47 48 49 50 5...

Page 52: ...he 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 2000 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 to WPC ...

Page 53: ...gnet should be mounted so that it can be sensed by the switch for 15 to 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 comes a...

Page 54: ...2000 Main Processor board as shown in Table 2 2 and Figure 2 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 Con...

Page 55: ...se instructions will result 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 pairs 8 9 and 10 11 though control reliable are suitable only for applications such as connecting to safety switches used with interlocking barrier guards Failure to comply with these instructions wi...

Page 56: ...essor board to your equipment and then back to either 24 Vdc or ground as shown in Table 2 3 and Figure 2 at the end of the manual There are several available Ground and 24 Vdc terminals on the Main Processor board from which to choose After you have wired the inputs you will use be sure to bypass all the unused inputs by connecting them to 24 Vdc or Ground Table 2 3 WPC 2000 User Inputs Stop Type...

Page 57: ...orner see Figure 2 12 page 2 23 or lower right corner see Figure 2 13 page 2 24 of the WPC 2000 Main Processor board Wiring connections are shown in Table 2 4 and in Figures 13 Herion DSV 14 Ross Serpar DSV and 17 Ross DM2 DSV at the end of the manual Wiring Auxiliary Outputs WPC 2000 provides three optional Auxiliary outputs that you can use to automate equipment connected to your clutch brake co...

Page 58: ... until the press reaches its Top stop position in order to avoid another Interrupted Stroke With switch 8 set to ON the operator may release the Run Inch buttons while inching the press to Top stop without initiating an Interrupted Stroke Auxiliary Output 1 can be wired to a customer supplied control relay and used to stop auxiliary equipment such as scrap choppers conveyors etc when one of the co...

Page 59: ...er normal conditions whenever the DSV is energized Aux Output 3 turns On sending a low voltage i e 24 Vdc input check signal to the DiPro 1500 or ProCam 1500 DiPro ProCam 1500 uses the input check signal to initiate monitoring of the programmed start time limit the interval within which the crankshaft must begin rotating in order to avoid a Loss of Rotation fault In Bar Control mode Aux Output 3 d...

Page 60: ...fore you wire complete all WPC 2000 installation initialization and checkout procedures Then run the press in all modes of operation Inch Single stroke and Continuous if applicable Also make sure that the press has working Top stop and Emergency stop circuits Since WPC 2000 is connected to the press stop circuits it is extremely important to verify that the press operates and stops properly before...

Page 61: ...igure 2 16 WPC 2000 Display Board Location of Important Components Table 2 7 Micro inch Wiring Connections Display Board TB705 Pin Signal 157 Micro inch input 155 Ground Stroke select TB 701 Micro inch Set auxiliary cams TB 705 Set cams switch S701 Operator station select TB 704 Automatic single stroke or Continuous on demand TB 703 Mode select TB 702 Display cable TB 706 Reset Select button WPC S...

Page 62: ...e manual The remote Reset terminal can be wired to other equipment e g the remote Reset circuit on a SmartPAC 2 or you can use a simple switch to activate the Reset function To wire the remote Reset circuit connect a wire from pin 70 to a normally open switch Connect another wire from the switch to a ground terminal e g pin 54 WPC 2000 is reset with a momentary connection to ground Installing 4 ch...

Page 63: ...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 2000 Main Processor board to the cam outputs and terminate the shield at each end near the entry point to the enclosure or console see Terminating Cable Shi...

Page 64: ... Dimensions inches mm 3 48 88 4 DS1 DS2 DS3 DS4 K1 F1 K2 F2 K3 F3 K4 F4 N O C N C N O C N C N O C N C N O C N C CHAN 1 CHAN 2 TB3 TB2 CHAN 3 CHAN 4 TB4 TB5 CHASSIS 24V GND CH 3 CH 2 CH 1 CH 4 5A 125 VAC SLO BLO 5A 125 VAC SLO BLO 5A 125 VAC SLO BLO 5A 125 VAC SLO BLO 4 35 110 5 4 75 120 7 5 50 139 7 5 10 129 5 0 20 5 1 TYP 0 20 5 1 TYP clearance hole for 6 screw 4 PLACES Dimensions inches mm ...

Page 65: ...ment do the following Table 2 9 WPC 2000 Main Processor Board TB109 to Cam Output Assembly TB1 Wiring Connections Wire Color WPC 2000 Main Proc Board Pin Signal 4 channel Cam I O Assembly TB1 Pin Signal Brown 130 Cam 1 7 Channel 1 Violet 129 Cam 2 6 Channel 2 Orange 128 Cam 3 5 Channel 3 Yellow 127 Cam 4 4 Channel 4 126 Counter 125 Zero Cam 124 Spec 1 123 Spec 2 Black 122 Ground 3 Ground Red 121 2...

Page 66: ...ts Install the suppressors across the load or as close to the load as possible Attach suppressors by connecting leads across existing terminals or junction points Figure 2 20 page 2 40 shows the correct way to install suppressors b Install a diode across each DC load such as relays solenoids and PLC inputs as shown in Figure 2 21 page 2 40 Generally you use the N O terminal so that equipment is of...

Page 67: ...witch block S102 on the WPC 2000 Main Processor board to ON Wiring a key switch Figure 2 20 Installing a Suppressor across an AC Load Figure 2 21 Installing a Diode across a DC Load RIGHT WRONG ACCEPTABLE not recommended c n o Power in Power Return Suppressor Relay c n o Power in Suppressor Power Return Power Return Relay c n o Power in Suppressor Power Return Relay DC IN DC RETURN Relay C N O IN4...

Page 68: ...may be preferable if the Display board is difficult to access Wiring a Remote Switch You can also enable the Set Cams function by wiring your own two position switch and turning the function On and Off remotely Wire the remote switch to pins 155 Ground and 156 Prog Cams on the WPC 2000 Display board referring to Figure 2 16 page 2 34 and Figure 5 at the end of the manual If you opt to use a remote...

Page 69: ...e both contacts to 24 Vdc as shown in Table 2 11 below and Figure 2 at the end of the manual Refer to page 3 27 for Foot Switch settings Table 2 10 Zero Cam Output Wiring Connections WPC 2000 Main Processor Board TB 109 Pin Signal AutoSet 1500 TB101B or 1504 TB101A Pin Signal pin 125 Zero Cam Output pin 2 Zero Cam UNGUARDED HAZARDS When using a foot switch ensure that light curtains and other safe...

Page 70: ...ermined by the setting on option switch 3 see Enabling Light Curtain Break Mode in a One hand Control page 3 27 When switch 3 is set to OFF One hand Control operates in Normal mode When switch 3 is set to ON One hand Control operates in Light Curtain Break mode INSTALL SAFEGUARDS TO PREVENT ACCESS TO HAZARDOUS AREA Follow all applicable OSHA and ANSI regulations for safeguarding your press system ...

Page 71: ... 2 45 for mounting dimensions DO NOT MOUNT OPERATOR CONTROL TOO CLOSE TO HAZARD Mount the One hand Control outside the area protected by the light curtain DO NOT mount the One hand Control between the light curtain and the point of operation Failure to comply with these instructions will result in death or serious injury Figure 2 23 One hand Control Switch Mounting Dimensions DANGER ...

Page 72: ...nections to both the Operator Station and to the WPC 2000 Main Processor board To do so perform the following steps 1 Turn off power to the press and to the WPC 2000 Figure 2 24 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 f...

Page 73: ... before cutting then make the appropriate wiring connections referring to Table 2 12 below and Figure 8 at the end of the manual Refer to Figure 2 25 above 6 Fasten 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 2000 9 Make sure that you have run al...

Page 74: ...connect the Bar selector switch input to pin 6 on the WPC 2000 Main Processor board and the Bar actuator input to pin 16 as shown in Table 2 13 and Figure 2 at the end of the manual Figure 2 26 Bar Control Enclosure Mounting Dimensions Table 2 13 Bar Control Wiring Connections WPC 2000 Main Processor Board Pin Bar Control Contacts 16 Bar actuator input 6 Bar selector switch input 24 Vdc e g 37 Com...

Page 75: ... Support for information on using this operating mode PRESS STARTING UNEXPECTEDLY Ensure that light curtains and other safeguards are properly installed and operating to protect operators when using Automatic Single stroke Since the external trigger starts the stroke a stroke can occur unexpectedly Ensure that guarding is properly installed to prevent access to the machine over under or around any...

Page 76: ...otch on its socket MACHINE MALFUNCTION AFTER INSTALLING REVISED SOFTWARE Perform the installation verification see page 2 58 and final checkout see page 3 35 tests after performing the firmware installation Failure to comply with these instructions could result in death or serious injury ELECTRIC SHOCK OR HAZARDOUS ENERGY Disconnect main power before installation Remove all power to the press pres...

Page 77: ...inues to malfunction call Wintriss Tech Support Each new WPC 2000 firmware chip must be installed with the notch facing in the same direction as the chip it is replacing If you use a screwdriver be careful not to insert the screwdriver under the socket or you may damage the board Failure to comply with these instructions could result in property damage CHIP INSTALLED INCORRECTLY Install each chip ...

Page 78: ... components in your enclosure or console When installing the mounting plate refer to Figure 2 27 page 2 52 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 Main Processor board Allow at least 2 1 2 in clearance on the right side of the plate for making wiring connections to terminal blocks TB101 TB104 The powe...

Page 79: ... at a height convenient for all users Experiment to determine a good height for every user before mounting the display TB105 TB104 TB103 TB102 TB101 TB 109 312 7 92 ID 4 places 45o x 125 3 18 4 places TB 106 Dimensions inches mm Allow 1 clearance on top bottom and left side of mounting plate and above board power supply Allow 2 1 2 clearance on right side i e side to which TB101 TB104 are connecte...

Page 80: ... hole in your enclosure or console and drill and tap twelve holes for 10 32 screws referring to Figure 2 28 Figure 2 28 WPC 2000 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 ...

Page 81: ...t 300 mm of the display CONNECT DISPLAY CABLE CORRECTLY Make sure that the display cable is connected correctly at both ends Connect the display cable to TB706 on the Display board with the black wire closest to the small numeral 1 toward the bottom of the board The black wire indicates pin 1 Table 2 15 Display Cable Wiring Connections Display Board to Main Processor Board Display Board TB706 Pin ...

Page 82: ...ke sure that your display board kit contains the following components Label PC board Push button Mute lamp Key switch with wiring harness assembly Four standoffs Four lock nuts Figure 2 29 Selector Switch Cutout Dimensions Table 2 16 Selector Switch Wiring Connections Selector Switch Terminal Block on WPC 2000 Display Board Stroke Select TB701 Mode Select TB702 Automatic Single stroke External Tri...

Page 83: ...nsions 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 console to match the cutouts then remove the protective paper from the label and carefully affix...

Page 84: ...the Reset Select button and the WPC 2000 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 31 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 ...

Page 85: ... tests at the end of Chapter 3 SPLICE ADDITIONAL WIRING ONTO MUTE LAMP WIRING The mute lamp comes with a 3 in wire pigtail You will need to butt splice an additional length of wire to the pigtail to make connections at the Main Processor board Use 18 or 20 AWG wire and a Wintriss supplied butt splice part no Amp 8 34070 4 or equivalent JUMPER JP720 ON DISPLAY BOARD MUST BE SET TO R RUN POSITION DO...

Page 86: ...es Test safeguarding devices as follows 1 Run the press in Inch mode Block the light curtain if one is installed with an opaque object The press should stop immediately If the press stops go to the next step If the press does not stop check the wiring of the light curtain and correct any problems Repeat the test If the press still doesn t stop call Wintriss Tech Support DO NOT USE NON SAFETY INTER...

Page 87: ...ram does not move and the display shows F79 or one of the DSV faults see page 5 16 the DSV is operating properly Go to the next step If the ram moves and or the display shows a fault other than F79 or one of the DSV faults check the wiring of the DSV and correct any problems then repeat step 3 If the ram still moves and or the display still shows a fault other than F79 or one of the DSV faults pow...

Page 88: ...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 Inch for a few strokes checking for error codes If you need assistance call Wintriss Tech Support Checking the Emergency stop Circuit To check the Emergency stop circuit do the following 1 Run the press in Inch mode While the ram is moving have someone push the Em...

Page 89: ...26 Unused input 70 Remote reset input 25 Ground 69 E stop string input connects internally to 45 24 Overrun limit switch input 68 E stop string center loop connection 23 24 Vdc output 67 E stop string drive output TB102 Top TB102 Bottom 22 Top stop limit switch input 66 Mute lamp 1 output 21 User input 1 65 Palm time lamp output 20 DSV monitor input 64 Prior act lamp output 19 Unused input 63 Prio...

Page 90: ...Pin Signal Wire Color 104 S4 Return Brown 105 R2 Ground Orange 106 S3 Return Yellow 107 R1 Drive Red 108 S2 Cosine Green 109 S1 Sine Black 110 Shield Table 2 22 Cam Outputs TB 109 Wiring Pin Signal 130 Cam 1 129 Cam 2 128 Cam 3 127 Cam 4 126 Counter 125 Zero cam 124 Spec 1 123 Spec 2 122 Ground 121 24 Vdc Table 2 23 Display Board Wiring Pin Signal 157 Micro inch selector input 156 Cams selector in...

Page 91: ...1128500 WPC 2000 User Manual 2 64 Installation ...

Page 92: ...tructions 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 stations Verify at every shift change that there are the same ...

Page 93: ...eadout These defaults are summarized in Table 3 1 When the press is stopped and Angle SPM is selected the crankshaft angle is displayed for all Stroke Select settings The Counter does not operate in Inch mode When the default indicator segment is selected the crank angle clock shows the crankshaft angle of the press in all Stroke Select settings Each LED on the clock represents approximately 11 Th...

Page 94: ...display see Figure 3 2 release the key INCORRECT STOP TIME LIMIT AFTER INITIALIZATION Determine the Stopping Time and set the Stop time Limit to a value that reflects the actual Stopping Time of your press whenever you initialize WPC 2000 Use the stop time measured in the 90 stop time test to calculate the safety distance When you initialize WPC 2000 the Stop time Limit is returned to its factory ...

Page 95: ...displays fault code F79 see Loss of Rotation page 5 17 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 ...

Page 96: ... 2000 will set the Start time Limit to twice the Start Time measured on the first stroke This value cannot be changed manually Viewing the Start time Limit To view the Start time Limit 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 clockwise The Start time Limit in milliseconds is shown in...

Page 97: ...e before installing the magnet Setting the Top stop On Angle To determine the angle at which the Top stop command is given on your press and change the Top stop On Angle setting on the WPC 2000 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 c...

Page 98: ...decreasing the on angle 2 Power down then power up the WPC 2000 to enable the new settings 3 Clear the Loc message on the WPC 2000 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 Turning the key to cou...

Page 99: ...you 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 2 The correct mounting angle for the overrun sensor magnet would be 330 See Figure 3 5 WHEN DETERMINING TOP STOP ON ANGLE Remember that the Top stop angle has an internal dwell of 20 ...

Page 100: ...tings 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 2 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 2000 Main Processor board to the positions you determined in step 12 referring to page 3 26...

Page 101: ...ew 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 If a fault occurs...

Page 102: ... 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 6 you can periodically adjust the Top stop angle to ensure that your press stops at top dead center Each time you adjust the Top stop angle you must verify that your overrun se...

Page 103: ... by turning the Mode Select switch to CONT select the Angle SPM indicator segment using the Reset Select button and check 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 N...

Page 104: ...ator can reach the pinch point the Auto Carry up Angle must be set so that any hazardous openings are smaller than 1 4 in by the time the crankshaft reaches the Auto Carry up Angle Determine the Auto Carry up Angle for each tool based on the crank angle at which the tool s hazardous openings are smaller than 1 4 in Change the Auto Carry up Angle to the correct value when you change tools Failure t...

Page 105: ...king Settings WPC 2000 s built in brake monitor constantly checks the condition of the brake by measuring the Stopping Time each time the press top stops Stopping time is the amount of time in milliseconds that it takes the crankshaft to stop once the Dual Safety Valve DSV has been de energized When the Stopping Time indicator is lit the Stopping Time of the press on the most recent stroke is show...

Page 106: ...top time Limit the setting WPC 2000 uses to determine when to alert the operator to the need for brake service The Stop time Limit is calculated by adding a percentage factor abbreviated Tbm i e Time 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 2000 does not stop the press for small increases in Stopping...

Page 107: ...et up your WPC 2000 Perform a 90 Stop Test any time you change the Stop time Limit of WPC 2000 See Determining the 90 Stop Time page 3 17 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 the Safety Distance page 3 19 Failure to compl...

Page 108: ...he 90 Stop Test Continuous Mode 1 Install the heaviest upper die in your press Adjust the counterbalance for ram weight if your press has a counterbalance 2 Set the Stroke Select switch to CONT and start the press 3 Press the Reset Select button repeatedly until the 90 Stop Test indicator becomes lit see Figure 3 8 INCORRECT SAFETY DISTANCE DUE TO INCORRECT STOP TIME Perform a 90 Stop Test any tim...

Page 109: ...st 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 To cancel the test press the Reset Select button 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 ...

Page 110: ...s the Stopping Time of your press as determined by the 90 stop time test see Determining the 90 Stop Time page 3 17 You must mount your light curtains slightly beyond this calculated distance to ensure that they are able to stop the press before an operator s hand reaches the hazardous area The first time you run this test the display shows a value of 0 zero until the test is completed In subseque...

Page 111: ...standards B11 1 2009 and B11 19 2003 see Appendix A Figure 3 9 Safety Distance Distance between Pinch Point and Light Curtain PRESS MAY NOT STOP BEFORE OPERATOR REACHES PINCH POINT Calculate the safety distance carefully according to the instructions below Mount your light curtain heads at least the safety distance from the hazardous area If a light curtain is too close to the hazard there may not...

Page 112: ...how far you could theoretically move your hand and arm in one second The Stopping Time of the press Ts is measured at approximately 90 of crankshaft rotation 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 2000 see Determining the 90 St...

Page 113: ...ng the 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 ...

Page 114: ...one second The Stopping Time of the press Ts is measured at approximately 90 of crankshaft rotation or at maximum closing velocity In addition to the Stopping Time of the press the OSHA Ts value must include the following factors Response time of the press control that activates the brake Response time of the light curtain Additional time Tbm added to the Stopping Time to compensate for brake wear...

Page 115: ...The light curtain must be mounted 17 89 in away from the pinch point When using the OSHA formula be sure to do the calculations in this order 1 Add the factors involved in the stopping time Ts first 2 Multiply the result by 63 This is Ds If you do no follow this order your safety distance calculation will be incorrect Adding to Safety Distance for Blanking Windows When using fixed or floating blan...

Page 116: ...ro inch setting unless the operator releases the Run Inch palm buttons before the period has expired You can enter Micro inch values from 6 to 600 milliseconds The default value set at the factory is 100 mS To set Micro inch do the following 1 With power on to the WPC 2000 and the press in Inch mode press the Reset Select button repeatedly until the Micro inch indicator becomes lit see Figure 3 10...

Page 117: ...es 1 and 2 control the range of angles within which the Top stop On Angle falls see Installing the Overrun Sensor Magnet page 3 6 WPC 2000 uses these switch settings to determine at what angle to begin the overrun sensor closure test which is used to make sure that the overrun limit switch closes at the same angle on every stroke Settings for option switches 1 and 2 are shown in Table 3 4 page 3 2...

Page 118: ...ight curtain This condition is called Light Curtain Break mode If the 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 compl...

Page 119: ...annot be adjusted backward beyond 211 the factory setting Adjustment of the Top stop angle always lags behind press speed changes because ACTS requires several 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 a...

Page 120: ...ual light curtains when two light curtains are wired to the system as shown in Table 3 9 Refer to page 2 18 for general light curtain installation instructions When switch 6 is set to OFF its default position dual light curtains are disabled and WPC 2000 recognizes only a single light curtain When switch 6 is set to ON dual light curtains are enabled and both light curtains if two light curtains a...

Page 121: ...e press top stops on the current stroke if an F or H fault occurs at any angle Table 3 10 Switch 7 Settings S101 Disabling Access to Stop time Limit and Auto Carry up Angle Setting Access to Stop time Limit and Auto Carry up Angle Settings OFF Normal operation Default Access to Stop time Limit and Auto Carry up Angle settings enabled Operator can change settings ON Access to Stop time Limit and Au...

Page 122: ...switches are factory set to the OFF position Only switches 1 2 and 6 are active To set a switch to ON push up on the switch with a small screwdriver or your fingernail NON SAFETY OUTPUTS USED FOR SAFETY FUNCTIONS Use auxiliary outputs 1 2 and 3 for non safety functions only such as convenience in automation They cannot protect personnel from a moving hazard Failure to comply with these instruction...

Page 123: ...troke after the Auto Carry up Angle has been reached see Setting the Auto Carry up Angle page 3 13 When switch 2 is set to OFF its default setting muting of the Auxiliary E Stop Output Relay board is disabled and penetration of the light curtain at any point in the stroke causes a stop command to be sent to auxiliary devices When switch 2 is set to ON the Auxiliary E Stop Output Relay board is mut...

Page 124: ...nd palm or synchronous time Setting Programmable Cams If you have ordered the optional four channel programmable cam output you can set cam on and off angles via the WPC 2000 display Before making settings verify that the cam outputs have been installed correctly see page 2 35 You should only change this switch from its default setting if you have installed more than two Operator Stations on your ...

Page 125: ...y see Figure 3 12 The Cam 1 ON angle is also represented at one end of an illuminated arc of LEDs on the crank angle clock 4 To change the current setting turn the WPC Settings key switch to counterclockwise to increase the angle or to clockwise to decrease the angle As you increase or decrease the angle additional LEDs at one end of the illuminated LED arc on the crank angle clock are turned on o...

Page 126: ...re 3 13 Cam Channel Settings Display Cam 1 OFF Setting 325 Shown If you do not disable the Set Cams function you will not be able to adjust the settings controlled by the indicator segments in the lower half of the display 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 Failure to comply with these ins...

Page 127: ...nd Display boards LED maps of the Main Processor board showing the locations of all LEDs are provided in Figure 3 14 center or right mounted board and Figure 3 15 left mounted board which are shown on the following pages An LED map of the Display board is shown in Figure 3 16 page 3 39 INCORRECT INSTALLATION Perform the necessary checkout procedures according to the instructions in this manual Ens...

Page 128: ...input 1 G R O U P 3 66 Mute lamp 1 output DSV B contact check 88 Light curtain B 2 input DSV A contact check DSV B drive check Lockout drive check Lockout contact check DSV A drive check G R O U P 5 24 Overrun limit switch 75 Unused input 74 User input 9 73 User input 7 72 User input 5 71 User input 3 70 Remote reset 26 Unused input G R O U P 6 24 VDC Serial port Display bus Receive Transmit Trans...

Page 129: ...c A 5 Logic B G R O U P 4 13 Top stop inch disable 60 Top stop B2 input 16 Bar actuator input 17 Motor reverse input 18 User input 11 19 Unused input 63 Prior act B input 22 Top stop limit switch 57 E stop B2 input 20 DSV monitor input G R O U P 3 12 Palm switch B N O 14 Foot switch N O 15 Automatic actuator N C Aux B contact check Aux A contact check Aux A drive check Aux B drive check 21 User in...

Page 130: ...n Single stroke mode T B 7 0 3 151 Automatic single stroke select T B 7 0 2 149 One hand control select 148 Foot control select 147 Spare T B 7 0 1 143 Single stroke select 142 Continuous stroke select 145 Off stroke select 144 Inch stroke select T B 7 0 4 154 Operator station 1 select 153 Operator station 2 select 157 Micro inch select 156 Set auxiliary cams select T B 7 0 5 Display cable transmi...

Page 131: ... 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 132: ...stop relays are open 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 pow...

Page 133: ...e transmitter see Figure 3 at end of manual Shadow VI pin 19 on auxiliary TB4 in the control see Figure 10 at end of manual Shadow VI WPC Interface Board pin 5 on TB4 see Figure 11 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 JP124 for Light Curtain 1 JP122 for Light Curtain 2 se...

Page 134: ...ort 4 Press the Emergency Stop button on the Operator 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 A input and E stop B input LEDs on the WPC 2000 Main Processor board turn off when the Emergency Stop button is pressed If the two LEDs do not turn off check the wiring of the E sto...

Page 135: ... the counterbalance air pressure 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 ...

Page 136: ... top dead center and a fault code between F80 and F89 or between H80 and H89 displays there is a problem with the overrun limit switch Try the remedies suggested for overrun limit switch faults starting on page 5 18 then inch the ram to the top of the stroke and repeat this test If the ram still does not make a complete stroke or does not stop at top dead center call Wintriss Tech Support INJURY D...

Page 137: ...in is successful go to the next step If the ram does move check to make sure the correct version of WPC 2000 firmware is installed and check the wiring of the palm buttons and light curtains correcting any problems Re run the test starting with step 4 If the ram still moves with the light curtain blocked call Wintriss Tech Support 6 Remove the object you used to interrupt the light curtain field i...

Page 138: ...rtains are not installed perform the following steps referring to Figure 3 14 or Figure 3 15 for LED locations on the WPC 2000 Main Processor board 1 Set the Stroke Select switch to SINGLE Verify that the Single stroke select LED on the WPC 2000 Display board is lit 2 Press and hold both Run Inch palm buttons observing the motion of the ram If the ram makes a complete stroke and stops at or near t...

Page 139: ... If the ram does not move or if it moves but does not stop immediately when you release the Run Inch buttons or if the Interrupted Stroke LED does not flash check the wiring of the palm buttons and light curtains correcting any problems and run the test again repeating step 5 If the ram still does not move or moves but does not stop immediately or if the ram stops but the Interrupted Stroke LED do...

Page 140: ... stroke When the press top stops continue to hold down the right button and remove your hand from the left button then after a moment replace your hand on the left button and continue to hold down both buttons If the press does not initiate the stroke the test has been completed successfully Go to the next applicable test If the press does initiate the stroke check the wiring of the palm buttons c...

Page 141: ...r board is lit 2 Verify that the light curtain is unobstructed and that the Light curtain A1 input and Light curtain A2 input LEDs on the WPC 2000 Main Processor board are lit If you are testing a second pair of light curtains verify that Light curtain B1 input and Light curtain B2 input LEDs are lit These LEDs turn off when the light curtain is obstructed 3 Press the Prior Act button on the Opera...

Page 142: ...goes out press both Run Inch palm buttons releasing them after bottom dead center on the first stroke The press should continue running 8 Press the Reset Select button on the WPC 2000 display until the Stopping Time indicator segment becomes lit 9 Press the Top Stop button on the Operator Station The ram should stop near top dead center and the Stopping Time in milliseconds should appear in the WP...

Page 143: ...NT Verify that the Continuous stroke select LED on the WPC 2000 Display board is lit 2 Press the Prior Act button on the Operator Station The Prior Act lamp should illuminate then turn off after eight seconds If the Prior Act lamp turns off after eight seconds go to the next step If the Prior Act lamp does not turn off after eight seconds stop Do not go any further Call Wintriss Tech Support When ...

Page 144: ...rator Station particularly the E stop wiring and rerun this test from step 3 If the conditions are still not present call Wintriss Tech Support 5 Press and hold the Run Inch palm buttons until the press returns to top dead center 6 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...

Page 145: ... Trip mode the press stroking each time the Foot Switch is depressed 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 Failure to comply with these instructions will result in death or serious injury MISSING SAFEGUARDS Install a light curtain for use with the Foot Switch option A light curtain is require...

Page 146: ... but stop immediately when the Foot Switch is released 9 Press and hold both Run Inch buttons The press should complete the stroke stopping at Top stop 10 Set the Stroke Select switch to CONT 11 Press the Prior Act button on the Operator Station and before the indicator lamp goes out depress and hold down the Foot Switch The press should run as long as the Foot Switch is depressed 12 Release the F...

Page 147: ...switch and release it immediately The press should make a single stroke and stop at top dead center Verify that the Palm switch A N C LED on the WPC 2000 Main Processor board turns off when the One hand Control is depressed and that the One hand A N O LED illuminates INJURY DURING TESTING Keep all personnel away from the press during testing Be sure there is no die or other tooling in the press du...

Page 148: ...witch LED on the WPC 2000 Main Processor 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 th...

Page 149: ...wing 1 Run the press Actuate one of the user inputs If 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 stil...

Page 150: ...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 151: ...RN 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 Loc ...

Page 152: ...h mode when the Emergency stop occurs WPC 2000 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 2000 display see Figure 1 1 page 1 2 for location illuminates whenever the Stopp...

Page 153: ...Stopping Angle recorded the last time a Stop command was sent to the press is shown in the digital readout and displayed graphically by an arc of LEDs on the crank angle clock Figure 4 1 shows a Stopping Angle of 75 as an example Stopping angle will compensate for the complete rotation when it takes more than 360 to stop Figure 4 1 WPC 2000 Display with Stopping Angle Value Shown When stop command...

Page 154: ...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 2 The Counter segment is selected automatically when the Stroke Select key switch is turned from INCH to SINGLE or CONT and the counter valu...

Page 155: ...n the counter reaches the preset value WPC 2000 sends a Top stop signal to the press and displays the F15 fault code on the digital LED display see Operational Faults page 5 7 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 unti...

Page 156: ... 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 3 WPC 2000 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 999 999 force the ...

Page 157: ...e light curtain will be muted on the upstroke if WPC 2000 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 2000 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 158: ... 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 Station...

Page 159: ...ring Micro inch page 2 33 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 160: ...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 48 and anti repeat see page 3 49 protection Failure to comply with these instructions will result in deat...

Page 161: ...Single stroke One hand operation can only be used with WPC 2000 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 initiate a stroke by pressing the left Run Inch palm button then releasing it The ram com...

Page 162: ...ure 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 2000 or a One hand Control as a safeguarding device Install and operate WPC 2000 and a One hand Control in accordance with OSHA and ANSI regulations Failure to comply with these instructions will result in death or se...

Page 163: ...e the One hand Control button if option switch 3 is set for Normal operation Break 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...

Page 164: ...oot Control mode 2 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 INCORR...

Page 165: ...itch 5 on switch block S101 on the WPC 2000 Main Processor board to OFF to select 30 seconds as the prior act timing or to ON to select 5 minutes Switch 5 Prior Act Time for Automatic Stroke Modes page 3 29 2 Set the selector switches as follows Stroke Select to SINGLE STROKE Mode Select to 2 HAND Automatic to ON 3 To initiate the first stroke depress the Prior Act button the Prior Act lamp will b...

Page 166: ...e The ram will stop in mid stroke if you do not hold the Run Inch palm buttons through the Auto Carry up Angle 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 ove...

Page 167: ...ut will stop if one of the following events occurs You press the Top Stop button You press the Emergency Stop 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 2000 properly in order to run the press in Continuous Foot mode Failure to comply with th...

Page 168: ...d 1910 217 ANSI B11 1 ANSI B11 19 and any other regulations and standards that apply Ensure that guarding is properly installed to prevent access to the machine over under or around any guarding device Failure to comply with these instructions will result in death or serious injury PRESS STARTING UNEXPECTEDLY Ensure that light curtains and other safeguards are properly installed and operating to p...

Page 169: ...ous time in ANSI terminology If you have dual Operator Stations make sure to set the Operator Station Select Switch on the front panel of your WPC 2000 to enable either the first station the second station or both stations When barring the press do not rotate the flywheel too quickly If the crankshaft moves faster than 6 SPM WPC 2000 will stop the ram and fault code F26 will appear in the LED disp...

Page 170: ...ockout Relay board or Auxiliary E stop Relay board see Figure 2 12 page 2 23 or Figure 2 13 page 2 24 before placing the WPC 2000 back into operation after the first occurrence of a fused relay If a relay fuses DO NOT reset the WPC 2000 to restart the machine Remove the WPC 2000 from operation immediately and replace the defective relay board before operating the press again Failure to comply with...

Page 171: ...mple fault code F11 which is shown in Figure 5 1 indicates that the ram moved when the DSV was de energized All E F and H faults are documented in numerical order starting on page 5 5 To respond to a fault do the following 1 Correct the problem that caused the fault Figure 5 1 WPC 2000 Display Showing Fault Code Table 5 1 Fault Codes Significance of Initial Letter Initial Letter Significance E To ...

Page 172: ...o INCH or one of the other stroke selections to clear the Loc message Fault codes that generate the Loc message are identified by an asterisk in documentation of the faults see E F and H Faults page 5 5 Brake Monitor Faults Brake Warning LED When the Stopping Time of the press increases to within 10 mS of the Stop time Limit the amber Brake Warning LED will flash Illumination of this LED often mea...

Page 173: ...ny time you change the Stop time Limit of WPC 2000 See Determining the 90 Stop Time page 3 17 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 the Safety Distance page 3 19 Failure to comply with these instructions will result in death or serious injury PRESS MALFUNCTION Correct or rep...

Page 174: ...aults This section documents in numerical order all WPC 2000 E F and H fault codes providing for each code a description of the problem that caused the fault and suggestions for how to correct it When you are unable to rectify a fault by following the suggested remedy contact Wintriss Tech Support for assistance BRAKE WARNING The Brake Warning LED alerts you when the Stopping Time of the press is ...

Page 175: ...ech Support for assistance or replacement of the resolver Problem Resolver wiring is faulty or the resolver itself is bad Remedy Check resolver wiring making sure that the screws on the terminals are tightened on bare wire and not on insulation see Installing the Resolver page 2 20 Also check the resolver If necessary contact Wintriss Tech Support for assistance or replacement of the resolver Prob...

Page 176: ...eck clutch brake and DSV components for correct operation Correct or repair any malfunction Problem The Emergency Stop button on the WPC 2000 Operator Station has been depressed or the E Stop circuit was open after initiation of the stroke Remedy If another control is connected to the WPC 2000 E stop circuit refer to the user manual for that control to check for a specific error condition and corr...

Page 177: ...utton on the Operator Station was depressed or the Top stop circuit was open after initiation of the stroke Remedy Check other equipment e g DiPro 1500 AutoSet etc wired into the Top stop string Correct the problem Reset the other equipment first then reset WPC 2000 and restart the press Problem Cross checked inputs 8 9 were in different states i e open or closed for longer than 100 mS Remedy Diag...

Page 178: ...e correct switch type Check and correct the palm switch wiring If the error persists call Wintriss Tech Support Problem The operating mode was changed while the press was running Remedy Make your operating mode selection before running the press F19 or H19 IMPROPER SAFETY SWITCHING RELAY REPAIR Replace the Auxiliary E stop Relay board see Figure 2 12 page 2 23 or Figure 2 13 page 2 24 before placi...

Page 179: ...cted Operator Station were pressed in a dual Operator Station setup Remedy Press only one Run Inch palm button when running the press in One hand mode or Select both Operator Stations in a dual Operator Station setup then initiate a stroke Problem The flywheel speed sensor is not turning off and on properly when spin down is enabled Remedy For Bliss non integrated disable by connecting pin 26 to 2...

Page 180: ...ver angles for A and B processors disagree by more than 2 F31 No reply to Check Start 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 proces...

Page 181: ... sure that there are no restrictions in the air supply line e g restrictive fittings quick disconnect fittings low flow filters or regulators or clogged filter elements and that the supply line is sized to match the DSV inlet port If the air pressure and air supply are sufficient check for dirt or water in the DSV and rebuild the valve if necessary F41 through F44 F41 Input buffer 1 check incorrec...

Page 182: ...ch Support Problem A failure has occurred in an auxiliary press function wired to WPC 2000 cross checked input pair 10 and 11 see Table 5 2 One or both inputs are open Remedy Diagnose and correct the condition that the inputs are monitoring If the error persists after you reset the unit contact Wintriss Tech Support F50 through F58 Table 5 2 Fault Codes for User Inputs Fault Code User Input Interl...

Page 183: ...t the light curtain is wired correctly referring to figures 3 10 11 15 16 18 and 19 at the back of the manual if you have Shadow light curtains referring to the appropriate user manual if you have another product If you need additional assistance contact Wintriss Tech Support Problem Two pairs of light curtains are wired to WPC 2000 but only one pair has been enabled on option switch 6 S101 on the...

Page 184: ...gency stop Circuit Driver Failure Problem The Emergency stop input circuit driver has failed or is about to fail Remedy Check E 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 driver Top stop Circuit Driver Failure Problem The Top stop input circuit driver has failed or is about to fail R...

Page 185: ...or one of the receiver outputs may be shorted Check the wiring at the receiver and correct if necessary If the wiring is good either the receiver needs to be replaced or there is a problem with WPC 2000 Contact Wintriss Tech Support for assistance DSV Interface and Lockout Relay Failures or F68 or H68 F69 or H69 F70 through F78 H72 through H76 IMPROPER SAFETY SWITCHING RELAY REPAIR Replace the DSV...

Page 186: ... the resolver may be defective Air pressure to the clutch may be low or the clutch may be bad resulting in no movement of the crankshaft and resolver even though the DSV is energized In addition an internal WPC 2000 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...

Page 187: ... page 3 6 If settings are correct and the error persists contact Wintriss Tech Support Overrun Limit Switch Fault Problem The overrun limit switch has provided more than one signal to WPC 2000 during a stroke The switch should open and close only once per stroke Remedy Check the overrun limit switch installation to make sure that the switch opens and closes only once per stroke referring to Instal...

Page 188: ...replaced If the resolver drive checks out also check the wiring and installation of the resolver see Installing the Resolver page 2 20 Check the diameter of the shaft on which the magnet is mounted to make sure there is enough dwell for the switch to provide an adequate signal see Planning Your Overrun Sensor Installation page 2 26 An ideal diameter is 4 in to 6 in If the shaft is larger than this...

Page 189: ...et the unit press the brass button on the bottom of the Reset solenoid while air is being applied to the DSV see Figure 5 4 page 5 21 If the fault occurs after the unit has been wired an F47 error will appear on the WPC 2000 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 12 If you have...

Page 190: ...pply line e g restrictive fittings quick disconnect fittings low flow filters or regulators or clogged filter elements and correct if necessary Also check to make sure that the air supply line matches the inlet port size of the DSV and replace with a properly sized supply line if it doesn t Figure 5 4 Ross DM2 DSV Showing Reset Button ...

Page 191: ...1128500 WPC 2000 User Manual 5 22 Troubleshooting ...

Page 192: ...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 193: ...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 194: ...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 195: ...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 196: ...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 197: ...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 198: ...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 199: ...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 200: ...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 201: ...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 202: ... 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 203: ... 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 204: ...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 205: ... 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 206: ... 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 207: ...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 208: ...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 209: ...1128500 WPC 2000 User Manual A 18 Extracts from OSHA and ANSI ...

Page 210: ...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 211: ...perator Stations page 3 33 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 guar...

Page 212: ...the factory and cannot be changed Ten of the non control reliable Option 1 user inputs are set for a stop type of Top stop eight are set for E stop and two are programmed for E stop Lockout see Table C 1 Of the control reliable cross checked input pairs two are set for E stop and two for E stop Lockout When any equipment connected via Option 1 user inputs to WPC 2000 issues a stop command by openi...

Page 213: ...p User input 24 PNP Top stop User input 25 PNP Top stop User input 26 PNP Top stop User input 27 PNP E stop User input 28 PNP E stop User input 29 PNP E stop User input 30 PNP E stop Lockout User input 31 PNP E stop User input 32 cross checked with input 33 PNP E stop User input 33 cross checked with input 32 PNP E stop User input 34 cross checked with input 35 PNP E stop User input 35 cross check...

Page 214: ...ic electricity can destroy electronic components Failure to comply with these instructions could result in property damage Be sure to save the shipping box and protective anti static bag in case you need to return the Option 1 board ELECTRIC SHOCK HAZARD Ensure that the power source is off before you replace electronic components in a control Disconnect power from the machinery it is connected to ...

Page 215: ...hillips screws provided 7 If you are ready to connect auxiliary equipment to the Option 1 board proceed to the next section Otherwise close the door of the WPC 2000 enclosure or console Figure C 1 Option 1 Board Installed on WPC 2000 Main Processor Board Green Orange 438 439 440 441 442 443 444 445 446 447 431 432 433 434 435 436 437 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 ...

Page 216: ...e jumpers installed at the factory make sure to bypass those inputs by connecting them to 24 Vdc or ground as shown in Table C 2 or Table C 3 TB601 provides one 24 Vdc terminal and one ground terminal for jumper connections TB602 provides two 24 Vdc terminals and two ground terminals Figure C 2 WPC 2000 Option 1 Board 5V A processor LED DS630 5V B processor LED DS629 438 439 440 441 442 443 444 44...

Page 217: ... User input 25 24 Vdc 452 User input 36 cross checked with user input 37 24 Vdc 453 User input 38 cross checked with user input 39 24 Vdc 454 Ground Table C 3 WPC 2000 Option 1 Board Wiring Connections TB602 Pin User Input Terminal for Jumper Bypass Connection Upper Row 438 User input 33 cross checked with user input 32 24 Vdc 439 User input 35 cross checked with user input 34 24 Vdc 440 User inpu...

Page 218: ... 434 User input 13 435 User input 14 GROUP 8 453 User input 38 x ch w 39 448 User input 22 449 User input 23 450 User input 24 451 User input 25 452 User input 36 x ch w 37 GROUP 11 445 User input 21 438 User input 33 x ch w 32 439 User input 35 x ch w 34 440 User input 16 441 User input 17 442 User input 18 443 User input 19 444 User input 20 GROUP 10 462 User input 39 x ch w 38 455 User input 26...

Page 219: ...top 435 Ground 123 User 15 Top stop 436 Ground 124 User 16 Top stop 440 Ground 125 User 17 E stop 441 Ground 126 User 18 E stop 442 Ground 127 User 19 E stop 443 Ground 128 User 20 E stop 444 Ground 129 User 21 E stop Lockout 445 Ground 130 User 22 Top stop 448 24 Vdc 131 User 23 Top stop 449 24 Vdc 132 User 24 Top stop 450 24 Vdc 133 User 25 Top stop 451 24 Vdc 134 User 26 Top stop 455 24 Vdc 135...

Page 220: ...eed changes or the brake wears Automatic Continuous On demand A WPC 2000 feature that allows an external device like a feeder or robot to signal WPC 2000 to start the press in Continuous mode and maintain operation in Continuous Automatic Single stroke A WPC 2000 feature that allows an external device like a feeder or robot to signal WPC 2000 to stroke the press when a feed has been completed BDC ...

Page 221: ... the press that controls the flow of air to the press s clutch emergency stop A signal sent to the press in response to a malfunction that stops the press immediately An Emergency Stop can be initiated manually by the operator or automatically by WPC 2000 or external devices fault error message An alphanumeric code that appears on the WPC 2000 display when an error condition occurs hand speed cons...

Page 222: ...ensitivity A value required in deriving the depth penetration factor for a light curtain Object sensitivity specifies the smallest diameter object that a light curtain will detect anywhere in its field ON OFF setting Stroke angle settings at which the cam channel is to turn ON activate and turn OFF deactivate OSHA Stands for Occupational Safety and Health Administration a government agency that ha...

Page 223: ...or that allows the press to resume operation after it has been stopped due to a malfunction The reset command clears the fault message from the WPC 2000 display resolver An electrical component mounted on the press used by WPC 2000 to provide continuous information about the position of the crankshaft and to maintain a count of the number of revolutions it makes The resolver which has internal win...

Page 224: ...s electrical noise synchronous time The ANSI term for palm time TDC Abbreviation for top dead center timing ON settings for critical press parameters like Auto Carry up Angle and Top Stop and ON and OFF settings for cam channels top stop A signal sent to the press in response to a malfunction that stops the press at the top of its current stroke 0 A Top Stop can be initiated manually by the operat...

Page 225: ...1128500 WPC 2000 User Manual G 6 Glossary ...

Page 226: ...0 mounting and wiring cam output assembly 2 36 setting cam channel timing 3 33 wiring cam relays 2 38 wiring zero cam output to AutoSet 2 42 clutch air pressure switch See air pressure switch concurrent time setting for multiple op stations 3 33 continuous mode operating the press in automatic continuous on demand 4 19 operating the press in continuous foot 4 18 operating the press in continuous t...

Page 227: ...g 3 54 wiring 2 42 H H faults responding to 5 5 Herion DSV installing and wiring 2 11 I inch mode operating the press in dead motor inch 4 10 operating the press in micro inch 4 10 operating the press in top stop bypass 4 9 operating the press in top stop in inch 4 9 indicator segment LEDs location 1 4 inputs user See user inputs interlocks See user inputs interrupted stroke location of interrupte...

Page 228: ... in continuous mode 3 39 testing emergency stop button in inch mode 2 61 testing top stop button 3 40 using multiple operator stations 2 17 4 20 wiring dual operator stations 2 17 wiring unwired operator station 2 16 option switches See press option switches setting outputs See auxiliary outputs overrun limit switch faults 5 19 5 20 mounting sensor magnet 3 9 mounting sensor switch 2 26 planning i...

Page 229: ...stroke select key switch installing and wiring display board kit 2 58 installing and wiring panel mount 2 55 location and function 1 1 suppressor installing across an AC load 2 40 system static test 3 43 T tests checkout 3 35 installation verification 2 58 ninety degree 90 stop time 3 17 top stop on angle adjusting 3 11 determining 3 6 setting 3 6 3 26 top stop button operator station location 1 3...

Page 230: ... 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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