Page 1 WPC 1000 Wintriss Clutch/Brake Control 1125100 Rev. R August 2015 Tech Support Hotline 800-586-8324 8-5 EST Wintriss Controls Group, LLC www.wintriss.com...
Page 2 1910.217 (b) (7). Refer also to ANSI B11.1-2009.  Use WPC 1000 clutch/brake control only on rotating machinery that can be stopped at any point in its stroke or cycle. Failure to comply with these instructions will result in death or serious injury.
Page 3  Ensure that the press on which WPC 1000 clutch/brake control is used meets the machine guarding requirements of OSHA standard 1910.217 and any other regulations and standards that apply.  DO NOT operate a press equipped with WPC 1000 clutch/brake control if the machine or any of its stopping mechanisms is not in proper working order.
Page 4: Wpc 1000 User Manual
Changes for Revision R of the WPC 1000 User Manual (1125100) This revision of the WPC 1000 user manual covers WPC 1000 software version 2.77 and higher. The changes include: Revised mounting dimensions for the WPC 1000 enclosure (see Figure 2-4, page 2-7)
Page 5 Wintriss Product. We appreciate your business and want to do whatever we can to ensure your satisfaction. Wintriss products are built to stay on the job day after day, and are backed by an ironclad guarantee, international standards approvals, and unbeatable support.
Page 6: Table Of Contents
WPC 1000 Components ........
Page 7 Mounting the One-hand Control........2-41 Wiring One-hand Control to WPC 1000....... . . 2-43 Mounting and Wiring the Bar Control Enclosure .
Page 8 WPC 1000 User Manual 1125100 Chapter 3. Initialization, Setup, and Checkout ....3-1 Viewing and Setting Press Parameters ....... .3-1 Initializing the System.
Page 9 Responding to WPC 1000 Faults........
Page 10 WPC 1000 User Manual 1125100 E, F, and H Faults ..........5-5 Resolver Faults .
Page 11 Figure 10. WPC 1000 Ross DM2 DSV Wiring Figure 11. WPC 1000 Mode Selector with Ross DM2 Reset Wiring Figure 12. WPC 1000 New Style and Shadow 8 Control Box Wiring Diagram Figure 13. WPC 1000 New Style and Shadow 8 Wiring Diagram List of Figures Figure 1-1.
Page 12 Figure 3-11. S101 Option Switch OFF and ON Settings ..............3-27 Figure 3-12. WPC 1000 Displays Showing Cam Indicator Segments ..........3-33 Figure 3-13. WPC 1000 Displays Showing Cam Channel 1 OFF Setting (Cam 1 ON = 180°) ..3-34 Figure 3-14. WPC 1000 LED Indicator Map ..................3-36 Figure 4-1.
Page 13 Table 2-19. WPC 1000 Control Board: Power (J103) Wiring Connections ....2-70 Table 2-20. WPC 1000 Display Board: Wiring Connections ......2-71 Table 3-1.
Page 14 Chapter 3 shows you how to initialize and set up WPC 1000 and perform final checkout tests. Chapter 4 shows you how to run the press, using WPC 1000’s Inch, Single-stroke, and Continuous stroke selections and Two-hand, One-hand, and Foot modes.
Page 15 1125100 WPC 1000 User Manual Important Highlighted Information Important danger, warning, caution and notice information is highlighted throughout the manual as follows: DANGER A DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.
Page 16 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.
Page 17 1125100 WPC 1000 User Manual Table of Contents...
Page 18: Chapter 1. Introduction
WPC 1000 can be shared with other Wintriss resolver-based products, such as DiPro 1500. Control Enclosure The WPC 1000 control enclosure (see Figure 1-1, page 1-2) can be ordered with the display and controls mounted on the front (center mount) or left (left mount) or right side (right mount).
Page 19: Figure 1-1. Wpc 1000 Control Panels
1125100 WPC 1000 User Manual Micro-inch (Optional)–Provides a setting for turning on the Micro-inch feature (see • Standard Features, page 1-7). WPC 1000 Center Mount with Optional WPC 1000 Center Mount Counter/Crank Angle Clock Display Standard Display INTERRUPTED STROKE °...
Page 20: Operator Station
The Operator Station is normally the device used to run the press in all Stroke Select positions. Wintriss provides operator stations with Run/Inch palm switches mounted on either the top or sides (see Installing Operator Station(s), page 2-12 for available configurations).
Page 21: Other Components
See Installing a Light Curtain, page 2-18 for more information. WPC 1000 is designed to be used with a Shadow light curtain. If you order WPC 1000 without a light curtain, the control enclosure does not have a Mode Select switch, and the unit operates only in Two-hand mode.
Page 22: Figure 1-3. Wpc 1000 Displays
Reset/Select button until that segment is illuminated. The segments in the lower group of four segments can only be selected when WPC 1000 is in Inch mode. When illuminated, indicator segments display press speed, crankshaft angle, 90°...
Page 23: Optional Counter And Crank-Angle Clock Display
When the count total reaches the value set on the Counter Preset indicator segment (see page 4-5), WPC 1000 stops the press. The counter is reset to “1” with the Reset/Select button. The counter preset feature is useful for batch sizing or periodic QC checks.
Page 24: Optional Features
Top-stop. When the press’s stopping time is within ten milliseconds of the preset Stop-time Limit, the Brake Warning LED flashes. When the stopping time exceeds the Stop-time Limit, WPC 1000 issues a Stop command to the press and prevents the press from being restarted until the brake has been serviced.
Page 25 1125100 WPC 1000 User Manual One-hand Control–A low-force switch that can be used with WPC 1000 running One- • hand/Two-hand/Foot firmware and equipped with a Shadow light curtain guarding the point of operation. The One-hand Control switch can be mounted on or near the press, allowing the operator to press the switch as part of his normal hand motion after loading a part.
Page 26: Specifications
WPC 1000 User Manual 1125100 Specifications WPC 1000 specifications are shown in Table 1-1. Table 1-1. WPC 1000 Specifications Control Enclosure: 12.88 x 17.62 x 7.11 in. (327.2 x 447.5 x 180.6 mm), NEMA 12, shock-mounted. Panel Mount: 7.50 x 10.00 in. (190.5 x 254.0 mm)
Page 27 12-150 PSI. Monitors counterbalance air supply (uses one custom input). Bar Mode Control Allows manual turning of crankshaft. Motor Control and Custom Packages Refer to Press Control/Motor Starter literature, and/or contact your Wintriss representative or factory for more details. * Shadow light curtain required 1-10...
Page 28: Chapter 2. Installation
• Follow all procedures in this manual. Perform only the tests and repairs listed in this manual. Use only factory-supplied replacement parts. • Ensure that WPC 1000 clutch/brake control is installed, tested and repaired by qualified personnel. • Wire, install and maintain WPC 1000 clutch/brake control in accordance with the applicable safety standards.
Page 29 NOTICE READ INSTALLATION INSTRUCTIONS BEFORE STARTING INSTALLATION If you install WPC 1000 yourself, read this installation chapter carefully and plan how you are going to proceed before you start drilling holes, running conduit, or cutting wires. Make sure you are familiar with the WPC 1000 display (see page 1-5). If you encounter problems during installation, contact Wintriss Tech.
Page 30: Installation Guidelines
Run one or two low-voltage conduits for the resolver wires to the knockouts on the bottom • of the WPC 1000 enclosure. Because WPC 1000 is rated NEMA 12 (protected against dust and oil), you must use • conduit of the same rating and make proper connections to ensure NEMA 12 protection.
Page 31: Figure 2-1. Wpc 1000 Wiring Overview
1125100 WPC 1000 User Manual Motor Control Wintriss Clutch/brake Control Operator Station Figure 2-1. WPC 1000 Wiring Overview Installation...
Page 32: Connecting Wires To Terminal Block Connectors
Perform the following steps to terminate shielded cables to the ground studs located inside the WPC 1000 enclosure near the cable’s point of entry, referring to Figure 2-3, page 2-6. Strip the cable jacket as far as the end of the conduit fitting.
Page 33: Mounting The Control Enclosure
Motor reverse auxiliary contact (24V), if applicable • Power to WPC 1000 should be provided by a step-down control transformer capable of handling 50 VA at 115 Vac ± 10%. Most of the original controls on the press will be replaced during rewiring except the disconnect, motor starter, and control transformer.
Page 34: Slide Adjust Considerations
WPC 1000 User Manual 1125100 NOTICE NON-ENCLOSURE INSTALLATION See Installing WPC 1000 without Enclosure, page 2-48 for installation instructions if you are installing WPC 1000 in your own enclosure or console. STOPPING TIME ANGLE / SPM ° STOP TEST STOPPING ANGLE...
Page 35: Connecting Ac Wiring
• Refer to Table 1-1, page 1-9 for DC power requirements • Wire 24 Vdc directly to connector J103 on the WPC 1000 Control board (see Figure 2-11, page 2-20 for location and Figure 10 at the back of the manual for wiring) Connect “+ volts”...
Page 36: Installing A Dual Safety Valve
WPC 1000 User Manual 1125100 Figure 2-5. AC Input Wiring Connections Connect the ground wire to the set screw terminal on the roof of the enclosure, referring to Figure 2-5 and to Figure 10 at the back of the manual.
Page 37 Connect all signal grounds through pins on the WPC 1000 Control board. If you have ordered a Ross or Herion DSV with your WPC 1000, refer to the appropriate wiring diagram at the end of this manual and to the documentation that came with your valve to install the DSV.
Page 38: Installing Clutch And Counterbalance Air Pressure Switches
Failure to comply with these instructions could result in property damage. Note that the DM2 Reset circuit is wired to the OFF position on the WPC 1000 Stroke Select switch (see Figure 11). To reset the Ross DM2 DSV after an F47 error (see page 5-11), press Reset/Select, and turn the Stroke Select switch to OFF, then back to one of the other operating modes (i.e., Inch, Single-stroke, or Continuous).
Page 39: Installing Operator Station(S)
Wire the normally open counterbalance terminals to User Input 1 (pin # 45) and + 24V (pin # 47), referring to Figure 3 at the end of the manual. See Wiring WPC 1000 User Inputs, page 2-28 for additional information.
Page 40: Wiring A Pre-Wired Operator Station
Wiring a Pre-wired Operator Station Checking Pre-wired Operator Station Wiring Before connecting your pre-wired Operator Station to WPC 1000, check the wiring to the mute lamp inside the Operator Station and modify, if necessary, according to the instructions below. Operator stations shipped as part of WPC 1000 systems should not need modification.
Page 41: Making Wiring Connections
1125100 WPC 1000 User Manual Figure 2-7. Wiring Steps to Modify Operator Station for WPC 1000 Making Wiring Connections To wire a pre-wired Operator Station, perform the following steps: Punch a hole in the Operator Station enclosure for conduit or sealtight.
Page 42: Figure 2-8. Pre-Wired Operator Station With Side Run Buttons: Mounting Dimensions
WPC 1000 User Manual 1125100 21.25 (539.8) 16.75 (425.5) 4.69 5.50 (119.1) (139.7) (148) Dimensions: inches (mm) Figure 2-8. Pre-wired Operator Station with Side Run Buttons: Mounting Dimensions 28.75 (730.3) 16.75 (425.5) 4.69 5.50 (119.1) (139.7) 6.06 (154.0) Dimensions: inches (mm) Figure 2-9.
Page 43: Wiring An Unwired Operator Station
Failure to comply with these instructions will result in death or serious injury. To wire the unwired Wintriss Operator Station, follow the wiring diagram in Figure 5 at the end of this 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.
Page 44: Wiring A User-Built Operator Station
Two-hand Control module. When you install more than one Operator Station, set option switch 5 on the WPC 1000 Control board to ON (see page 3-30). If you have any questions about installing multiple operator stations, contact Wintriss Tech. Support.
Page 45: Installing A Light Curtain
Shadow user manual. NOTICE You cannot permanently mount the light curtain until the WPC 1000 is working properly and you have measured the Stopping Time, set the brake monitor, and calculated the correct safety distance. However, you will be able to wire the light curtain.
Page 46: Setting Jumpers For Shadow Vii And Shadow 8 Light Curtains
JP106 JP107 Installing Non-Shadow Light Curtains If you plan to interface a light curtain system other than Shadow with your WPC 1000, please call Wintriss Tech. Support for instructions. WARNING It is your responsibility to ensure that your light curtains are control reliable and intended for use on a mechanical power press as a primary point-of-operation guard.
Page 47 Option switches Firmware chip A Firmware chip B Ribbon cable connector for Display board WPC 1000 LEDs LED # WPC 1000 connectors Figure 2-11. WPC 1000 Control Board with DSV/Lockout Relay Board: Location of Important Components 2-20 Installation...
Page 48 (to WPC 1000 Display board) WPC 1000 LEDs Light curtain test mode jumper LED # Light curtain output type jumper WPC 1000 connectors Figure 2-12. WPC 1000 Control Board with DSV/Lockout Relay Board Removed: Location of Important Components Installation 2-21...
Page 49: Installing The Resolver
Failure to comply with these instructions will result in death or serious injury. Because the resolver must provide WPC 1000 with the exact position of the crankshaft at every degree of the stroke (see Resolver, page 1-1), the device must be driven smoothly at a 1:1 ratio with the crankshaft of the press.
Page 50: Mounting The Resolver
WPC 1000 User Manual 1125100 0.34 (8.6) dia holes 3.62 2 places (91.9) 1.50 (38.1) 3.75 (95.3) 3.00 (76.2) RESOLVER IS AT ZERO WHEN KEYWAY IS ALIGNED WITH ARROW 9.16 (232.7) 3/4” dia. shaft (19.05) Electrical connector standard key for cable 2.00...
Page 51: Wiring The Resolver
Figure 2-1, page 2-4 for an example). If you do so, make sure not to cut the cable and wires until both the resolver and the overrun limit switch are installed. Find the resolver terminal block, TB 103, on the WPC 1000 Control board (see Figure 2-11, page 2-20), and remove the L-shaped connector.
Page 52: Checking The Resolver's Direction Of Rotation
The overrun sensor provides a signal to WPC 1000 at the same resolver angle on every stroke. Whenever this angle changes, WPC 1000 “knows” that the resolver is no longer rotating at a 1:1 ratio with the crankshaft and sends an Emergency-stop command to the press and displays an error code.
Page 53: Planning Your Overrun Sensor Installation
1125100 WPC 1000 User Manual Planning Your Overrun Sensor Installation The overrun sensor consists of a magnetic switch and a magnet. Select a mounting location for both components that ensures that the magnet moves past the switch once on every stroke and within 1/8 in.
Page 54: Wiring The Overrun Sensor Switch
Run the cable for the magnetic switch through conduit to the WPC 1000. Connect the wires to terminal blocks on the WPC 1000 Control board, as shown in Table 2-2 and Figure 3 at the end of the manual.
Page 55: Wiring Wpc 1000 User Inputs
CHECK PRESS TO MAKE SURE IT STOPS WHEN USER INPUT ACTUATES • WPC 1000 comes from the factory with the inputs bypassed by jumpers. Make sure to remove the appropriate jumper from the Control board connector when you wire a user input.
Page 56: Wiring The Lockout Relay
Stroke Select switch to OFF and then back to INCH. Wire the function you want to be controlled by the Lockout relay to TB 301 on the DSV/ Lockout relay board, which is located in the lower right corner of the WPC 1000 Control Installation...
Page 57: Wiring The Auxiliary Output
Failure to comply with these instructions will result in death or serious injury. WPC 1000 provides an output called Auxiliary 1 (pin #14 on the WPC 1000 Control board). Auxiliary 1 is normally closed (N/C), or On. The output opens, or turns Off, when a fault condition occurs, an E-stop string opens, or a light curtain is interrupted while the press is running.
Page 58: Connecting Multiple Controls To The Resolver
2-24. Locate the 7-conductor shielded resolver cable. Run the cable through 1/2-in. conduit from the WPC 1000 to the other control. If there is a connector on one end of the cable, cut it off. Pull the TB103 resolver connector out of its socket.
Page 59: Connecting Other Wintriss Products To Wpc 1000
WPC’s operation is extremely important because it will be tied in to the press stop circuits. Do not forget to mark on your electrical prints where you wire in WPC 1000. When the Stopping Time is critical to your operation, as it is with die protection, be sure to wire as follows.
Page 60: Disabling Top-Stop In Inch
Inch mode as long as the Run/Inch buttons are depressed. To do so, connect pin #156 on terminal block TB 705 on the WPC 1000 Display board to ground (pin #155). See Table 2-20, page 2-71. Installation...
Page 61: Wiring A Remote Reset Switch
Wiring a Remote Reset Switch If you would like to be able to reset the WPC 1000 from a location remote from the enclosure, the WPC 1000 Control board provides a terminal (i.e., pin #19 on TB102) for wiring a remote Reset switch (see Table 2-8).
Page 62: Figure 2-17. Cam Output Enclosure: Mounting Dimensions
Select a convenient location for mounting the cam output assembly, choosing one that allows you to easily run conduit from WPC 1000 to the cam outputs. You do not need to access the cam outputs once they are installed and wired.
Page 63: Figure 2-18. Cam Output Board: Mounting Dimensions
CHAN 1 CHAN 2 CHAN 3 CHAN 4 Figure 2-18. Cam Output Board: Mounting Dimensions Table 2-9. WPC 1000 Control Board to Cam Output Assembly (TB1) Wiring Connections Wire Color WPC 1000 Control Board 2-channel Cam I/O Assembly (TB1) Pin #...
Page 64: Making Wiring Connections To Cam Relays
“on” during the cam angle interval set in WPC 1000 Connect the other wire to the terminal labelled “N/C” if you want your equipment to be “on” except during the cam angle interval set in WPC 1000 CHAN 1 CHAN 2 Figure 2-19.
Page 65: Figure 2-20. Installing A Suppressor Across An Ac Load
Install arc suppressors across each inductive AC load (motors, coils, etc.) that is connected to a cam relay. Suppressors are supplied with your WPC 1000 cam outputs. 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.
Page 66: Wiring Zero Cam Output To Autoset
Wiring Zero Cam Output to AutoSet WPC 1000 provides a zero cam output that automatically turns on at 270° and turns off at 30° on every stroke. You can wire this output to AutoSet 1500 and 1504 load analyzers, as shown in Table 2-10, below, and Figure 2 at the end of the manual.
Page 67: Installing One-Hand Control
1125100 WPC 1000 User Manual Wire the Foot Switch’s normally closed contact to pin #16 on the WPC 1000 Control board and the normally open contact to pin #3, then wire both contacts to +24 Vdc, as shown in Table 2-11, below, and Figure 1 at the end of the manual.
Page 68: Mounting The One-Hand Control
Failure to comply with these instructions will result in death or serious injury. To mount the One-hand Control, do the following: Shut off power to the press and to WPC 1000. Choose a mounting location on or near the press convenient to the operator. The One-hand Control should be mounted so the operator can reach it as part of normal hand movement after loading a part.
Page 69: Figure 2-22. One-Hand Control Switch: Mounting Dimensions
1125100 WPC 1000 User Manual Figure 2-22. One-hand Control Switch: Mounting Dimensions 2-42 Installation...
Page 70: Wiring One-Hand Control To Wpc 1000
Failure to comply with these instructions will result in death or serious injury. To wire One-hand Control, you need to make connections to both the Operator Station and to the WPC 1000 Control board. To do so, perform the following steps: Turn off power to the press and to the WPC 1000.
Page 71: Figure 2-24. Wiring Connections In One-Hand Control Switch
Fasten the switch cover onto the base with the screws provided. Tighten all conduit connections that may have been loosened during installation. Close and latch the cover of the Operator Station and WPC 1000. Make sure that you have run all your ground wires. Do not use conduit as ground.
Page 72: Mounting And Wiring The Bar Control Enclosure
Bar control Operate button. Refer to Figure 2-25 for mounting dimensions. To wire the Bar Control, connect the Bar selector switch input to pin #31 on the WPC 1000 Control board and the Bar actuator input to pin #17, as shown in Table 2-13 and Figure 1 at the end of the manual.
Page 73: Installing Revised Firmware In Wpc 1000
2-20). Note that each chip has a white label and the semi-circular notch on each chip faces up. NOTICE Both new WPC 1000 firmware chips must also be installed with the notch facing up. CAUTION If you use a screwdriver, be careful not to insert the screwdriver under the socket or you may damage the board.
Page 74 Turn the power off, and repeat the procedure in the Notice for step 6 for each chip. Power the unit up again. If WPC 1000 continues to malfunction, call Wintriss Tech. Support.
Page 75: Installing Wpc 1000 Without Enclosure
2-49 or Installing Display Board Kit with Selector Switches, page 2-52. Installing the WPC 1000 Mounting Plate The mounting plate has a hole in each corner to facilitate mounting of the WPC 1000 Control board and related components in your enclosure or console. When installing the mounting plate, refer to Figure 2-26 for mounting dimensions.
Page 76: Installing The Panel-Mount Display
WPC 1000 User Manual 1125100 The power supply on the mounting plate is pre-wired to the power terminal, J103, on the Control board and to the input power terminal block on the plate. To connect AC wiring to the input power terminal block, follow the instructions in Connecting AC Wiring, page 2-8.
Page 77: Connecting The Panel-Mount Display To The Wpc 1000 Control Board
Dimensions: inches (mm) Figure 2-27. WPC 1000 Panel Mount Display: Mounting and Cutout Dimensions Connecting the Panel-mount Display to the WPC 1000 Control Board Connect the display cable from J706 on the Display board to J104 on the Control board, referring to Installing the Display Cable, page 2-55 for instructions.
Page 78: Installing Selector Switches And Final Assembly
Figure 2-28. Selector Switch: Cutout Dimensions Install the selector switches. Wire each selector switch to the appropriate terminal block on the WPC 1000 Display board, referring to Table 2-14 and Figure 4 at the back of the manual for wiring connections Table 2-14.
Page 79: Installing Display Board Kit With Selector Switches
1125100 WPC 1000 User Manual Installing Display Board Kit with Selector Switches NOTICE Install the panel mount display at a height convenient for all users. Experiment to determine a good height for every user before mounting the display. Make sure that your display board kit contains the following components: Label •...
Page 80: Figure 2-29. Wpc 1000 Display Board Kit: Mounting And Cutout Dimensions
WPC 1000 User Manual 1125100 Figure 2-29. WPC 1000 Display Board Kit: Mounting and Cutout Dimensions Install the Reset/Select button in the left cutout below the display. Wiring for the Reset/ Select button is provided on the Settings key switch wiring harness (see step 10).
Page 81: Table 2-15. Reset Button, Settings Key Switch, And Mute Lamp Wiring Connections
Plug the connector on the other arm of the Settings key switch wiring harness into J707 on the WPC 1000 Display board. Plug the connector terminating the mute lamp wiring into terminal block TB708 on the Display board. Table 2-15 summarizes these wiring connections.
Page 82: Installing The Display Cable
34-conductor shielded ribbon cable (10’, 30’, or 100’) to connect the WPC 1000 Control board to the Display board. There is a connector already installed on one end of the cable. An extra connector is included for installation after the cable has been routed through conduit.
Page 83: Figure 2-32. Display Cable (Multicolored) With Gray Stripes Indicating Flat Area
Leave enough cable inside the WPC 1000 enclosure to reach the 34-pin connector J104 on the WPC 1000 Control board (see Figure 2-11, page 2-20) and to allow for a service loop. Also, make sure that there is enough cable at the Display board end to reach J706, measuring from the last pair of gray stripes on the cable (see step 4).
Page 84: Figure 2-33. Display Cable Jacket With Multicolored Ribbon Cable Exposed
WPC 1000 User Manual 1125100 Brown wire Ribbon cable Cable jacket Purple wire Tan wire 4” Figure 2-33. Display Cable Jacket with Multicolored Ribbon Cable Exposed Locate the three components of the extra connector–the strain relief, connector top, and connector bottom–as shown in Figure 2-34.
Page 85: Figure 2-35. Connector Top With Multicolored Ribbon Cable Conductors
1125100 WPC 1000 User Manual Brown wire Ribbon cable Purple wire Tan wire Recessed side Connector top (inverted) Figure 2-35. Connector Top with Multicolored Ribbon Cable Conductors Lay the end of the flattened ribbon cable over the connector top, as shown in Figure 2-36.
Page 86: Figure 2-37. Connector Halves Brought Together (Multicolored Conductors)
WPC 1000 User Manual 1125100 NOTICE The edge of the ribbon cable with the brown wire should be positioned beneath the end of the connector bottom with the groove inset farthest from the tip (see Figure 2-37). This orientation is identical to that of the ribbon cable on the connector that is already installed at the other end of the display cable.
Page 87: Installing The Shielded Gray Ribbon Cable
To attach the gray ribbon cable to the extra connector and make connections at the WPC 1000 control and display boards, do the following:...
Page 88: Figure 2-39. Gray Ribbon Cable With Connector And Insulated Shield
Figure 2-39. Gray Ribbon Cable with Connector and Insulated Shield At the Display board end of the ribbon cable connection, cut the cable jacket at a point that allows enough cable to make a comfortable connection at J706 on the WPC 1000 Display board.
Page 89: Figure 2-40. Display Cable Jacket With Gray Ribbon Cable And Shield Exposed
1125100 WPC 1000 User Manual Red wire Ribbon cable Cable jacket Braided shield 4” Figure 2-40. Display Cable Jacket with Gray Ribbon Cable and Shield Exposed Slide the black plastic sleeve that came with the cable over and down the shield until you reach the cable jacket (see Figure 2-39).
Page 90: Figure 2-41. Connector Top With Gray Ribbon Cable Conductors And Shield
WPC 1000 User Manual 1125100 Connector top (inverted) Red wire Ribbon cable Recessed side Insulated shield Figure 2-41. Connector Top with Gray Ribbon Cable Conductors and Shield Lay the end of the flattened ribbon cable over the connector top, as shown in Figure 2-42.
Page 91: Figure 2-43. Connector Halves Brought Together (Gray Conductors)
1125100 WPC 1000 User Manual NOTICE The edge of the ribbon cable with the red wire should be positioned beneath the end of the connector bottom with the groove inset farthest from the tip (see Figure 2-43). This orientation is identical to that of the ribbon cable on the connector that is already installed at the other end of the display cable.
Page 92: Installation Verification
Plug the completed ribbon cable connector assembly into J706 on the WPC 1000 Display board (see Figure 2-16, page 2-33). The connector must be inserted with the same orientation as the connector you plugged into J104 on the WPC 1000 Control board in step 3.
Page 93: Checking Safeguarding Devices
NOTICE DISPLAY DOES NOT WORK If the WPC 1000 display does not work properly, check to make sure that the display cable is connected correctly on both the Control and Display board ends, referring to Installing the Display Cable, page 2-55 for help. If the display still does not work, call Wintriss Tech. Support.
Page 94: Checking Dual Safety Valve (Dsv) Wiring
WARNING PREVENT ELECTRIC SHOCK WHEN WORKING INSIDE THE ENCLOSURE Turn off and disconnect power from the WPC 1000, the press and any other machinery it is connected to before working inside the enclosure. This includes power to the press motor.
Page 95: Checking For Error Messages
Recheck wiring and correct any problems, then repeat this test. If the press still does not Emergency-stop, call Wintriss Tech. Support. Do not continue with this checkout procedure until the press E-stops correctly. Installation Verification Complete The WPC 1000 Installation Verification procedure is complete. Clear any error message by pressing the Reset/Select button. 2-68 Installation...
Page 96: Wiring Tables
E-stop String Center Loop Connection Mute Lamp 1 Output E-stop String Drive Output. * Input polarity depends on setting (NPN or PNP) of Light Curtain Output Type jumper JP106 on the WPC 1000 Control board (see Figure 2-12, page 2-21). Installation...
Page 97: Table 2-17. Wpc 1000 Control Board: Resolver (Tb103) Wiring Connections
S1 Sine (Black) S2 Cosine (Green) R1 drive (Red) S3 ground (Yellow) R2 ground (Orange) S4 ground (Brown) Table 2-18. WPC 1000 Control Board: DSV/Lockout Relay Board Wiring Connections Terminal Block Pin # Signal TB303 DSV A Relay DSV A Relay...
Page 98: Table 2-20. Wpc 1000 Display Board: Wiring Connections
WPC 1000 User Manual 1125100 Table 2-20. WPC 1000 Display Board: Wiring Connections Terminal Block Pin # Signal LED Grp. & # TB708 Mute Lamp J707 Reset Button Settings Key Switch TB705 Micro-inch key switch wiring Top-stop in Inch (Ground to Disable)
Page 99 1125100 WPC 1000 User Manual 2-72 Installation...
Page 100: Chapter 3. Initialization, Setup, And Checkout
Viewing and Setting Press Parameters The WPC 1000 allows you to view and, in some cases, to set up to ten press parameters, the number of items depending on the WPC 1000 display option you have ordered. On the...
Page 101: Table 3-1. Wpc 1000 Standard Display Default Parameters (Press Running)
To select a parameter so you can view or adjust its setting, press the Reset/Select button on the WPC 1000 display until the indicator segment for that parameter is illuminated. The value of the parameter appears in the digital LED readout. Locations of the indicator segments on the WPC 1000 display are shown in Figure 3-1.
Page 102: Initializing The System
Stopping Time of your press whenever you initialize WPC 1000. Use the stop time measured in the 90° stop time test to calculate the safety distance. When you initialize WPC 1000, the Stop- time Limit is returned to its factory setting of 500 mS.
Page 103: Re-Zeroing The Resolver
• adjust this setting (see Setting the Stop-time Limit, page 3-17). Start-time Limit–Set to two times the Start Time measured by WPC 1000 on the first stroke • after the system has been initialized. The Start Time is the interval between the closing...
Page 104: Initializing Only The Start-Time Limit
Limit and Resolver Zero settings (see Initializing the System, page 3-3), do the following: Power down WPC 1000. While powering WPC 1000 back up, turn the WPC Settings key switch to “–” (i.e., clockwise) and hold it there. When “Str” appears in the LED display (see Figure 3-4, page 3-6), release the key.
Page 105: Viewing The Start-Time Limit
Figure 3-4. WPC 1000 Displays Showing “Initializing Start-time Limit” (“Str”) Message The next time you start the press, WPC 1000 will set the Start-time Limit to twice the Start Time measured on the first stroke. This value cannot be changed manually.
Page 106: Installing The Overrun Sensor Magnet
This section shows you how to install the magnet that, with the overrun sensor, makes up the overrun limit switch. You should already have installed the overrun sensor (see page 2-25). The overrun limit switch enables WPC 1000 to monitor operation of the resolver and to stop the press whenever the resolver fails to work properly.
Page 107 WPC 1000 User Manual Make sure the following WPC 1000 features are set correctly: Option switches 1 and 2 on switch block S101 on the WPC 1000 Control board should • be set to OFF so that any Top-stop “On” Angle between 211° and 355° can be set on the WPC 1000 display.
Page 108: Table 3-3. Overrun Sensor Magnet Location And Option Switch Settings
WPC 1000 User Manual 1125100 EXAMPLE If the displayed Top-stop “On” Angle is 287°, you would calculate as follows: 360° - 287° = 73° 211° + 73° = 284° You would set your Top-stop “On” Angle to 284°. NOTICE WHEN DETERMINING TOP-STOP “ON” ANGLE Remember that the Top-stop angle has an internal dwell of 20°.
Page 109: Figure 3-5. Setting Overrun Timing: Example
300° column in Table 3-3. The correct switch settings would be OFF for switch 1 and ON for switch 2. See Figure 3-5. Set option switches 1 and 2 on S101 on the WPC 1000 Control board to the positions you determined in step 12, referring to Switches 1 and 2 – Top-stop “On” Angle Range, page 3-27 for instructions.
Page 110: Mounting The Overrun Sensor Magnet
Check to make sure that the “Overrun Limit Switch input” LED (#6) in LED Group 2 on the WPC 1000 Control board is lit, referring to the LED map in Figure 3-14, page 3-36 for location. This LED illuminates when the overrun magnetic switch senses the magnet.
Page 111: Adjusting The Top-Stop Angle
If another fault code displays, look up the fault in Chapter 5 and follow the suggested • remedy. After correcting the problem, press the Reset/Select button and run the press again for a few strokes, checking for faults. If you need assistance, contact Wintriss Tech. Support. WARNING INJURY FROM MAGNETS THAT DETACH Mount the magnets with the brass screws provided.
Page 112 Install the heaviest upper die in your press. Adjust the counterbalance for ram weight (if the press has a counterbalance). With WPC 1000 powered up and the press in Inch mode, press the Reset/Select button repeatedly until the “Top Stop Angle” indicator is lit.
Page 113: Setting The Auto Carry-Up Angle
Set the Auto Carry-up Angle at the correct value to protect the operator. To do so, perform the following steps: Set option switch 7 on switch block S101 on the WPC 1000 Control board to OFF to enable changes to the Auto Carry-up Angle (see Switch 7 – Disabling Access to Stop-time Limit and Auto Carry-up Angle Settings, page 3-31).
Page 114: Running Brake Monitor Tests And Making Settings
Install the heaviest upper die in your press. Adjust the counterbalance for ram weight (if the press has a counterbalance). Turn power on to the WPC 1000, and observe the current crankshaft angle shown in the LED display. Run the press in Continuous mode by turning the Mode Select switch to “CONT,” and check the press speed shown in the LED display.
Page 115: Calculating The Stop-Time Limit
= stopping time + Tbm The Tbm value represents normal wear on the brake and ensures that WPC 1000 does not stop the press for small increases in Stopping Time. The minimum value that you can set is 10 mS.
Page 116: Setting The Stop-Time Limit
• Determine and enter the correct Stop-time Limit when you set up your WPC 1000. • Perform a 90° Stop Test any time you change the Stop-time Limit of WPC 1000. (See Determining the 90° Stop Time, page 3-18.) Base the Stop-time Limit on the actual Stopping Time.
Page 117: Determining The 90° Stop Time
DANGER INCORRECT SAFETY DISTANCE DUE TO INCORRECT STOP TIME • Perform a 90° Stop Test any time you change the Stop-time Limit of WPC 1000. • Recalculate the safety distance based on the new Stop-time Limit and adjust or reinstall safeguarding devices according to the new safety distance (see Calculating the Safety Distance, page 3-20).
Page 118: Performing The 90° Stop Test (Single-Stroke Mode)
DANGER INCORRECT SAFETY DISTANCE DUE TO INCORRECT STOP TIME • Perform a 90° Stop Test any time you change the Stop-time Limit of WPC 1000. • Recalculate the safety distance based on the new Stop-time Limit and adjust or reinstall safeguarding devices according to the new safety distance (see Calculating the Safety Distance, page 3-20).
Page 119: Calculating The Safety Distance
1125100 WPC 1000 User Manual Press and hold the Run/Inch palm buttons to initiate a stroke. WPC 1000 will stop the press when it reaches 90°. When WPC 1000 stops the press, record the value shown in the LED display.
Page 120: Ansi And Osha Safety Distance Formulas
(or another object) reaches the hazard. • Call Wintriss Tech. Support if you are not sure how to calculate the safety distance. Failure to comply with these instructions will result in death or serious injury.
Page 121: Ansi Safety Distance Formula
90° stop-time test run on the WPC 1000 (see Determining the 90° Stop Time, page 3-18). You can use the value generated by the 90° stop-time test for the variables Ts + Tc in the ANSI formula.
Page 122 WPC 1000 User Manual 1125100 Tbm is the additional time added to the Stopping Time of the press to allow for brake wear and is used to calculate the brake monitor’s Stop-time Limit (see Calculating the Stop-time Limit, page 3-16). The Tbm value is usually calculated by multiplying the press’s Stopping Time at Top-stop by a predetermined factor based on the age of the brakes.
Page 123: Osha Safety Distance Formula
Failure to comply with these instructions will result in death or serious injury. NOTICE Wintriss recommends that you use the American National Standards Institute (ANSI) formula for calculating safety distance because it contains more factors, allowing you to calculate the safety distance more precisely.
Page 124: Adding To Safety Distance For Blanking Windows
WPC 1000 User Manual 1125100 NOTICE OSHA SAFETY DISTANCE FORMULA FOR USE WITH TWO-HAND CONTROL The formula for safety distance when using a Two-hand Control as a safeguarding device is similar to the formula above, but does not include the response time of the light curtain. Use the following...
Page 125: Setting Micro-Inch
100 mS. To set Micro-inch, do the following: With power on to the WPC 1000 and the press in Inch mode, press the Reset/Select button repeatedly until the “Micro-inch” indicator becomes lit (see Figure 3-10). Turn the WPC Settings key switch to “+” (counterclockwise) to increase the Micro-inch time setting shown in the LED display, or turn the key to “–”...
Page 126: Setting Press Option Switches
This section shows you how to make settings on switch block S101, which is located roughly in the center of the WPC 1000 Control board just to the left of the DSV/Lockout Relay board (see Figure 2-11, page 2-20 for Control board layout). All eight S101 switches are factory-set to the OFF position.
Page 127: Switch 3 - One-Hand Control And Foot Switch Settings
When switch 3 is set to ON, the Foot Switch is in Foot Control mode, which requires that the operator depress and hold down the Foot Switch through the Auto Carry-up Angle in order to complete a stroke. If the Foot Switch is released before the Auto Carry-up Angle, WPC 1000 issues an Emergency-stop command to the press.
Page 128: Switch 4 - Enabling Auto Compensated Top Stop (Acts)
When you have Auto Compensated Top Stop (ACTS) firmware, switch 4 controls enabling of the ACTS feature (see Table 3-8). ACTS is a WPC 1000 option that adjusts the Top-stop “On” Angle to an earlier point in the stroke to compensate for increases in press speed.
Page 129: Switch 5 - Selecting Concurrent Time For Multiple Op. Stations
(called the “palm” or “synchronous” time) in order to stroke the press. When switch 5 is set to ON and two or more Operator Stations are connected to WPC 1000, palm switches on all connected Operator Stations must be pressed within a 5-second concurrent time window to start the press.
Page 130: Settings
Switch 8 has two different functions. It controls how quickly the press top-stops when an F or an H fault occurs, and if the Auxiliary Output on the WPC 1000 Control board has been wired, it also specifies how that output responds to an Interrupted Stroke condition.
Page 131: Auxiliary Output 1 Response To Interrupted Stroke
1125100 WPC 1000 User Manual When switch 8 is set to OFF, its default setting, the press top-stops on the current stroke when an F or H fault occurs before 210°, or takes an additional stroke before it top-stops if the error occurs after 210°.
Page 132: Setting Programmable Cams
To make cam channel settings, perform the following steps: Set option switch 6 on S101 on the WPC 1000 Control board to ON to enable changes to cam settings (refer to Switch 6 – Enabling Access to Cam Settings, page 3-30).
Page 133: Figure 3-13. Wpc 1000 Displays Showing Cam Channel 1 Off Setting (Cam 1 On = 180°)
6 setting may remain in effect. NOTICE If you do not cycle power to the WPC 1000 after moving option switch 6 back to its default setting, WPC 1000 will remain in cam-setting mode, and you will not be able to adjust the settings controlled by the indicator segments in the lower half of the display.
Page 134: Final Checkout
• Stroke Select to “OFF” • Mode Select to “2 HAND” This section provides the tests you need to perform to verify that your WPC 1000 is installed and set up correctly. These tests must be performed before you proceed to Chapter 4.
Page 135: Checking The Emergency-Stop Circuit
1125100 WPC 1000 User Manual Many of the tests ask you to check the state of LEDs on the WPC 1000 Control board. An LED map, showing the locations of all LEDs, is provided in Figure 3-14. GROUP 1 GROUP 3...
Page 136: Checking The Top-Stop Circuit
If the press does not top-stop, check the wiring of your Top-stop circuit, correcting any • problems, and run the test again. If the press still does not top-stop, call Wintriss Tech. Support. Do not continue with this checkout procedure until the press top-stops correctly.
Page 137: Power Supply Test
Open the front cover of the control enclosure or the door of your console. Turn on power to WPC 1000. On the WPC 1000 Control board, check to see whether the +24 V, +5 V (A), and +5 V (B) LED indicators are illuminated.
Page 138 The Light Curtain Test Mode jumper, which is located in the lower right corner of the WPC 1000 Control board (see Figure 2-12, page 2-21), should be positioned at the “INT” setting when Shadow VII or Shadow 8 light curtains are installed. Reposition the jumper to the correct setting if necessary.
Page 139: System Static Test
If the Interrupted Stroke LED is unlit, check to see whether the “Inch select” LED on • the WPC 1000 Control board is lit. If the LED is unlit, check the wiring of the Stroke Select switch and correct any problems. If the “Inch select” LED is still unlit, call Wintriss Tech.
Page 140 If F48 does not display, check to see whether the “Clutch air pressure switch input” • LED on the WPC 1000 Control board is unlit. If the LED is unlit, check the wiring of the Clutch Air Pressure Switch input and correct any problems. Press both Run/Inch palm buttons again.
Page 141: Single-Stroke Mode Test With Light Curtain(S)
To test Single-stroke mode when light curtains are installed, perform the following steps, referring to Figure 3-14, page 3-36 for LED locations on the WPC 1000 Control board: Set the Stroke Select switch to “SINGLE,” and verify that the “Single-stroke select” LED on the WPC 1000 Control board is lit.
Page 142 If the ram does not move and you have only one light curtain, go to the next step. • If the ram does move, check to make sure the correct version of WPC 1000 firmware is • installed and check the wiring of the palm buttons and light curtains, correcting any problems.
Page 143: Single Stroke Mode Test Without Light Curtain(S)
To test Single-stroke mode when light curtains are not installed, perform the following steps, referring to Figure 3-14, page 3-36 for LED locations on the WPC 1000 Control board: Set the Stroke Select switch to “SINGLE.” Verify that the “Single-stroke select” LED on the WPC 1000 Control board is lit.
Page 144: Anti-Tiedown Test
• 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 both buttons at the same time and no one can press both buttons with one hand or with one hand and one elbow.
Page 145: Anti-Repeat Test
Failure to comply with these instructions will result in death or serious injury. The anti-repeat test verifies that the press cycles only once when WPC 1000 is in Single-stroke mode and both Run/Inch buttons are pressed simultaneously. To perform the test, do the following: Set the Stroke Select switch to “SINGLE.”...
Page 146: Continuous Mode Test With Light Curtain(S)
To run the Continuous mode test with light curtains, do the following, referring to Figure 3-14, page 3-36 for LED locations on the WPC 1000 Control board: Set the Stroke Select switch to “CONT.” Verify that the “Continuous select” LED on the WPC 1000 Control board is lit.
Page 147 If the press comes to an immediate stop and the Interrupted Stroke LED flashes, go to • the next step. If your WPC 1000 has the muting option, and the ram stops as soon as it reaches the • non-muted (i.e., downward) portion of the stroke, go to the next step.
Page 148: Continuous Mode Test Without Light Curtain(S)
Continuous mode test without light curtain, do the following, referring to Figure 3-14, page 3-36 for LED locations on the WPC 1000 Control board: Set the Stroke Select switch to “CONT.” Verify that the “Continuous select” LED on the WPC 1000 Control board is lit.
Page 149: Foot Switch Test
This test, which should be run only if you have an optional Foot Switch, verifies that your Foot Switch is operating properly. To perform the test, do the following, referring to Figure 3-14, page 3-36 for LED locations on the WPC 1000 Control board: NOTICE...
Page 150 “Single-stroke select” and “Foot select” LEDs on the WPC 1000 Control board are lit. Make sure that option switch 3 on the WPC 1000 Control board is set to OFF, its default setting (see Enabling Foot Control in a Foot Switch, page 3-28).
Page 151: One-Hand Control Test
Verify that the “Single-stroke select” and “One-hand select” LEDs on the WPC 1000 Control board are lit. Make sure that option switch 3 on the WPC 1000 Control board is set to OFF, its default setting (see Enabling Light Curtain Break Mode in a One-hand Control, page 3-28).
Page 152: Bar Mode Control Test
Stroke before you can operate the One-hand Control. Set option switch 3 to ON. Power down, then power back up WPC 1000 to enable the settings change. You are now in Light Curtain Break mode. The press should cycle to Top-stop only if the One-hand Control is pressed within eight seconds of the operator’s hand clearing the light curtain.
Page 153: Checking Operation Of The User Inputs
You can now bar the press, using a spring-loaded turnover bar. NOTICE As you bar the press, WPC 1000 monitors the speed of the crank. If you bar the press too quickly, the DSV de-energizes and an F26 fault code displays, stopping the press.
Page 154: Chapter 4. Operation
• Lockout/Tagout the press during all installation, modification, repair or maintenance procedures. • Perform and ensure that WPC 1000 passes all tests described in previous chapters. • Ensure that the machine guarding system is installed and maintained according to OSHA standard 1910.217, ANSI B11.1, ANSI B11.19 and any other regulations and standards that...
Page 155 NOTICE PRESS STOPS WHEN SYSTEM FAULT DETECTED OR LIGHT CURTAIN BLOCKED • The WPC 1000 stops the press if a system fault is detected or if the light curtain is blocked during any non-muted portion of the stroke. • If the press stops, the Interrupted Stroke LED on the WPC 1000 display (see Figure 1-3, page 1-5) will flash and a three-character fault code, consisting of the letter “E,”...
Page 156: Responding To An Interrupted Stroke
Reset/Select button; then you can return the press to top dead center. If the press is being operated in Inch mode when the Emergency-stop occurs, WPC 1000 stays in Inch mode, allowing the operator to return the press to Top-stop by simultaneously pressing and holding the Run/Inch palm buttons just as he does in Two-hand Maintained Single-stroke mode.
Page 157: Displaying And Clearing The Stroke Counter
WPC 1000 User Manual Displaying and Clearing the Stroke Counter The stroke counter, which is available only on WPC 1000 units with the optional counter display, maintains the number of strokes made by the press in Single-stroke and Continuous modes. The “Counter” indicator segment is the default segment in these two modes.
Page 158: Resetting The Counter Value To Zero
Setting and Maintaining the Counter Preset Value The counter preset feature allows you to set a stroke count that WPC 1000 uses to stop the press after the specified number of strokes. This feature is useful for batch sizing and making periodic QC checks.
Page 159: Disabling The Counter Preset
Disabling the counter preset has no effect on the counter itself, which will still maintain a cumulative total of press strokes. However, since there is no preset value, WPC 1000 will not stop the press. The counter continues to increment up to the value 999999, then rolls over to zero, and starts counting again at one (1).
Page 160: Forcing The Counter Preset Value To 999999
If a light curtain is installed on the press, set the switch to “2 HAND” or “1 HAND.” The light curtain will be muted on the upstroke if WPC 1000 has the muting option. If no light curtain is installed, set the switch to “2 HAND.” If you set the switch to “1 HAND,”...
Page 161: Top-Stop In Inch
1125100 WPC 1000 User Manual There are four different ways to operate the press in Inch mode: Top-stop in Inch • Top-stop Bypass • Micro-inch • Dead Motor Inch • Top-stop in Inch Top-stop in Inch is the default Inch mode. To run the press in Top-stop in Inch, do the...
Page 162: Micro-Inch
In Micro-inch, the distance the ram moves is controlled by a time setting you make on the WPC 1000 display (see Setting Micro-Inch, page 3-26). When that time has elapsed, the ram comes to a stop even though the Run/Inch palm buttons are still depressed.
Page 163: Operating The Press In Single-Stroke Mode
1125100 WPC 1000 User Manual Operating the Press in Single-stroke Mode DANGER 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.
Page 164: Single-Stroke, One-Hand Operation
DANGER INCORRECT INSTALLATION You must install a Shadow light curtain correctly and connect it to WPC 1000 properly in order to run the press in Single-stroke, One-hand mode. Failure to comply with these instructions will result in death or serious injury.
Page 165: Single-Stroke, One-Hand Control Operation
DANGER INCORRECT INSTALLATION You must install a Shadow light curtain correctly and connect it to WPC 1000 properly in order to run the press in Single-stroke, One-hand Control mode. Failure to comply with these instructions will result in death or serious injury.
Page 166 Light Curtain Break mode prevents inadvertent operation of the press when an operator is loading or unloading parts. You select the mode by setting option switch 3 on the WPC 1000 Control board (see step 1, below). To run the press in Single-stroke, One-hand Control mode, do the following: Set option switch 3 to OFF to operate the press in Normal One-hand Control mode (see Enabling Light Curtain Break Mode in a One-hand Control, page 3-28).
Page 167: Single-Stroke, Foot Operation
DANGER INCORRECT INSTALLATION You must install a Shadow light curtain correctly and connect it to WPC 1000 properly in order to run the press in Single-stroke, Foot mode. Failure to comply with these instructions will result in death or serious injury.
Page 168: Operating The Press In Continuous Mode
The light curtain is blocked during the non-muted portion of the stroke • NOTICE If the press is Emergency-stopped, WPC 1000 automatically changes to Two-hand Maintained Single-stroke mode and the Interrupted Stroke LED flashes. To clear the Interrupted Stroke, press and hold both Run/Inch buttons to complete the stroke and return the ram to Top-stop.
Page 169: Continuous, Foot Operation
DANGER INCORRECT INSTALLATION You must install a Shadow light curtain correctly and connect it to WPC 1000 properly in order to run the press in Continuous, Foot mode. Failure to comply with these instructions will result in death or serious injury.
Page 170: Operating The Press In Bar Mode
When barring the press, do not rotate the flywheel too quickly. If the crankshaft moves faster than 6 SPM, WPC 1000 will stop the ram and fault code F26 will appear in the LED display. Press the Reset/Select button to continue barring the press.
Page 171: Multiple Operator Stations
Failure to comply with these instructions will result in death or serious injury. If you have wired a single Operator Station to your WPC 1000 and option switch 5 is set to OFF (see page 3-30), the palm switches on that Operator Station must be pressed within a 1/2- second “palm time”...
Page 172: Chapter 5. Troubleshooting
Please supply: product name (e.g., WPC 1000); installed options; and firmware version number (e.g., Vs. 2.77). You can determine firmware version number from either processor chip (A or B) on the WPC 1000 Control board (see Figure 2-11, page 2-20).
Page 173: Responding To Wpc 1000 Faults
Whenever WPC 1000 detects a problem with the clutch/brake control, the press, or peripheral equipment, it sends a Stop command to the press and generates a fault on the WPC 1000 display. Most of these faults are shown as a three-character alphanumeric code in the digital LED readout (see Figure 5-1).
Page 174: Lockout Message
If the brake checks out, your Stop-time Limit is too tight, not allowing for normal wear. Set a new Stop-time Limit, following the instructions in Running Brake Monitor Tests and Making Settings, page 3-15. Power down the WPC 1000, then power the unit back up to turn off the Brake Warning LED. Troubleshooting...
Page 175: Stop Time Exceeded
DANGER INCORRECT SAFETY DISTANCE DUE TO INCORRECT STOP TIME • Perform a 90° Stop Test any time you change the Stop-time Limit of WPC 1000. See Determining the 90° Stop Time, page 3-18. • Recalculate the safety distance based on the new Stop-time Limit and adjust or reinstall safeguarding devices according to the new safety distance.
Page 176: E, F, And H Faults
1125100 NOTICE If you try to run the press without first repairing the brake, WPC 1000 will stop the press on the next stroke and again display the Stop Time Exceeded fault in the digital LED readout. The fault will continue to display until the brake has been repaired.
Page 177: Operational Faults
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 2-22). Also check the resolver. If necessary, contact Wintriss Tech. Support for assistance or replacement of the resolver.
Page 178 E-Stop circuit was open after initiation of the stroke. Remedy: If another control is connected to the WPC 1000 E-stop circuit, refer to the user manual for that control to check for a specific error condition, and correct the error.
Page 179 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 1000 and restart the press. Problem: Cross-checked inputs 3A & 3B were in different states (i.e., open or closed) for longer than 100 mS.
Page 180 WPC 1000 User Manual 1125100 Problem: The operating mode you selected (i.e., One-hand, Two-hand, or Foot) is not valid for your stroke selection (i.e., Inch, Single-stroke, or Continuous). Remedy: Refer to the discussion of operating modes starting on page 4-7 to determine the correct operating mode for your stroke selection.
Page 181: Inter-Processor Failures
Input Buffer Test Failures F41* through F43* Problem: The following errors may occur when WPC 1000 performs input buffer tests, which compare the input data provided by processor A with the data provided by processor B. When the input data doesn’t match, an error is generated.
Page 182: Component Failures
Diagnose and correct the condition that the input is monitoring. If the error persists after you reset the unit, contact Wintriss Tech. Support. Problem: A failure has occurred in an auxiliary press function wired to WPC 1000 cross-checked input pair 3A and 3B (see Table 5-2, page 5-12). One or both inputs are open.
Page 183: Light Curtain Faults
3A Light Curtain Faults F60 or H60 Problem: The light curtain failed the WPC 1000 internal test. There may be a problem with the wiring from the light curtain to WPC 1000. Remedy: Check to make sure that light curtain wiring is correct. If you have Shadow light curtains, refer to figures 2, 6, 7, 8, 9, 12 and 13 at the back of the manual for correct wiring.
Page 184: Emergency-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 F67 or H67 Problem: The Top-stop input circuit driver has failed or is about to fail.
Page 185: Dsv Interface And Lockout Relay Failures
Failure to comply with these instructions will result in death or serious injury. Problem: The following errors indicate failures on the WPC 1000 Control board or the DSV/ Lockout Relay board. Error codes F70, F71, F72/H72, F73/H73, and F76/H76 indicate failures with the DSV driver logic on the Control board.
Page 186: Loss Of Rotation
F80 or H80 - and - F82 or H82 Problem: There is an internal problem with the WPC 1000 timing inputs. Remedy: Press Reset/Select. If the error persists, contact Wintriss Tech. Support for assistance or replacement of the timing inputs.
Page 187: Top-Stop And Overrun Setting Faults
Wintriss Tech. Support. Overrun Limit Switch Fault Problem: The overrun limit switch has provided more than one signal to WPC 1000 during a stroke. The switch should open and close only once per stroke.
Page 188: Overrun Limit Switch Test Angle Fault
F90* through F98* - or - H90* through H98* Problem: There is a problem with the main or second processor on the WPC 1000 Control board. The board may need to be serviced or replaced. Remedy: Press Reset/Select. If the error persists, contact Wintriss Tech. Support for assistance or replacement of the Control board or firmware chip.
Page 189: Resetting Ross Dm2 Dsv Faults
Reset solenoid while air is being applied to the DSV (see Figure 5-4). If the fault occurs after the unit has been wired, an F47 error will appear on the WPC 1000 display. To clear the fault and reset the DSV, press Reset/Select and turn the Stroke Select key switch to OFF, then to one of the other operating modes (see page 5-11).
Page 190: Appendix A. Extracts From Osha Regulations And Ansi
PMA are shown in the right-hand column. Wintriss makes no claim for the accuracy or effectiveness of the PMA interpretations, and persons making use of this material do so at their own risk. PMA interpretations should not be relied upon for use in any specific application.
Page 191 1125100 WPC 1000 User Manual Extracts from OSHA Regulation 1910.217 OSHA Regulations PMA Interpretation OSHA 1910.217 (c). TABLE 0-10 (c) SAFEGUARDING THE POINT OF Distance of opening Maximum width of OPERATION. – from point of operation opening (inches) hazard (inches) (1) General requirements.
Page 192 WPC 1000 User Manual 1125100 Extracts from OSHA Regulation 1910.217 OSHA Regulations PMA Interpretation (d) Muting (bypassing of the protective Top of stroke is the point at which muting shall cease as it is not possible to set a point on the...
Page 193 1125100 WPC 1000 User Manual Extracts from OSHA Regulation 1910.217 OSHA Regulations PMA Interpretation OSHA 1910.217 (c) (3) (vii) (c) (c) The safety distance (Ds) between each two hand control device and the point of operation shall be greater than the distance...
Page 194: Standards
WPC 1000 User Manual 1125100 Extracts from ANSI Standards for Presence-sensing Devices and Two-hand Controls WARNING REFER TO CURRENT REVISIONS OF OSHA/ANSI DOCUMENTS The following extracts from OSHA and ANSI documents are provided for the user’s convenience only. Refer to the most recent revisions of the original OSHA safety regulations and ANSI standards to ensure that you have the most up-to-date information.
Page 195 1125100 WPC 1000 User Manual Extracts from ANSI B11.1-2009 8.6.2.1 Standards Requirements Explanatory Information 8.6.2.1.7 Each operator’s hand controls shall be E8.6.2.1.7 The total stopping time of the press located at a distance from the point-of-operation should include the total response time of the...
Page 196 WPC 1000 User Manual 1125100 Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3 Presence-sensing safeguarding device 8.6.3.1 A presence-sensing device, when used E8.6.3.1 Various presence-sensing devices for safeguarding, shall protect the operator as employ different sensing and adjustment specified in E8.6.1 (a).
Page 197 1125100 WPC 1000 User Manual Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.7 Muting of the device shall be E8.6.3.7 Muting is typically accomplished by accomplished in a manner that conforms to the interface circuits or auxiliary controls. The requirements of 6.11 and 8.8.
Page 198 WPC 1000 User Manual 1125100 Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.11 (cont) Means of supplemental safeguarding can include completely filling the fixed blanked area to restrict access to the hazard, installing the device at a distance that accounts for the worse case object sensitivity (see 8.6.3.16), or...
Page 199 1125100 WPC 1000 User Manual Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.16 (cont) Tbm = the additional stopping time allowed by the stopping-performance monitor before it detects stop time deterioration. Dpf = the added distance due to the penetration factor as recommended in ANSI B11.19, Annex...
Page 200 WPC 1000 User Manual 1125100 Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.17 If the position of the device will allow E8.6.3.17 Additional means may include the operator or others to place themselves manual reset outside of the sensing field of the...
Page 201 1125100 WPC 1000 User Manual Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information 8.3 Electro-optical, RF, and area scanning presence-sensing safeguarding devices 8.3.1 Design and construction 8.3.1.1 The presence-sensing device shall be E8.3.1.1 The device should be designed and...
Page 202 WPC 1000 User Manual 1125100 Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information 8.3.1.6 The presence-sensing device shall have a maximum response time that shall not be affected by object sensitivity or environmental changes. The safeguarding supplier shall provide the maximum response time of the presence- sensing device.
Page 203 1125100 WPC 1000 User Manual Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information 8.3.2 Installation, operation and maintenance 8.3.2.1 Exposure to the hazard(s) shall not be E8.3.2.1 The user should select a presence- possible by reaching over, under or around the sensing device adequate to prevent individuals sensing field of the device.
Page 204 WPC 1000 User Manual 1125100 Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information The device shall be installed such that it does Some installation hazards include, but are not not create additional hazards. limited to: pinch point hazards created by interference between the device and moving members of the machine;...
Page 205 1125100 WPC 1000 User Manual Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information The reset device shall be located outside of the Key lock reset switches located at various safeguarded area such that it cannot be positions around the safeguarded area may be reached from within the safeguarded area.
Page 206 WPC 1000 User Manual 1125100 Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information When the device is bypassed, other When bypassed, the device's normal status safeguarding must be provided and used. indicators can be misleading if still active. One...
Page 207 1125100 WPC 1000 User Manual A-18 Extracts from OSHA and ANSI...
Page 208: Appendix B. Specifications For User-Built Operator Stations
• 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.
Page 209: Switch Requirements
WPC 1000 User Manual NOTICE A Run-button timer is built into the WPC 1000. If the Run buttons on a standalone Operator Station are not pressed within the 1/2-second “palm time” (“synchronous time” in ANSI terminology) or the Run buttons on multiple Op. Stations are not pressed within the 5-second “concurrent time,”...
Page 210: Appendix C. Old Control Board
Old boards have assembly number D4315202; new boards have assembly number 4332701. This appendix provides a drawing of the old WPC 1000 Control board (see Figure C-1) that was included in previous revisions of this manual. The old board is almost identical to the new board shown in Figure 2-11, page 2-20 and Figure 2-12, page 2-21 except that it lacks jumpers J106 and J107, and jumper J102 is located in a different position.
Page 211: Table C-1. Differences Between New And Old Control Boards
Shadow VII or Shadow 8 light curtains to be connected directly to WPC 1000. WPC 1000 firmware versions V 2.77 or higher are compatible with both old and new control boards. Firmware versions lower than V 2.77 only work with the old board. If you install a new board in WPC 1000 systems running firmware earlier than V2.77, you will get an F35...
Page 212: Glossary
A ring of LEDs on the WPC 1000 optional display that shows the angle of rotation of the press’s crankshaft. Glossary...
Page 213 Micro-inch A WPC 1000 feature that allows the operator to set the amount of time in milliseconds that the Dual Safety Valve is open and, therefore, the distance the ram will travel when the Run/Inch switches on the Operator Station are pushed in Inch mode.
Page 214 When the signal is not received at the same resolver angle on every stroke, WPC 1000 knows that the resolver is no longer rotating at a 1:1 ratio with the press.
Page 215 (1:1) with the crankshaft. response time The length of time it takes the WPC 1000 control to activate the machine’s brake. safety distance The distance from the pinch point that OSHA requires safety...
Page 216 (0°). A top stop can be initiated manually by the operator or automatically by WPC 1000 or other devices. zero cam A closure-to-ground signal that turns on at approximately 270°...
Page 217 1125100 WPC 1000 User Manual Glossary...
Page 218: Index
, 3-47 American National Standards Institute (ANSI) testing without light curtain(s) , 3-49 extracts of standards , A-5 control enclosure. See enclosure (WPC 1000) safety distance formula , 3-22 controls (Wintriss), connecting to WPC 1000 , 2-32 anti-repeat test , 3-46...
Page 219 , 2-68 enclosure (WPC 1000) –L– components , 1-1 mounting and wiring , 2-6 LEDs errors. See faults (WPC 1000) brake warning LED , 4-3 digital readout , 1-4 –F– indicator segments , 1-5 interrupted stroke LED...
Page 220 PC boards, location of components ninety degree (90°) stop-time test, WPC 1000 control board (old version) , C-1 performing , 3-18, 3-19 WPC 1000 control board (with relay board) , 2-20 noise (electrical), reducing , 2-38 WPC 1000 control board (without relay board) , 2-21 –O–...
Page 221 1125100 WPC 1000 User Manual start time top-stop in inch fault (loss of rotation) disabling , 5-15 , 2-33 initializing the start-time limit operating the press in , 3-4, 3-5 , 4-8 viewing the start-time limit top-stop mode for F and H errors, setting...
Page 222: Wintriss Manuals
Wintriss Brake Monitor DA71432 DA71448 Wintriss Clock Display N. A. * DA67206 * WPC II Wintriss Press Control DA71438 DA71453 WPC 1000 Wintriss Press Control DA71423 DA71446 WPC 2000 Wintriss Press Control DA71421 DA71444 WPC 2000 Option 2 DA71408 DA71442 Installation Manual not available;...

Wintriss WPC 1000 User Manual

Chapter 1. Introduction

Chapter 2. Installation

Chapter 3. Initialization, Setup, and Checkout

Chapter 4. Operation

Chapter 5. Troubleshooting

Appendix A. Extracts from OSHA Regulations and ANSI

Standards

Appendix B. Specifications for User-Built Operator Stations

Appendix C. Old Control Board

Glossary

Index

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