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Honeywell AutoSet 1500 User Manual

Wintriss two-channel load analyzer.
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®
AutoSet 1500
®
Wintriss Two-channel Load Analyzer
1088500
Rev. C1
June 1998
Tech Support Hotline
800-586-8324
8-5 EST
®
Wintriss Controls Group
100 Discovery Way
Acton MA 01720-3648 USA
Phone (978) 264-9550 (800) 586-8324
Fax (978)263-2491
www.wintriss.com
PRINTED IN USA
DA45897

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   Summary of Contents for Honeywell AutoSet 1500

  • Page 1 ® AutoSet 1500 ® Wintriss Two-channel Load Analyzer 1088500 Rev. C1 June 1998 Tech Support Hotline 800-586-8324 8-5 EST ® Wintriss Controls Group 100 Discovery Way Acton MA 01720-3648 USA Phone (978) 264-9550 (800) 586-8324 Fax (978)263-2491 www.wintriss.com PRINTED IN USA...
  • Page 2 Honeywell 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. Whenever you need assistance or service, we back all our products with excellent spare parts inventories, training programs, and prompt repair service.
  • Page 3 Changes for Revision C1 of the AutoSet 1500 User Manual (1088500) Revision C1 of the AutoSet 1500 User Manual covers all AutoSet 1500 models. Change(s) for Revision C1 include: • Label Switch 2 in location figure. (Figure 2-2, Chapter 2) •...
  • Page 4: Table Of Contents

    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 full scale tonnage..................35 Adjusting AutoSet to read the correct tonnage............37...
  • Page 5 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 Preparation for mounting AutoSet using your enclosure.............51 Final assembly ......................51...
  • Page 6 Chapter 1 introduces you to AutoSet 1500, tells how it works, lists features, and explains how to use AutoSet. Chapter 2 is the installation chapter. Use it to install AutoSet 1500 if you are installing AutoSet yourself. Note that the 1500 processor board has changed. This is covered in Chapter 2.
  • Page 7 DATA INSTRUMENTS ® AUTOSET ® 1500 Wintriss ® Controls Group USER MANUAL 75 Discovery Way Revision C1 Acton, MA 01720-3648 June 1998 Telephone: (800) 586-TECH (8234) ©1998, Data Instruments Inc. (508)264-9550 Fax: (978) 263-2491 Internet: http://www.wintriss.com AutoSet 1500 User Manual 1088500...
  • Page 8: Chapter 1 The Autoset ® 1500

    It protects your press and dies from overloads without the need to change or readjust settings from die to die. That is because the AutoSet 1500 creates load limits (or setpoints) automatically—for any job. You never have to calculate and enter settings yourself.
  • Page 9: The Autoset 1500 Front Panel

    (optional). Illuminates when the zero cam is closed, generally through top Zero Cam LED of stroke. AutoSet 1500 has a lock and key so the cover can be locked. This prevents Keylock. unauthorized changes to settings. The two cover latches keep the AutoSet front panel door firmly closed. To Cover latches.
  • Page 10: How Tonnage Is Recorded On The Autoset Displays

    AutoSet 1500 is proportional to the force being exerted by the press. The two strain links provided with the AutoSet 1500 are called differential strain links. The part number on your links should be 9641601 (30' cable), 9641602 (100' cable), or 9641801 (with Hirschmann connector), depending on the cable length or connector you choose.
  • Page 11: How Autoset 1500 Works

    AutoSet 1500 How AutoSet 1500 works AutoSet is so easy to use because it creates and displays load setpoints automatically. You never have to calculate and enter setpoints. Once AutoSet is installed and properly calibrated, there are only two settings you have to make.
  • Page 12 AutoSet 1500 Example of how setpoints are calculated To better understand how AutoSet 1500 automatically creates setpoints, let's look at an example. Let's say AutoSet is installed on a 50 ton press. The percent tolerance setting is at 10%, indicating that AutoSet will create setpoints 10% higher than the highest measured load during the sample period.
  • Page 13: Specifications

    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 provided AutoSet 1500 User Manual Ch 1 1088500...
  • Page 14: Chapter 2 Autoset 1500 Installation

    ZER O C AM 12.75 SETPOINTS (32.39) RESET AutoSet ® 1500 W I N T R I S S LO A D A N A LY Z E R Figure 2-1. AutoSet mounting dimensions AutoSet 1500 User Manual Ch 2 1088500...
  • Page 15: Connecting Ac Wiring And Stop Circuit

    The AutoSet box 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. Wires go through top right knockout hole. Leave a small service loop inside box. AutoSet 1500 User Manual Ch 2 1088500...
  • Page 16 Installation Figure 2-2. Location of components in AutoSet 1500 (important components shown and labeled) CAUTION POWER POWER TRANSFORMER FUSES VOLTAGE SELECTOR CALIBRATION MODE COMMS SELECTOR % Tolerance Selector Notch Tonnage Settings Zero LED Chart SETUP Dialog Recorder Station Zero Remote Reset Power CPU NO.
  • Page 17 NOTE: The connector can only plug in one way. Make sure you don't start at the wrong end when connecting AC wires. Put the connector over the base the way it will plug in and note wire marking next to base before starting. AutoSet 1500 User Manual Ch 2 1088500...
  • Page 18 WARNING PREVENT SHOCK Do not connect AC wires to the power source until after all other installation procedures are finished. 14. Go on to the next procedure, mounting strain links. AutoSet 1500 User Manual Ch 2 1088500...
  • Page 19: Mounting And Connecting Strain Links

    Installation Mounting and connecting strain links The two strain links provided with the AutoSet 1500 are called differential strain links. The part number on your links should be 9641601, 9641602, or 9641603, depending on the cable length or connector you chose. If you plan to use other strain links, contact Data Instruments to find out if they will work with the AutoSet 1500.
  • Page 20 (Forward load read as tension). Middle arrows indicate strain links can be mounted either on front or side of columns when using other placement methods. Figure 2-6. Strain link mounting options on a straight side press AutoSet 1500 User Manual Ch 2 1088500...
  • Page 21 9. The strain link connectors are at the lower right inside the box. They are marked "right input" (TB6) and "left input" (TB5). Determine which connector each set of strain link wires go to. AutoSet 1500 User Manual Ch 2 1088500...
  • Page 22 14. Replace the second connector. Double check connections. 15. You are done installing the strain links and connecting them to the AutoSet. Go on to next section—connecting AC wires to power source. AutoSet 1500 User Manual Ch 2 1088500...
  • Page 23: Connecting Ac Wires To Power Source

    Once all connections are made Once you've made all connections and AutoSet has power, you are ready to begin calibration. Calibration is covered in Chapter 3. Go to Chapter 3 and begin the calibration procedure. AutoSet 1500 User Manual Ch 2 1088500...
  • Page 24: Optional Wiring Connections

    Before installing a zero cam, be sure some other condition (loose wires, improper calibration) is not causing erroneous tonnage readings. Also, do not hesitate to contact Data Instruments if you need assistance in determining whether to install a zero cam. AutoSet 1500 User Manual Ch 2 1088500...
  • Page 25 30° of stroke. There should be a dwell of 150° between the two magnets across the top of the stroke, and the switch will be open during the forming portion of the stroke. AutoSet 1500 User Manual Ch 2 1088500...
  • Page 26 (see "Mounting and connecting strain links" and "Connecting AC wires to power source" in this chapter). Make sure you did not get wiring backwards due to turning connector the wrong way once removed from socket. AutoSet 1500 User Manual Ch 2 1088500...
  • Page 27 (toggle switch S2 must be set to "operate" before pushing Reset). This must be done any time the switch is changed with power on. If power is off, AutoSet automatically resets at start-up. Figure 2-10. Zero cam enable switch. AutoSet 1500 User Manual Ch 2 1088500...
  • Page 28: Wiring A Remote Reset Switch To Autoset (optional)

    6 (LEFT). Connect wire for right strain link to pin 7 (RIGHT). See Figure 2-9 for connections. Connect third wire to pin 5 (GND). Replace the connector and close cover. Connect wires to chart recorder. Follow manufacturer's instructions for your chart recorder. AutoSet 1500 User Manual Ch 2 1088500...
  • Page 29: Final Checkout For Autoset 1500

    You need to make a few test press runs to ensure that AutoSet 1500 is working properly and will stop on a fault condition. You will have to load tonnage-related settings and then run a test tool (refer to Chapter 4 (Operation) for more assistance).
  • Page 30: Chapter 3 Autoset 1500 Calibration

    Chapter 3 AutoSet 1500 Calibration This chapter explains calibration of AutoSet. Calibration means adjusting AutoSet 1500 so tonnage readings are accurate. After calibration, the tonnage AutoSet displays will indicate the true tonnage applied by the press. You must calibrate the AutoSet after installation and any time you move the strain links to a different location on the press, restres the tie rods, or perform major repair work to the press frame.
  • Page 31: Types Of Calibration Kits You Can Use

    You can use either a Wintriss Load Analyzer (WLA) with calibration kit or another AutoSet 1500 with calibration kit to read the tonnage applied to the load cells. How to use each type of calibration kit is described below.
  • Page 32 Ignore this display for now. A "HI" or "LO" means the setting is still too close to the outer limits of the range, but we will take care of that in the next step. AutoSet 1500 User Manual Ch 3...
  • Page 33: Setting Up And Adjusting A Wintriss Load Analyzer (wla) Calibration Kit

    To set the dial switches, use a screwdriver to aim the pointer at the number you want. The switch for the most significant digit (the "1" in 100 for instance) is at the left . When done, replace the display module. AutoSet 1500 User Manual Ch 3 1088500...
  • Page 34 You should now see a number between 170 and 190 on the display. If no calibration number appears, change the TENSION/COMPRESSION switch to the opposite position. If the calibration number is incorrect, stop the calibration procedure. Call Data Instruments for help. AutoSet 1500 User Manual Ch 3 1088500...
  • Page 35 You are done setting up the WLA calibration unit. The WLA will now read the correct tonnage when you apply a load to the load cells. Go to the procedure titled "Calibrating your AutoSet 1500" to set up the press and calibrate your AutoSet 1500.
  • Page 36: Setting Up And Adjusting An Autoset 1500 Calibration Kit

    Calibration Setting up and adjusting an AutoSet 1500 calibration kit Follow the steps below if you are using another AutoSet 1500 with calibration kit for calibrating your AutoSet 1500. The kit contains two load cells, calibration modules, and cables. The steps below tell you how to set up and adjust the AutoSet to display the correct tonnage applied to the load cells.
  • Page 37 Find the three blocks in a column with white dials on them. See Figure 3-2. They are at the right middle of the box. Figure 3-2. Blocks for setting full scale tonnage on calibration unit AutoSet 1500 User Manual Ch 3 1088500...
  • Page 38 NOTE : Make sure the decimal point switch (No. 3 on S6) is set to the "on" position. See Figure 3–2. If not set to "on", push switch all the way to the left with a pen or your thumbnail. AutoSet 1500 User Manual Ch 3 1088500...
  • Page 39 You are done setting up the AutoSet calibration unit. It will now read the correct tonnage when you apply a load to the load cells. Go to the next procedure— "Calibrating your AutoSet 1500." AutoSet 1500 User Manual Ch 3...
  • Page 40: Calibrating Your Autoset 1500

    Calibrating your AutoSet 1500 Whether you are using the AutoSet 1500 or the WLA calibration kit, the unit should now be set up so it will read the correct tonnage applied to the load cells. Follow the steps below to set up the loads cells on the press and calibrate the AutoSet 1500 installed on your press.
  • Page 41 NOTE Figure 2-2 in Chapter 2 is a drawing of the components. If necessary, use it to locate the dials and switches which will be mentioned in the following steps. AutoSet 1500 User Manual Ch 3 1088500...
  • Page 42: Setting Full Scale Tonnage

    (away from the OPEN position). Make sure you push it all the way to the right. This allows AutoSet to display accurate readings within the 1000 to 1500 tonnage range. AutoSet 1500 User Manual Ch 3 1088500...
  • Page 43 Turn power to AutoSet off, then back on. This must be done to reset the unit after changing the tonnage switches. (Also resets decimal point if decimal point switch was changed.) AutoSet 1500 User Manual Ch 3 1088500...
  • Page 44: Adjusting Autoset To Read The Correct Tonnage

    Figure 3-8. Jumper position for low gain and high gain Cycle the press and determine whether the tonnage displayed on AutoSet is greater or less than the tonnage displayed on your calibration unit. AutoSet 1500 User Manual Ch 3 1088500...
  • Page 45 Then turn the screw counterclockwise and keep cycling the press until tonnages match. Reset the unit any time the displays flash. Keep adjusting tonnage downward. When tonnage on AutoSet matches tonnage on your calibration unit, you are done. AutoSet 1500 User Manual Ch 3 1088500...
  • Page 46 AutoSet Write your Calfactors and Gain Settings in these spaces. Figure 3-9. Schematic of AutoSet label Set the toggle switch back to operate. Calibration is finished and AutoSet is now ready for use. AutoSet 1500 User Manual Ch 3 1088500...
  • Page 47: Linearity Check

    If the tonnages disagree, the problem may be the positioning of your strain links or twisting forces on the press. Consult your service representative or Data Instruments. Note, however, that perfect linearity is unachievable. Typically tonnages are 5% to 10% off at 20-80% of press capacity. AutoSet 1500 User Manual Ch 3 1088500...
  • Page 48: Chapter 4 Autoset 1500 Operation

    Chapter 4 AutoSet 1500 Operation The AutoSet 1500 load monitor automatically sets high tonnage limits based on measured load. It measures the load at two points on the press—the points where its two strain links are mounted. Operation is very simple. You make only two settings. This chapter tells you how to make these settings.
  • Page 49: Setting The Percent Tolerance Selector

    However, you do not have to understand how AutoSet calculates setpoints to do the following procedure. The steps have been designed so you can make the right setting whether or not you understand how AutoSet works. AutoSet 1500 User Manual Ch 4 1088500...
  • Page 50 NOTE The 15% setting is a good setting to start with for most jobs. As you become more experienced using AutoSet, you may want to start at different settings depending on the job. AutoSet 1500 User Manual Ch 4 1088500...
  • Page 51: Creating Setpoints For The Job

    2. Proceed below based on whether or not AutoSet shut down the press in Step 1. However, be sure you understand the difference between a nuisance stop and a tonnage fault before you go any further. AutoSet 1500 User Manual Ch 4 1088500...
  • Page 52 IMPORTANT: If you have to keep moving the dial up and AutoSet still keeps shutting down the press, there may a problem with the die or your setup. Check for other causes of press stoppage besides nuisance stops. AutoSet 1500 User Manual Ch 4 1088500...
  • Page 53: When You May Want To Change The Setpoint Percentage

    120% of full scale tonnage. Setpoints will not be created. To disable AutoSet, you set the percent tolerance selector to 0. This clears the old setpoints. AutoSet 1500 User Manual Ch 4 1088500...
  • Page 54: Chapter 5 Autoset 1500 Troubleshooting

    AutoSet 1500 Troubleshooting AutoSet Alarms AutoSet 1500 is designed to let you know when fault conditions occur. This chapter explains the faults that occur when AutoSet shuts down the press and how to correct them. Four types of faults are explained here: •...
  • Page 55: When Autoset Displays A High Setpoints Fault

    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. AutoSet 1500 User Manual Ch 5 1088500...
  • Page 56: When Autoset Displays An Offset Error

    (more than two seconds), the setpoints will change to 120% of full scale tonnage. This indicates AutoSet will recalculate setpoints once the press is started. Most of the time, you will not want to recalculate setpoints after an overload. . AutoSet 1500 User Manual Ch 5 1088500...
  • Page 57: Autoset Troubleshooting

    However, the calibration information and full scale tonnage settings are retained. When power is restored, the tonnage displays will read zero and the setpoint displays will read 120% of full scale tonnage. The AutoSet will automatically recalculate setpoints after the appropriate number of strokes. AutoSet 1500 User Manual Ch 5 1088500...
  • Page 58: Appendix A Autoset 1500 Panel Mount

    Standard Enclosure versus Optional Panel Mount AutoSet 1500 is available either with an enclosure or as a panel mount. The panel mount can be mounted from the inside or outside. Be sure to allow at least 4" (10.2 cm) of clearance behind the panel mounting plane to allow enough room for the electronics.
  • Page 59: Panel Mount

    Panel Mount Figure A-1. Mounting and "cutout" dimensions for AutoSet 1500 panel and your enclosure 0.34 (8.6) 0.35 (8.9) 8.25 (209.6) 0.50 4.13 0.25 (6.4) (12.7) (104.8) YOUR 3.75 PANEL (95.3) 12.25 7.50 (311.2) (190.5) allow at least 4" (100) clearance 11.25...
  • Page 60: Appendix B Modification For Selectable Sampling

    Appendix B Modification for Selectable Sampling For those AutoSet 1500 load monitors which include custom selectable sampling, the stroke sample length can be set to 1, 15, 30 or 60 strokes. Dip switches 1 and 4 on switch block S1 are used to make the settings. On the standard AutoSet, dip switch 4 is not used.
  • Page 61 Selectable Sampling AutoSet 1500 User Manual App B 1088500...
  • Page 62: Index

    When AutoSet displays a high full scale tonnage 3, 5, 30, 35 setpoints fault 48 When power is turned off 50 AutoSet 1500 with calibration kit 24 Gain potentiometer 32, 37 AutoSet label (for recording data) 39 ground block 10...
  • Page 63 42, 43, 46 zero signal 17, 18 potentiometer 25, 26, 32 Zeroing strain links 24 power supply cover 8, 11, 29 ram 33 recalculating setpoints 46 recording calfactors and gain settings 39 remote reset switch 21 AutoSet 1500 User Manual Index 1088500...

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