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 Troubleshooting 
 

AutoSet 1500 User Manual 

48 

Ch 5 

1088500 

When AutoSet displays a high setpoints fault 

When the actual "LOAD" tonnage exceeds the "SETPOINT" tonnage on one or both 
inputs, an overload condition exists.  AutoSet will open the output relay. The "LOAD" 
display for the overloaded input will flash, and "HI" will flash on the one or both of the 
setpoints displays, depending upon which strain links affected.  See Figure 5-1. 

 

LOAD

SETPOINTS

HI

59.4

48.1

RIGHT

LEFT

HI

RESET

 

 

             

Figure 5-1.  Displaying high setpoints exceeded on both inputs

 

 

 

 

Check to see why AutoSet stopped the press.  Is it due to a problem in the die, such as 
stuck part, variation in shut height, drastic change in material thickness, etc.?  If so, 
correct the problem immediately.   

Or is it due to a nuisance stop because the high setpoints are too tight?  Then see 
"Creating setpoints for the job" to change the high tolerance percent.   

AutoSet is cleared by holding the reset button down for less than two seconds. The 
displays will stop flashing, and the overload values remain on the "LOAD" displays until 
the next stroke, or until power has been turned off.  

Remember that holding the reset button for more than two seconds signals AutoSet to 
recalculate setpoints. Therefore, when clearing an overload condition, press and release 
the button quickly (less than two seconds). This will clear the overload, but 

will not

 

signal AutoSet to recalculate setpoints. 

 

Note:

  Data Instruments recommends you connect AutoSet to the top stop circuit (not E-

Stop circuit) of the press.This is so the press will not stick on bottom if an 
overload occurs.  

 

Remember that top stop circuits are active only in continuous (automatic) 
operations on most press controls. If overload protection is required during inch 
or single stroke mode, you may have to install an additional relay so AutoSet will 
stop the press. 

Содержание AutoSet 1500

Страница 1: ...Load Analyzer 1088500 Rev C1 June 1998 Tech Support Hotline 800 586 8324 8 5 EST www wintriss com Wintriss Controls Group 100 Discovery Way Acton MA 01720 3648 USA Phone 978 264 9550 800 586 8324 Fax 978 263 2491 PRINTED IN USA DA45897 ...

Страница 2: ...t 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 Program Rush service provid...

Страница 3: ...ks Chapter 3 PROVIDE IMPORTANT INFO DURING TROUBLESHOOTING WITH DI TECH SUPPORT Whenever you need to contact Data Instruments for technical assistance be ready to provide some important information to expedite a resolution to the problem Please supply product name e g AutoSet model e g 1500 or 1504 type e g standard or plus and firmware version number e g Vs 2 00 You can determine firmware version...

Страница 4: ...1 Final checkout for AutoSet 1500 22 Chapter 3 AutoSet 1500 Calibration 23 Calibration 23 Types of calibration kits you can use 24 How many load cells to use 24 How to begin 24 Zeroing strain links 24 Setting up and adjusting a Wintriss Load Analyzer WLA calibration kit 26 Setting up and adjusting an AutoSet 1500 calibration kit 29 Calibrating your AutoSet 1500 33 Setting up the press 33 Setting f...

Страница 5: ...9 AutoSet Troubleshooting 50 When none of the load or setpoint LEDs are displayed 50 When either of the load displays shows no tonnage 50 When the tonnage is lower than it should be 50 What happens when power is turned off and restored 50 Appendix A AutoSet 1500 Panel Mount 51 Standard Enclosure versus Optional Panel Mount 51 PreparationformountingAutoSetusingyourenclosure 51 Final assembly 51 App...

Страница 6: ...ut calibration Read this chapter to calibrate AutoSet properly Chapter 4 explains how to use AutoSet Use it to create and adjust setpoints Chapter 5 talks about what happens when AutoSet stops the press and what to do to remedy the situation It displays the alarms that AutoSet will provide explains what they mean and how to correct them This chapter also discusses how to troubleshoot certain situa...

Страница 7: ...cident or unauthorized modification The provisions of this warranty do not extend the original warranty of any product which has either been repaired or replaced by D I No other warranty is expressed or implied D I accepts no liability for damages including any anticipated or lost profits incidental damages consequential damages costs time charges or other losses incurred in connection with the pu...

Страница 8: ...its that can cause catastrophic damage 3 Tooling setups are more accurate because of the actual tonnage information AutoSet provides The correct information about tonnage can be stamped on the die shoe per OSHA regulation 1910 217 d 6 i 4 AutoSet can detect die malfunctions through tonnage variations and can there fore monitor misfeeds slug stacking misuse of stop blocks increases in mate rial thi...

Страница 9: ...load occurred will flash Both displays will flash if an overload occurs on both sides of the press The press stops Once AutoSet is reset the displays stop flashing You can once again run the press Be sure to check for the cause of the overload first Holding the button down for more than two seconds signals AutoSet to recalculate setpoints the next time the press is started This can be done while t...

Страница 10: ...convert press frame deflection into an electrical signal They detect and measure the forces tension or compression acting on the press frame When the press is loaded the strain link is either stretched or compressed On straight side presses strain links measure tension stretching of the frame On gap frame presses OBI or OBG strain links can measure either tension front mounted or compression rear ...

Страница 11: ...ain link It records the load for each stroke in the sample period 2 After the sample period ends AutoSet determines the highest load at each strain link It ends up with two numbers the highest measured load at the right strain link and the highest measured load at the left strain link 3 It then calculates the setpoints using this formula highest measured load on each strain link during sample peri...

Страница 12: ... tonnage on the left is 16 tons and on the right is 10 tons See Figure 1 2 TONS 11 tons RIGHT CHANNEL 20 30 tons 10 30 16 tons 17 6 tons LEFT CHANNEL 0 STROKES 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17 18 30 tons STROKES 10 tons 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 10 30 0 TONS Figure 1 2 Tonnage produced at each strain link in example Highest load is on stroke 7 for left strain link and...

Страница 13: ...perature 32 o to 122 o F 0 o to 50 o C Relay contact rating 5 amps 120 or 240 Vac Normally open held closed Speed To 400 SPM without zero cam to 2000 SPM with optional zero cam Display 2 3 digit 43 1 1 cm high for tonnages 2 3 digit 30 76 cm high for setpoints Strain links two provided Size 3 75 x 1 19 x 0 75 9 5 x 3 x 1 9 cm Cable 30 ft 9 1m standard other lengths optional Drill fixture One provi...

Страница 14: ...lation instructions and mounting and cutout dimensions 1 Determine a convenient place for the control box Ideally it should be close to the press control so operators and setup personnel can easily see the readouts and reach the reset button Also make sure the strain link cables will reach to the mounting site selected Leave enough room to open the door at least 120 The box can be mounted to the p...

Страница 15: ...stroke mode you may have to install an additional control relay so AutoSet will stop the press 3 Open the cover of the control box See Figure 2 2 for a drawing of the inside of the box Near the top of the enclosure you will see a metal cover This cover protects the power supply Remove it by first unsnapping the two white plastic plugs at the bottom of the cover pull plug straight up Then loosen th...

Страница 16: ...er Zero Cam Power Zero LED DS1 Remote Reset LED DS3 TB1 COMMS TB4 CPU NO S9 S8 Gain Settings Dialog Station TB8 LEFT INPUT TB6 RIGHT INPUT TB7 Notch FIRMWARE RAM CHIP U8 U15 LINE STOP CIRC VOLTAGE SELECTOR FUSES POWER TB3 Tonnage Settings FOR CALIBRATION S7 Tolerance Selector MODE SELECTOR S1 S5 S4 S3 CAUTION POWER TRANSFORMER COMMS LED DS2 1 J6 J7 R17 R25 S2 ...

Страница 17: ... shown in Figure 2 3 Leave the ground wire attached to the connector while making connections If you remove this wire in order to pull the connector all the way out of the box be sure to replace it when done 8 Connect wires to the L shaped top section as shown in Figure 2 3 For 115 Vac connect black wire to HI slot and white wire to NEU For 230 Vac connect black wire to HI slot and red wire to NEU...

Страница 18: ...u did not wire it backwards Note first GND from left in Figure 2 3 is not used 11 Make all necessary conduit connections to ensure NEMA 12 protection 12 Replace the power supply cover removed earlier Snap in the white plastic plugs at the bottom of the cover and tighten down screw at top 13 Do not connect wires to AC power source until you are done with all other installation procedures Also make ...

Страница 19: ...n diagonal corners one on front left one on back right They measure tension stretching of the frame For gap frame OBI or OBG presses strain links can be mounted on the front of the press to measure tension or on the back of the press to measure compression Usually mounting on back is better because the strain links are away from the work area Typical strain link locations for most gap frame and st...

Страница 20: ...adings WARNING Use caution when determining an appropriate location for each strain link Do not mount any strain link under or above a hole 1 in diameter or larger on the press column Avoid mounting the strain link inside the die area where it would be subjected to harsh chemicals If necessary use a cover to protect the strain link A Diagonal mounting Right arrow indicates second link mounted diag...

Страница 21: ...t or right Leave the mounting screws loose for now Strain links must be properly zeroed set close to a 0 volt electrical output under no load before mounting screws are tightened This zeroing procedure must be done as part of the calibration procedure in Chapter 3 Therefore do not tighten links until you get to that part of the calibration procedure 8 Run the strain link cables through flexible co...

Страница 22: ...ctions for strain links 11 Start with connector TB7 for the right strain link marked right input Strain link connectors are the same L shaped type as used for the AC wires Pull the L shaped top section of connector from base Make wiring connections in the same way as for AC wires 12 Replace the connector It only goes in one way Double check connections 13 Remove connector TB6 for the left strain l...

Страница 23: ...ps prevent shock if you re working inside the box with power on What you should see when power is turned on After connecting AutoSet to a power source set switch S2 to zero close the cover and turn power on The top LOAD displays should show 0 s or other numbers The bottom setpoint displays should show either numbers dashes or the numbers HI or LO It does not matter what at this point If the displa...

Страница 24: ... zero cam is not usually needed AutoSet has enough time during the stroke to zero itself automatically However in some instances a zero cam may be needed even for a slower press Without a zero cam connected AutoSet will not read tonnages less than 5 percent of full scale tonnage Therefore if you will be using AutoSet on jobs where less than five percent of press capacity is used you will need a ze...

Страница 25: ...tself However you might also use the pitman above the adjusting screw or a drive shaft to a feed or other device 2 Fabricate a bracket to position the LMCS 1 16 to 1 8 from the face of the magnets If possible make the bracket adjustable To aid in mounting the LMCS is supplied with a slotted mounting bracket These slots are 1 5 apart and approximately 1875 3 16 wide by 75 long Use size 6 32 hardwar...

Страница 26: ...uit rated NEMA 12 and make proper conduit connections to ensure NEMA 12 protection 6 Pull connector out of socket How you wire the switch depends on the type used The LMCS will require power Some other switches are mechanical so you do not need to apply power to the switch If you are using a programmable limit switch PLS to supply the zeroing signal you will not need power for the switch either Se...

Страница 27: ...previously adjust the cam switch so the zero signal comes on at 240 and turns off at 30 approximately In other words the switch should close to ground between 240 and 30 9 The last thing you need to do is set DIP switch 2 on switch block S1 refer to location of components You must set switch 2 to the right With a ball point pen not a pencil or your thumbnail push the switch to the right to the zer...

Страница 28: ...ire to pin 1 RESET and the other to pin 5 GND See Figure 2 9 for connections 7 Replace the connector 8 You are done installing the remote reset switch Wiring a strip chart recorder to AutoSet optional You can connect a strip chart recorder to AutoSet to graphically plot tonnage produced at both strain links The AutoSet outputs for a strip chart recorder are 5V to 5Vdc To connect a strip chart reco...

Страница 29: ... the final checkout Set a high setpoint value using the High Percent Tolerance Selector on the AutoSet board see location of components Figure 2 2 For simplicity program the high setting at 2 position 1 on the selector Run a few parts Check that the press top stops and that an error condition HI flashes on the AutoSet LED display and the display flashes the strain link input s affected If AutoSet ...

Страница 30: ...ibed in this chapter NOTE Calibration with a hydraulic jack is also possible although much less accurate than load cells It is also not as easy a procedure as using load cells Data Instruments does not recommend hydraulic jack calibration and it is not covered in this manual For more information on hydraulic jack calibration contact a Data Instruments service representative 3 Setting the full scal...

Страница 31: ...00 calibration kit Calibrating your AutoSet 1500 First follow the procedure for setting up and adjusting the calibration unit you are using Then go directly to the section titled Calibrating your AutoSet 1500 Zeroing strain links 1 Before you can adjust the AutoSet 1500 to the tonnage on your calibration unit you have to set the strain links to read zero 0 at no load First make sure there is no lo...

Страница 32: ...he strain link is not working properly Contact Data Instruments for as sistance 8 Now begin tightening the strain link screws evenly all around As you tighten check the display The numbers on the tonnage display will change When the strain link is fully tightened 150 inch pounds the number on the display must be between 90 If the number is not between 90 loosen and adjust the mounting screws until...

Страница 33: ...nnage readings Follow these steps to set up and adjust the WLA calibration unit 1 Make sure the power to the Wintriss Load Analyzer is off Then remove both signal conditioning modules if installed These modules are the ones which have knobs for setting tonnage setpoints and a span adjustment Loosen the screw at the bottom of the module and pull it out Important you must remove both modules 2 Inser...

Страница 34: ... the TENSION COMPRESSION switch to COMPRESSION Set the display switch to LEFT 7 Use a screwdriver to adjust the span control on the left calibration module until the display flickers between 00 and L0 8 For two cell calibration only Set the display switch to RIGHT Adjust the right calibration module span control with screwdriver until the display flickers between 00 and L0 9 On the WLA Set the mod...

Страница 35: ...t which tells it when the press reaches top dead center Without a zero signal the WLA does not know when to clear the readings for one stroke and display readings for the next You tell it when by manually zeroing it You should zero the WLA after every stroke of the press A normally open momentary pushbutton switch is recommended Install the switch between terminals 1 and 4 on terminal TB2 TB2 is o...

Страница 36: ...ply cover to connect 115 Vac wires make sure you put the cover back on The cover fits over the power supply near the top of the enclosure It helps prevent shock if you are working inside the box with power on 3 For one cell calibration take one calibration module and plug the cable into the slot marked left input in the AutoSet box This slot is at the lower right hand corner of the box The connect...

Страница 37: ...s do not light up 7 Familiarize yourself with the location of the switches and dials inside the box See Figure 2 2 in Chapter 2 for a drawing of the components inside the box 8 You must set the full scale tonnage on the AutoSet calibration unit to 2 times the tonnage of one load cell Even if you are using two load cells you still set this number to 2 times the tonnage of 1 load cell Determine the ...

Страница 38: ...s For instance 1500 would be set as 1 5 0 the same as if you were setting full scale tonnage to 150 tons You must also set DIP switch number 3 on Switch block S6 to the closed position decimal point off Switch block S6 is located below the full scale tonnage switches See Figure 3 3 With a ball point pen not a pencil or your thumbnail push the switch to the right away from the OPEN position Make su...

Страница 39: ...er for setting calfactors on calibration unit 14 Find the block marked R17 top block This controls the left display Turn the screw one way or another until the left tonnage display reads 157 2 For two cell calibration adjust the right display as well Turn the screw on block R25 bottom block until the right display reads 157 2 To calibrate the press in metric tons set the calfactor to read 173 2 15...

Страница 40: ...Make sure they are centered under the connecting rods to ensure even load distribution on the press frame 4 Turn on the press and cycle the press through one stroke 5 Use the shut height adjustments to lower the ram 0 003 or 0 004 0 076 0 102 mm on successive strokes until the readout on your calibration unit indicates that contact on the load cell s is being made at bottom dead center NOTE DO NOT...

Страница 41: ...nage is equal 8 When tonnage is correct lock the shut height adjustment 9 Check to make sure the load cells shims and parallels will not move during calibration If using the WLA as the calibration unit zero it first then recheck tonnage If using the AutoSet calibration kit recheck tonnage no zeroing is required See if there has been a decrease in tonnage on the load cells If so re adjust the press...

Страница 42: ...tructed below When full scale tonnage is from 1 to 999 Set the 100 s 10 s and 1 s digit to the tonnage of your press For presses under 200 tons AutoSet will display tonnage in tenth s of a ton 15 5 20 0 99 9 etc up to 100 tons For presses 200 tons and over AutoSet displays tonnage in whole numbers only NOTE Make sure the decimal point switch No 3 on S6 is set to the on position See Figure 3 5 If n...

Страница 43: ... same as if you were setting full scale tonnage to 200 tons For presses over 1500 tons you must multiply all readings by 10 For instance 155 tons would be displayed as 15 5 tons 1500 tons would be displayed as 150 tons NOTE Make sure the decimal point switch No 3 on S6 is set to the on position See Figure 3 5 If not set to on push switch all the way to the left with a pen or your thumbnail 4 Turn ...

Страница 44: ...etting gain 3 Start with the left strain link The gain potentiometer R17 on top in line with the left strain link connector TB6 adjusts the gain for this strain link First take a look at the jumper J6 above R17 see Figure 2 2 for exact location It should be set to the left in other words the right pin of the jumper connections will not be covered by the jumper block See Figure 3 8 This jumper sett...

Страница 45: ...age is less on AutoSet than on your calibration unit turn the screw clock wise while cycling the press and watching the left display If you fail to see any tonnage displayed on AutoSet do not worry Just keep turning the screw clockwise while cycling the press and tonnage will begin to appear Continue adjusting AutoSet tonnage upward If you get the tonnage on AutoSet to match you are done Go to Ste...

Страница 46: ...hen if you ever have to replace the control board you can simply set the switch to calibrate and adjust each potentiometer screw until the calfactor number you recorded is displayed You will not have to go through the whole calibration process Record the gain setting as well For example low gain jumper to left hi gain jumper to right The gain has to be set properly in order to set the right calfac...

Страница 47: ...s To check linearity change the load on the press For instance if you calibrated at 75 capacity reduce the load on the load cells to about 45 If you calibrated at 50 increase the load to about 80 The tonnage on AutoSet at each strain link should equal tonnage on the calibration unit at each load cell If the tonnages disagree the problem may be the positioning of your strain links or twisting force...

Страница 48: ...ings before it calculates setpoints selecting the sample period and setting the percent tolerance selector Here is how to make these settings Selecting the sample period AutoSet has two different sampling periods 15 strokes or 1 stroke As a rule of thumb use the 15 stroke sample period when running in continuous mode or when the percent tolerance selector is set at values less than or equal to 50 ...

Страница 49: ...sample period will be in effect Setting the percent tolerance selector The percent tolerance selector tells AutoSet what percentage to use in calculating setpoints The procedure below tells you how to determine the correct setting for your die You will not have to follow this procedure for every die In most cases once you make the setting for one die it will work for most of the dies you use on th...

Страница 50: ...tomatically sets setpoints at 120 of full scale tonnage This disables AutoSet it does not create setpoints However it will stop the press if tonnage exceeds 120 of full scale 0 2 4 6 8 8 50 7 35 6 25 5 20 4 15 3 10 2 5 1 2 of actual load 9 100 of Percent tolerance selector 0 120 of Full Scale disable actual load Figure 4 2 Percent tolerance selector switch 4 Set the percent tolerance selector to 1...

Страница 51: ...completed AutoSet will display new setpoints based on the sampled load If AutoSet shuts down the press because these setpoints are exceeded at one or both strain links go to Step 2 You know AutoSet stopped the press if one or both LOAD displays flash C If the press does not stop after the sample period is completed run the press for about 20 more strokes beyond the sample period See if AutoSet sto...

Страница 52: ...nuisance stop occurs now this is the right setting for the job Note A 1 setting is the lowest you can go A zero setting will not create setpoints D Complete this step only if a nuisance stop occurred in Step B or C If so make sure the press did not stop for some other reason Then click the dial up one from 2 back to 3 for instance Run the press If no nuisance stop occurs now this is the right sett...

Страница 53: ...the old settings whenever you run the old die again without trial and error When you must recalculate setpoints You always have to recalculate setpoints after a tool change This is so that setpoints will be based on the new press load This is done by pressing and holding the RESET button until the numbers in the setpoint display flash once and change to 120 of full scale ap proximately 2 seconds R...

Страница 54: ...ed if the press shutdown because of a nuisance stop or a tonnage fault Here is the difference between the two A nuisance stop occurs when setpoints are so tight that normal variations in tonnage cause AutoSet to shutdown the press A tonnage fault occurs when the tonnage has fluctuated enough to exceed the high and or repeatability setpoints being used by the load monitor A fault may be caused by a...

Страница 55: ...ee Creating setpoints for the job to change the high tolerance percent AutoSet is cleared by holding the reset button down for less than two seconds The displays will stop flashing and the overload values remain on the LOAD displays until the next stroke or until power has been turned off Remember that holding the reset button for more than two seconds signals AutoSet to recalculate setpoints Ther...

Страница 56: ...ust re zero the strain link To re zero refer to the section Zeroing the strain links in Chapter 3 Calibration You do not have to recalibrate AutoSet even when replacing the strain link unless it has been moved to a different location When you reset AutoSet ERR will disappear and the setpoint display will once again show the correct setpoints and the affected tonnage display will show 0 Resetting A...

Страница 57: ...nnecting strain links in Chapter 2 for more information When the tonnage is lower than it should be If when running your press you find that that tonnage is lower than you think it should be If new installation or calibration If you had installed the optional zero cam switch LMCS check that it is closed to ground during the top of the stroke and that it opens at bottom Also look at where the red a...

Страница 58: ...r mounting dimensions 3 Prop AutoSet near the location where it will ultimately be mounted see Figure A 1 You can do this by connecting ty wraps from two of the left holes on the panel to the corresponding holes on the enclosure for a hinge like effect Allow at least 9 of service loop when performing the wiring connections Also make sure all cables will reach 4 Refer to Chapter 2 of the AutoSet 15...

Страница 59: ...nd your enclosure YOUR PANEL 0 218 DIA 5 5 14 places allow at least 4 100 clearance behind panel 0 50 12 7 8 95 227 3 13 50 323 9 12 25 311 2 10 38 263 7 0 25 6 4 0 34 8 6 3 75 95 3 11 25 285 8 0 35 8 9 4 13 104 8 8 25 209 6 When wiring allow at least 9 230 mm service loop 7 50 190 5 AUTOSET PANEL MOUNT xx xx in xx x mm ...

Страница 60: ...switches 1 and 4 on switch block S1 are used to make the settings On the standard AutoSet dip switch 4 is not used Figure B 1 Stroke select switch S1 with on off positions for switch 4 shown The following chart shows how to set dip switches 1 and 4 for 1 15 30 or 60 stroke settings set stroke select 1 to set switch 4 to 1 stroke ON 1 stroke 15 strokes ON 15 strokes 30 strokes OFF 15 strokes 60 str...

Страница 61: ...Selectable Sampling AutoSet 1500 User Manual 54 App B 1088500 ...

Страница 62: ...rt recorder 21 continuous stroke 41 44 Cover latches 2 custom selectable sampling 53 cutout dimensions 52 D decimal point switch 31 36 differential strain links 3 12 disable AutoSet 46 F final checkout 22 front panel 2 full scale tonnage 3 5 30 35 G Gain potentiometer 32 37 ground block 10 H high gain setting 37 high setpoints failure 48 How AutoSet 1500 works 4 How tonnage is recorded 3 I Install...

Страница 63: ...erload 48 P panel mount 51 parallels 33 34 percent tolerance selector 4 5 32 41 42 43 46 potentiometer 25 26 32 power supply cover 8 11 29 R ram 33 recalculating setpoints 46 recording calfactors and gain settings 39 remote reset switch 21 Reset button 2 5 42 49 S sample period 4 5 41 Setpoint displays 2 setpoints 4 44 45 47 settings for full scale tonnage 35 shim stock 34 single stroke 44 48 S Sp...

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