1. Manuals
  2. Brands
  3. Wintriss Manuals
  4. Measuring Instruments
  5. AutoSet PAC 120 VAC
  6. User manual

Wintriss AutoSet PAC 120 VAC User Manual

Load analyzer a smartpac module
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
AutoSet PAC
®
Wintriss Load Analyzer
®
A SmartPAC Module
1101600
Rev. N
December 2018
®
Wintriss Controls Group, LLC
100 Discovery Way
Unit 110
Acton MA 01720 USA
Phone (800) 586-8324
Fax (978) 263-2048
PRINTED IN USA
DA46021
Tech Support Hotline
800-586-8324
8-5 EST
www.wintriss.com
®

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the AutoSet PAC 120 VAC and is the answer not in the manual?

Questions and answers

Related Manuals for Wintriss AutoSet PAC 120 VAC

Summary of Contents for Wintriss AutoSet PAC 120 VAC

  • Page 1 ® A SmartPAC Module 1101600 Rev. N December 2018 Tech Support Hotline 800-586-8324 8-5 EST ® Wintriss Controls Group, LLC 100 Discovery Way Unit 110 Acton MA 01720 USA Phone (800) 586-8324 Fax (978) 263-2048 www.wintriss.com PRINTED IN USA DA46021...
  • Page 3 Changes for Revision N of the AutoSetPAC User Manual (1101600) This revision of the AutoSetPAC user manual covers AutoSetPAC software version 2.28 and higher. The changes include: • Addition of SmartPAC PRO installation, usage information, and wiring diagrams 8 – 12. •...
  • 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 7: Table Of Contents

    Table of Contents Chapter 1 Introduction ......................19 AutoSetPAC Benefits ............................ 20 SmartPAC PRO, SmartPAC 2, and Original SmartPAC ................20 Original SmartPAC and SmartPAC 2 Front Panels ..................22 SmartPAC PRO Front Panel ......................... 23 Strain Links ..............................25 Calibration ..............................
  • Page 8 Chapter 4 Using AutoSetPAC in Program Mode .............. 93 AutoSetPAC’s Setpoint Calculation Process ....................93 Startup Counter ............................. 95 Accessing the Tonnage Monitor Programming Menu .................. 96 Making Tonnage Monitor Settings ....................... 98 Loading Tonnage Monitor Settings ......................99 Copying Tonnage Monitor Settings ......................100 Changing Tonnage Monitor Settings ......................101 Viewing and Adjusting Setpoints ........................101 High Setpoint Limits ..........................102...
  • Page 9 AutoSetPAC User Manual 1101600 List of Figures Figure 1-1. SmartPAC 2 and Original SmartPAC ................21 Figure 1-2. SmartPAC PRO ......................... 23 Figure 2-1. AutoSetPAC Enclosure: Mounting Dimensions ..............30 Figure 2-2. AutoSetPAC Enclosure with AutoSet 4-Channel Display: Mounting Dimensions ..31 Figure 2-3.
  • Page 10 Figure 4-8. Tool Manager Screen with Copy Tool Message and Numeric Entry Window Displayed ........................100 Figure 4-9. Adjust Setpoints Screen: High Setpoint Limits Display ..........102 Figure 4-10. Adjust Setpoints Screen: Low Setpoint Limits Display ..........103 Figure 4-11. Adjust Setpoints Screen: Repeatability Setpoint Limits Display ........104 Figure 4-12.
  • Page 11 AutoSetPAC User Manual 1101600 Table 4-1. Tonnage Monitor Programming Menu Settings ..............99 Table 5-1. Tonnage History Information for Each Strain Link Input ..........117 Table 5-2. Tonnage History Information for Total Tonnage .............. 118 Table 6-1. Common Causes of Tonnage Faults ................. 124 Table 6-2.
  • Page 12 Table of Contents...
  • Page 13 Wiring diagrams at the end of the manual show connections between AutoSetPAC and all three versions of SmartPAC (original SmartPAC, SmartPAC 2, SmartPAC PRO) and the connections necessary to conduct a loopback test. NOTICE DOWNLOAD WINTRISS DOCUMENTS Download any needed Wintriss documents from www.wintrissdocs.com...
  • Page 15 Important Highlighted Information Important danger, warning, caution and notice information is highlighted throughout the manual as follows: A DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. A WARNING symbol indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.
  • Page 17 90 days from date of shipment. Wintriss’s obligations under this warranty are limited to repairing or replacing, at its discretion and at its...

  • Page 19: Chapter 1 Introduction

    Chapters 3 through 6 tell how to initialize, program, run, and troubleshoot your AutoSetPAC/SmartPAC system. Refer to your SmartPAC manual. Download any needed Wintriss documents from www.wintrissdocs.com SmartPAC with AutoSetPAC is a reliable, easy-to-use load monitoring system that provides overload and underload protection for your press and dies without the need to change settings manually on each die change.

  • Page 20: Autosetpac Benefits

    1101600 AutoSetPAC User Manual AutoSetPAC Benefits AutoSetPAC provides the following benefits: Identifies machine overloading, enabling you to prevent unnecessary wear on load-bearing • components • Provides repeatability, or stroke-to-stroke, tonnage monitoring. Repeatability setpoints allow you to monitor your stamping process more precisely, enabling you to detect punch breakage, quality problems, and loss of tonnage due to end of stock.

  • Page 21: Figure 1-1. Smartpac 2 And Original Smartpac

    CURSOR RESET SINGLE CLEAR STROKE INCH CONT PROG ENTER SmartPAC HELP Wintriss Press Automation Control RESET CLEAR Contrast keys original SmartPAC only Help key SmartPAC 2 8 Function keys 6 Function keys only Figure 1-1. SmartPAC 2 and Original SmartPAC Original SmartPAC, SmartPAC 2, and SmartPAC PRO panel displays use a different number of function, or “F,”...

  • Page 22: Original Smartpac And Smartpac 2 Front Panels

    1101600 AutoSetPAC User Manual Original SmartPAC and SmartPAC 2 Front Panels NOTICE See SmartPAC PRO Front Panel, page 23 for SmartPAC PRO front panel information. Programming and operation of AutoSetPAC is accomplished via the SmartPAC front panel, Figure 1-1. A brief description of each panel component is below, Table 1-1. Refer to your original SmartPAC or SmartPAC 2 manual for more information.

  • Page 23: Smartpac Pro Front Panel

    AutoSetPAC User Manual 1101600 SmartPAC PRO Front Panel NOTICE Original SmartPAC and SmartPAC 2 Front Panels , page 22, for front panel information on these products. SmartPAC PRO Help key Crank angle/ SPM display 8 Function keys Figure 1-2. SmartPAC PRO Programming and operation of AutoSetPAC is accomplished via the SmartPAC PRO front panel, Figure 1-2.

  • Page 24: Table 1-2. Smartpac Pro Panel Features

    1101600 AutoSetPAC User Manual Table 1-2. SmartPAC PRO Panel Features On-Screen Whenever you select a field that requires numbers only, SmartPAC PRO Numeric will display a numeric keypad. Keypad The up and down arrow cursor keys on the keypad will increment or decrement the value by 1.

  • Page 25: Strain Links

    AutoSetPAC User Manual 1101600 “ALT” On certain screens, an alternate navigation menu called the “ALT” menu appears. Typically, the ALT menu is displayed Menu when traditional “Cursor-and-Enter” navigation is used on a screen rather than the touch screen. It consists of the following buttons: HELP or ? –...

  • Page 26: Autosetpac Operation

    1101600 AutoSetPAC User Manual AutoSetPAC Operation AutoSetPAC calculates high, low, and repeatability setpoints automatically based on the setpoint percentage and sample period settings you make for each tool in Program mode (see Chapter 4, page 93). The sample period is the number of strokes during which AutoSetPAC collects tonnage information to use in calculating setpoints.

  • Page 27: Autosetpac Specifications

    AutoSetPAC User Manual 1101600 AutoSetPAC Specifications AutoSetPAC specifications are shown in Table 1-3. Table 1-3. AutoSetPAC Specifications Enclosure 10.25” (260.4 mm) x 12” (304.8 mm) x 4” Equipment (101.6 mm), NEMA 12, shock-mounted 115 or 230 Vac ±15%, 50-60 Hz, 30 W Power 24 ±...
  • Page 28 1101600 AutoSetPAC User Manual Chapter 1 Installation...

  • Page 29: Chapter 2 Installation

    Chapter 2 Installation NOTICE WIRING CONNECTIONS FOR AUTOSETPAC WITH ORIGINAL SMARTPAC Most of the instructions provided in this chapter assume that you are installing AutoSetPAC on a SmartPAC 2 or SmartPAC PRO control. However, if you are connecting your AutoSetPAC to an original SmartPAC, see Connecting a New AutoSetPAC to Original SmartPAC, page 53.

  • Page 30: Mounting The Autosetpac Enclosure Without Display

    1101600 AutoSetPAC User Manual Installing the AutoSetPAC Processor Board, 85 to 264 Vac Version (No Enclosure), page 34 • Installing the AutoSetPAC Processor Board (24 Vdc Version), page 35 • Mounting the AutoSetPAC Enclosure without Display To mount the standard AutoSetPAC enclosure, follow these steps: 1.

  • Page 31: Mounting The Autosetpac Enclosure With Autoset 2-Channel/4-Channel Display

    AutoSetPAC User Manual 1101600 Mounting the AutoSetPAC Enclosure with AutoSet 2-Channel/4- Channel Display To mount the AutoSetPAC enclosure with an AutoSet 2-Channel or 4-Channel display, follow these steps: 1. Determine a convenient mounting location, considering the following factors: • The enclosure should be mounted as close as possible to the press control so that operators and setup personnel can easily see the readouts Strain link cables must be capable of reaching the mounting site •...

  • Page 32: Installing The Autosetpac Panel Mount

    1101600 AutoSetPAC User Manual Installing the AutoSetPAC Panel Mount If you have received a panel-mount version of AutoSetPAC, perform the following steps to install the panel mount in your enclosure. The panel mount is usually installed from outside the enclosure. Be sure to allow at least 4”...

  • Page 33: Figure 2-3. Autosetpac Panel Mount: Mounting And Cutout Dimensions

    AutoSetPAC User Manual 1101600 Figure 2-3. AutoSetPAC Panel Mount: Mounting and Cutout Dimensions 3. Place the AutoSetPAC panel mount near the cutout (for example, connect ty wraps from two of the left holes in the panel to the corresponding holes in the unit, creating a hinge). 4.

  • Page 34: Installing The Autosetpac Processor Board, 85 To 264 Vac Version (No Enclosure)

    1101600 AutoSetPAC User Manual Installing the AutoSetPAC Processor Board, 85 to 264 Vac Version (No Enclosure) To mount the AutoSetPAC 2-Channel or 4-Channel processor board in your enclosure, do the following: 1. Determine a convenient, accessible location within your enclosure in which to mount the AutoSetPAC board, allowing enough room for installation and maintenance of the board.

  • Page 35: Installing The Autosetpac Processor Board (24 Vdc Version)

    AutoSetPAC User Manual 1101600 Installing the AutoSetPAC Processor Board (24 Vdc Version) To mount the board in your enclosure or console, do the following: 1. Determine a convenient, accessible location in which to mount the board, allowing enough room for installation and maintenance. 2.

  • Page 36: Connecting Ac And Stop Circuit Wiring

    AutoSetPAC must be wired into the stop circuit on the press. Otherwise, SmartPAC cannot stop the press if AutoSetPAC detects a tonnage fault. Wintriss recommends you connect AutoSetPAC to the top-stop rather than to the E-stop circuit of your press to prevent the press from sticking on the bottom if an overload occurs.

  • Page 37: Figure 2-6. Autosetpac 2-Channel Processor Board: Location Of Important Components

    AutoSetPAC User Manual 1101600 T101 TB103 S110 6 5 4 3 2 1 F102 F101 115V K101 1/4 AMP 4 AMP 250VAC 250VAC DS112 - 12V P102 DS111 +12V XU106 Power and stop circuit connector Mode switches MODE S101 High/low gain jumper J115 RESET...

  • Page 38: Figure 2-7 Autosetpac 4-Channel Processor Board: Location Of Important Components

    1101600 AutoSetPAC User Manual T101 TB103 S110 6 5 4 3 2 1 F102 F101 115V K101 1/4 AMP 4 AMP 250VAC 250VAC DS112 - 12V P102 DS111 XU106 +12V Power and stop circuit connector Mode switches MODE S101 High/low gain jumper Connector for J115...

  • Page 39: Figure 2-8. Ac Power Connections

    AutoSetPAC User Manual 1101600 5. Connect the ground (green or green/yellow) wire to the ground stud on the ceiling at the top right of the enclosure, as shown in Figure 2-8. To make the connection, strip the ground wire about 1/4”...

  • Page 40: Table 2-1. Autosetpac Ac Power And Stop Circuit Wiring Connections, Tb103

    Either wire can be connected to either pin. NOTICE WIRING FOR WINTRISS CLUTCH/BRAKE CONTROL If you are wiring the AutoSetPAC stop circuits to a WPC II, WPC 1000, or WPC 2000 clutch/brake control, connect the wire from pin #6 on TB103 on the AutoSetPAC processor board to terminal #79 on the WPC processor board and the wire from pin #5 on TB103 to terminal #80 on the WPC board.

  • Page 41: Installing Strain Links

    Type 9647101 9647301 30 ft. cable 9647102 9647302 100 ft. cable 9647201 9647305 Hirschman connector If you plan to use other strain links, contact Wintriss Tech. Support to make sure they are compatible with your AutoSetPAC unit. Chapter 2 Installation...

  • Page 42: Mounting Strain Links

    1101600 AutoSetPAC User Manual Mounting Strain Links To mount strain links, perform the following steps, referring to Figure 2-9 for mounting dimensions Figure 2-9. Strain Link: Mounting Dimensions 1. Select locations on the press where you plan to mount the strain links. On gap-frame (OBI or OBG) presses, strain links can be mounted on the front, where they measure tension, or on the rear, where they measure compression (see Figure 2-10).

  • Page 43: Figure 2-10. Strain Link Mounting Options On Gap-Frame Presses

    AutoSetPAC User Manual 1101600 NOTICE STRAIN LINKS MUST BE MOUNTED ON A FLAT SURFACE Make sure there are no imperfections, ridges, or cavities on the mounting surface. If strain links are not mounted on a flat surface, they will be difficult or impossible to zero. Irregular surfaces also cause inaccurate tonnage readings.

  • Page 44: Figure 2-11. Strain Link Mounting Options On Straight-Side Presses

    1101600 AutoSetPAC User Manual Figure 2-11. Strain Link Mounting Options on Straight-side Presses 2. Select the area for the first mounting hole. Using a No. 7 drill bit, drill the hole 1/2” deep and bottom tap for a 1/4 x 20 thread. NOTICE DRILLING AND TAPPING FOR METRIC SCREWS If you are installing metric strain links, use a 5 mm drill bit, drill the hole 12 mm deep, and tap with...

  • Page 45: Figure 2-12. Strain Link Drill Jig: Mounting Dimensions

    AutoSetPAC User Manual 1101600 Figure 2-12. Strain Link Drill Jig: Mounting Dimensions NOTICE INSTALLING METRIC STRAIN LINKS If you are installing metric strain links, the drill jig includes both a metric and a standard 1”-long screw. The metric screw is M6X1 and is easily identified because it is made of stainless steel and has more threads (25 vs.

  • Page 46: Wiring Strain Links

    1101600 AutoSetPAC User Manual Wiring Strain Links To wire strain links, perform the following steps: 1. Run the strain link cables through flexible, liquid-tight conduit to AutoSetPAC. If you ordered an enclosure, it 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 47: Figure 2-13. Shield Drain Wire Connected To Ground Stud On Enclosure

    AutoSetPAC User Manual 1101600 Table 2-6. Strain Link Wiring Connections, TB105 - TB108: Tension Pin # Wire Color * Function Unused Green Input + White Input - Black Ground Exc + * Shield should be connected to ground stud on enclosure nearest entry of strain link wiring.

  • Page 48: Connecting The Zero Cam Signal To Smartpac 2 Or Smartpac Pro

    1101600 AutoSetPAC User Manual Connecting the Zero Cam Signal to SmartPAC 2 or SmartPAC PRO NOTICE WIRING CONNECTIONS FOR AUTOSETPAC WITH ORIGINAL SMARTPAC If you are connecting a new AutoSetPAC to an original SmartPAC, see Connecting a New AutoSetPAC to Original SmartPAC, page 53, and the appropriate wiring diagrams at the end of the manual.

  • Page 49: Table 2-7. Zero Cam Wiring Connections To Smartpac 2

    AutoSetPAC User Manual 1101600 Table 2-9. Zero Cam Wiring Connections to SmartPAC 2 AutoSetPAC 120 VAC 24 VDC 2-Channel 4-Channel 2-Channel 4-Channel SmartPAC 2 TB101B TB 101(A) TB102 TB 102 TB107 Connection Pin# Pin# Pin# Pin# Pin# Zero Wiring Figure 1 Figure 2 Figure 7 Figure 6...

  • Page 50: Connecting Communications Wiring To Smartpac 2 Or Smartpac Pro

    3. Make communications wiring connections as shown in Table 2-10, above, referring also to Figure 2-6 or Figure 2-7 and to the appropriate wiring diagram at the back of the manual. Use one of the Wintriss cables listed in the table below. Chapter 2 Installation...

  • Page 51: Wiring An Oscilloscope (Optional)

    AutoSetPAC User Manual 1101600 Wintriss Part Cable Length Number 30 feet (9.1 m) 4328501 100 ft (30.5 m) 4328502 Make sure to connect the cable shield to the ground stud on the enclosure nearest the knockout through which you bring the communications wiring, as shown in Figure 2-13, page 47.

  • Page 52: Table 2-9. Oscilloscope Wiring Connections, 120 Vac Autosetpac

    1101600 AutoSetPAC User Manual Table 2-11. Oscilloscope Wiring Connections, 120 VAC AutoSetPAC AutoSetPAC Terminal Pin # Label 120 VAC Model Block Ground 2-Channel TB101B Channel 1 (Left Rear) Channel 2 (Right Rear) Channel 1 (Left Rear) Channel 2 (Right Rear) 4-Channel TB101(A) Channel 3 (Left Front)

  • Page 53: Connecting Ac Wires To Power Source

    If Character Generator is earlier than V1.07, you must replace it with version V1.07. • Contact Wintriss Tech. Support to arrange for updated firmware. 2. If you must replace SmartPAC firmware, record the settings for start and stop time limits on the Set Brake Monitor screen in Initialization mode.

  • Page 54: Connecting An Autoset To Smartpac

    SELECT CAM NAMES) you recorded in step 2. Refer to your SmartPAC user manual. 9. When you are finished, proceed with initialization and calibration of your AutoSetPAC. 10. Return the obsolete SmartPAC firmware board to Wintriss. When you are ready to make parts, go to Program mode (see Chapter 4) and enter setpoint percentages and a sample period setting for each tool that was programmed previously.

  • Page 55: Table 2-11. Communications Wiring Connections: Autoset And Smartpac 2 Or Smartpac Pro

    AutoSetPAC User Manual 1101600 knockout on the SmartPAC enclosure and through the bottom left knockout on the AutoSet enclosure. 2. Make communications wiring connections as shown in Table 2-13, referring also to Figure 1 or Figure 2 at the end of the manual for SmartPAC 2, Figure 8 or Figure 9 for SmartPAC PRO. Table 2-13.

  • Page 56: Connecting An Autoset To Original Smartpac

    (see Making Tonnage Monitor Settings, page 98). 13. Return the old AutoSet firmware chip to Wintriss. Connecting an AutoSet to Original SmartPAC To connect an AutoSet to original SmartPAC, perform the following steps. Refer to your Original SmartPAC manual and the wiring diagrams 4 and 5 at the end of this manual.

  • Page 57: Powering Up Autosetpac

    SmartPAC (see Making Tonnage Monitor Settings, page 98). 14. Return the obsolete SmartPAC firmware board and the old AutoSet firmware chip to Wintriss. Powering Up AutoSetPAC Once AutoSetPAC is connected to a power source, do the following to power up the unit: 1.

  • Page 58: Installing New Autosetpac Firmware

    Option Does Not Display at Power-up (Communications Error) troubleshooting procedure, page 127. Then power up the unit again. 5. If TONNAGE/WAVEFORM still does not display, call Wintriss Tech. Support. Once you have made all connections and AutoSetPAC has power, you are ready to calibrate the unit.
  • Page 59 AutoSetPAC User Manual 1101600 3. Making sure that you are grounded, open the AutoSetPAC enclosure and locate the firmware chip, labelled XU106, on the AutoSetPAC Processor board (see Figure 2-6 or Figure 2-7). Note that the chip has a white label and the semi-circular notch on the chip faces to the left. NOTICE The new AutoSetPAC firmware chip must also be installed with the notch facing left.
  • Page 60 SmartPAC manual if necessary. AutoSetPAC should be displayed in the options list along with its new firmware version number (for example, V2.00). 9. If AutoSetPAC appears in the list, you have completed installation of your new firmware successfully. 10. If AutoSetPAC is not in the list, contact Wintriss Tech. Support. Chapter 2 Installation...

  • Page 61: Chapter 3 Initialization And Calibration

    Chapter 3 Initialization and Calibration This chapter shows you how to set Initialization parameters for AutoSetPAC in SmartPAC Initialization mode and calibrate the AutoSetPAC unit. It is organized in the following sections: Making Settings on Switch Block S101 ......................61 Accessing the SmartPAC Main Initialization Menu ..................

  • Page 62: Figure 3-1. Switch Block S101 (Default Settings Shown)

    1101600 AutoSetPAC User Manual settings. Switch 6 can be set to allow two AutoSetPACs to be connected to a single SmartPAC. Switch 7 allows you to set an AutoSetPAC 4-Channel load monitor, which by default is configured with four strain link channels, as a two-channel unit. Switches 1 through 5 and switch 8 are unused. All eight switches on S101 are set to OFF by default, as shown in Figure 3-1, page 62.

  • Page 63: Accessing The Smartpac Main Initialization Menu

    AutoSetPAC User Manual 1101600 Accessing the SmartPAC Main Initialization Menu NOTICE Many of the menus in this manual are from the original SmartPAC. However, the menus on SmartPAC 2 and SmartPAC PRO are similar. The menu organization is the same for all versions of SmartPAC.

  • Page 64: Figure 3-2. Smartpac 2 Main Initialization Menu

    1101600 AutoSetPAC User Manual Figure 3-2. SmartPAC 2 Main Initialization Menu Figure 3-3. SmartPAC PRO Initialization Menu Chapter 3 Initialization and Calibration...

  • Page 65: Making Tonnage/Waveform Initialization Settings

    AutoSetPAC User Manual 1101600 Making Tonnage/Waveform Initialization Settings This section shows you how to make settings on the Tonnage/Waveform Initialization Menu (see Figure 3-4), which you access by selecting TONNAGE/WAVEFORM on the Main Initialization Menu. Figure 3-4. Tonnage/Waveform Initialization Menu The following settings are covered: Initializing Parameters, page 65 •...

  • Page 66: Setting Input Names

    1101600 AutoSetPAC User Manual Figure 3-5. Initialize Parameters Warning Message 2. Press ENTER to confirm that you want to continue with initialization. Setting Input Names The SET INPUT NAMES item on the Tonnage/Waveform Initialization Menu allows you to change the default names for AutoSetPAC’s strain link channels. If you have an AutoSetPAC 2-Channel load analyzer, two input names can be set.

  • Page 67: Figure 3-6. Load Monitor Input Name Menu With "Input 1" Highlighted

    AutoSetPAC User Manual 1101600 Figure 3-6. Load Monitor Input Name Menu with “INPUT 1” Highlighted 2. To change an input name, select that entry. An Alphabetic Entry window displays, as shown in Figure 3-7. Figure 3-7. Load Monitor Input Name Menu with Alphabetic Entry Window Displayed 3.

  • Page 68: Disabling/Enabling Autosetpac Parameters

    1101600 AutoSetPAC User Manual NOTICE The Press Capacity and Calibration items on the Tonnage Monitor Initialization Menu are used during the calibration procedure. Instructions for setting them are provided in Setting Full-scale Tonnage on Your AutoSetPAC, page 85, and Adjusting AutoSetPAC To Read the Correct Tonnage, page 87.

  • Page 69: Locking Run Mode Actions

    AutoSetPAC User Manual 1101600 To set the reverse tonnage setpoint percentage, do the following: 1. Select “SET REVERSE SETPOINT %.” When the Numeric Entry window (see Figure 3-8) displays, key in the desired percentage value, following the directions in the window. Figure 3-8.

  • Page 70: Figure 3-9. Security Access Menu With Load Monitor Setting Highlighted

    1101600 AutoSetPAC User Manual Figure 3-9. Security Access Menu with Load Monitor Setting Highlighted 2. Select the “LOAD MONITOR” item, and press ENTER to cycle through the available settings: ALLOW RECALC/ADJUST, ALLOW RECALC ONLY, NO RECALC/ADJUST, and PASSWORD REQUIRED. The ALLOW RECALC ONLY setting locks out the setpoint adjustment capability from Run mode.

  • Page 71: Viewing Communications

    AutoSetPAC User Manual 1101600 Viewing Communications The “COMMUNICATIONS” item on the Diagnostic Menu (see Figure 3-10) allows you to verify communications between SmartPAC and AutoSetPAC. To view communications, perform the following steps: 1. Select “DIAGNOSTICS” on the Main Initialization Menu (see Figure 3-2) to display the Diagnostic Menu.

  • Page 72: Calibrating Autosetpac

    Recording Tonnage on an AutoSet Calibration Kit, page 77. You can use your own calibration gear, or rent an AutoSet 2-Channel calibration kit from Wintriss. 3. Determine the tonnage capacity of your press, and set the full-scale tonnage of your AutoSetPAC to that value, following the instructions in Setting Full-scale Tonnage on Your AutoSetPAC, page 4.

  • Page 73: Zeroing Strain Links

    AutoSetPAC User Manual 1101600 AutoSetPAC should be calibrated after installation and whenever • Strain links are moved to a different location on the press • Tie rods are restressed Major repair work is performed on the press frame • Before starting calibration, make sure the press is adjusted for optimal operation. Check to make sure that the ram is parallel to the bed and that the gib/ways adjustment and tie rod tension are correct.

  • Page 74: Figure 3-14. Potentiometer Adjustment Screw On Strain Links Without Access Hole In Cover

    1101600 AutoSetPAC User Manual NOTICE If the strain link Zero Offsets reading is greater than ±99, a message like the following displays: Offset Error, signal too low on INPUT 1 LEFT The message specifies whether the strain link is set too high (i.e., >+99) or too low (i.e., >-99) and identifies the strain link channel that is out-of-range.

  • Page 75: Table 3-2. Strain Link Potentiometer: Direction Of Screw* Adjustment

    If you cannot get the Zero Offsets display to read in the ±5 range, make sure strain link wiring connections are tight and the connector is firmly seated. If loose connections are not the problem, the strain link may not be working properly. Contact Wintriss Tech. Support for assistance. NOTICE Make sure to use removable-strength Loctite (i.e., No.

  • Page 76: Using A Voltmeter To Zero Strain Links

    Contact Wintriss Tech. Support for assistance. 16. Replace the strain link cover, if necessary, when you have finished zeroing the strain link.

  • Page 77: Recording Tonnage On An Autoset Calibration Kit

    USE OF HYDRAULIC JACK FOR CALIBRATION NOT RECOMMENDED Wintriss does not recommend use of a hydraulic jack for calibration. A hydraulic jack is much less accurate than load cells and more difficult to use. For more information on hydraulic jack calibration, contact Wintriss Tech.
  • Page 78 1101600 AutoSetPAC User Manual ELECTRIC SHOCK HAZARD If the AutoSet 2-Channel calibration unit does not have a plug and you wire it to a power source, make sure power at that outlet is off before you connect the wires. Failure to comply with these instructions could result in death or serious injury. MAKE SURE POWER SUPPLY COVER IS IN PLACE ON OLD PROCESSOR BOARDS On some old-style calibration kit processor boards, there is a cover on the power supply, which helps to prevent shock when personnel are working inside the enclosure with the power on.

  • Page 79: Figure 3-15. Autoset 2-Channel Calibration Kit Processor Board: Old Style

    AutoSetPAC User Manual 1101600 Figure 3-15. AutoSet 2-Channel Calibration Kit Processor Board: Old Style Chapter 3 Initialization and Calibration...

  • Page 80: Figure 3-16. Autoset 2-Channel Calibration Kit Processor Board: New Style

    1101600 AutoSetPAC User Manual Figure 3-16. AutoSet 2-Channel Calibration Kit Processor Board: New Style Chapter 3 Initialization and Calibration...

  • Page 81: Figure 3-17. Autoset 2-Channel Calibration Kit Processor Board: Autoset V2.0 Board

    AutoSetPAC User Manual 1101600 Figure 3-17. AutoSet 2-Channel Calibration Kit Processor Board: AutoSet V2.0 Board 5. Check the AutoSet displays. The Load LED displays should show 0’s or other numbers. The Setpoint displays should show either numbers, dashes (- - -), or the message “HI” or “LO.” 6.

  • Page 82: Figure 3-18. Tonnage Dial Indicators: Old-Style Board (Left), New-Style Board (Right)

    “ZERO SET.” Then turn power on again and check the displays. If the displays are still inactive, call Wintriss Tech. Support. 7. Locate the dial indicators labelled “TONNAGE” (S1, S4, and S5 in Figure 3-15, S3, S4, and S5 in Figure 3-16) on the right side of the AutoSet processor board.

  • Page 83: Table 3-3. Autoset Load Cell Tonnage Display Formats

    ±50. If the Load displays are not within this range, there is a problem with your calibration unit. Call Wintriss Tech. Support for assistance. 13. Move the lever on switch S3 or S2 to the “CALFACTOR” position.

  • Page 84: Figure 3-20. Load Cell Gain Adjustment Potentiometer With Adjustment Screw

    1. Make sure that the die is removed from the press and that any bolster/bed openings or ram holes are covered with a plate or plates rigid enough to prevent flexing. Wintriss strongly recommends using 1”- to 2”-thick steel plates, or parallels, above and below the load cells to distribute the load evenly on the bed and ram.

  • Page 85: Setting Full-Scale Tonnage On Your Autosetpac

    Setting Full-scale Tonnage on Your AutoSetPAC NOTICE Wintriss recommends that AutoSetPAC be calibrated at the tonnage at which the press will normally operate. If you usually run between 60-90% of press capacity, calibrate at 75% of capacity. For example, if the press is a 100-ton press, calibrate for 75 tons. Do not calibrate at less than 50% of press capacity.

  • Page 86: Figure 3-21. Tonnage/Waveform Initialization Menu With Numeric Entry Window Displayed

    1101600 AutoSetPAC User Manual 1. On the SmartPAC Main Initialization Menu, select the TONNAGE/WAVEFORM item, and press ENTER. The Tonnage/Waveform Initialization Menu (see Figure 3-4) displays. Select “SET PRESS CAPACITY,” and press ENTER to display the Numeric Entry window (see Figure 3-21).

  • Page 87: Adjusting Autosetpac To Read The Correct Tonnage

    AutoSetPAC User Manual 1101600 Adjusting AutoSetPAC To Read the Correct Tonnage To adjust the tonnage displayed in AutoSetPAC so it agrees with the value(s) shown on the calibration unit, perform the following steps: 1. Select CALIBRATION on the Tonnage/Waveform Initialization Menu to display the Calibration screen (see Figure 3-22).

  • Page 88: Table 3-5. Gain Adjustment Potentiometer And High/Low Gain Jumper Identifiers

    1101600 AutoSetPAC User Manual Table 3-5. Gain Adjustment Potentiometer and High/Low Gain Jumper Identifiers AutoSetPAC Strain Link Gain High/Low Model (Input Adjustment Gain Connector) Potentiometer Jumper 2-Channel Left (TB105) R144 J115 Right (TB106) R133 J116 4-Channel Left Rear R144 J115 (TB105) Right Rear R133...

  • Page 89: Figure 3-23. Autosetpac 4-Channel Processor Board: High/Low Gain Jumper And Gain Adjustment Potentiometer For Left Rear Strain Link

    AutoSetPAC User Manual 1101600 Figure 3-23. AutoSetPAC 4-Channel Processor Board: High/Low Gain Jumper and Gain Adjustment Potentiometer for Left Rear Strain Link 3. Cycle the press and compare the reading in the “Left” (AutoSetPAC 2-Channel) or “Left Rear” (AutoSetPAC 4-Channel) channel display on the Calibration screen with the tonnage displayed on the calibration unit.
  • Page 90 1101600 AutoSetPAC User Manual NOTICE PRESS MUST BE STROKED AFTER EACH POTENTIOMETER ADJUSTMENT You must stroke the press after each adjustment of the potentiometer. Stroking the press clears the previous tonnage reading and refreshes the Calibration display with new values. 5.

  • Page 91: Checking Linearity

    AutoSetPAC User Manual 1101600 9. If you are calibrating an AutoSetPAC 4-Channel unit, cycle the press and compare AutoSetPAC and calibration kit tonnage readings for the “Left Front” and “Right Front” strain links, then repeat steps 4 through 7 for each channel. Refer to Table 3-5, page 88, for processor board labels identifying the gain potentiometer and high/low gain jumper for each strain link.

  • Page 92: Final Checkout

    Consult your service representative or contact Wintriss Tech. Support. Note, however, that perfect linearity is unachievable. Typically, tonnages are accurate within 5% to 10% at 20-80% of press capacity.

  • Page 93: Chapter 4 Using Autosetpac In Program Mode

    Chapter 4 Using AutoSetPAC in Program Mode This chapter shows you how to make the settings that AutoSetPAC uses to calculate setpoints. You make these settings on the Tonnage Monitor Programming screen in SmartPAC Program mode. The chapter also shows you how to copy Program settings from one job to the next, change Program settings, and recalculate setpoints.
  • Page 94 1101600 AutoSetPAC User Manual Low setpoint percentage • Repeatability setpoint percentage • The sample period is the number of strokes during which AutoSetPAC collects tonnage information for calculating setpoints, using the highest measured load as a reference tonnage. During the sample period, setpoints are maintained at 120% of the full-scale capacity of the press to provide overload protection.

  • Page 95: Startup Counter

    AutoSetPAC User Manual 1101600 Figure 4-1. Tonnages Produced on Left Strain Link during Sample Period: Example Reverse setpoints are calculated by multiplying the reverse setpoint percentage set in Initialization mode (see Setting Reverse Setpoint % of Press Capacity, page 68) by the full-scale tonnage of the press.

  • Page 96: Accessing The Tonnage Monitor Programming Menu

    1101600 AutoSetPAC User Manual This setting can be used to allow high-speed presses to reach their normal operating speed before monitoring tonnage. The setting can also be used to allow any press to achieve stable tonnages before tonnage monitoring or setpoint recalculation begins. AutoSetPAC maintains a high setpoint of 120% of press capacity to provide overload protection during the interval specified in the Startup Counter as it does during the sample period.

  • Page 97: Figure 4-3. Tool Manager Screen

    AutoSetPAC User Manual 1101600 Figure 4-3. Tool Manager Screen 3. Highlight the tool you wish to Program, and press F4 (Edit Tool). The Tool Program Menu displays (see Figure 4-4). Figure 4-4. Tool Programming Menu 4. Select “TONNAGE/WAVEFORM.” The Tonnage Monitor Programming Menu (see Figure 4-5) displays.

  • Page 98: Making Tonnage Monitor Settings

    1101600 AutoSetPAC User Manual Figure 4-5. Tonnage Monitor Programming Menu Making Tonnage Monitor Settings To make settings on the Tonnage Monitor Programming Menu, perform the following steps, referring to Figure 4-5 and Table 4-1, page 99: 1. Make sure that the die is properly adjusted and ready to make parts. 2.

  • Page 99: Loading Tonnage Monitor Settings

    AutoSetPAC User Manual 1101600 Table 4-1. Tonnage Monitor Programming Menu Settings Field Settings HIGH PERCENTAGE The percentage above the reference tonnage at which you want AutoSetPAC to establish high tonnage setpoints. Valid range: 1% to 120%. Zero percent (0%) setting disables setpoint. Suggested initial setting: 25%.

  • Page 100: Copying Tonnage Monitor Settings

    1101600 AutoSetPAC User Manual Figure 4-6. Load Tool Warning Message 2. Press ENTER to load the tool. (Press RESET if you want to cancel.) The message shown in Figure 4-7 displays briefly; then you are returned to the Tool Program Menu. Figure 4-7.

  • Page 101: Changing Tonnage Monitor Settings

    AutoSetPAC User Manual 1101600 2. Key in a new tool number in the Numeric Entry window, and press ENTER. You are taken to the Tool Programming Menu (see Figure 4-4) with the tool number you specified in step On the Tool Manager screen displayed in the screen header in the upper left corner.

  • Page 102: High Setpoint Limits

    1101600 AutoSetPAC User Manual Figure 4-9. Adjust Setpoints Screen: High Setpoint Limits Display 2. The Adjust Setpoints screen allows you to make adjustments to the following Program tonnage settings: High setpoint • Low setpoint • • Repeatability setpoint NOTICE IMPORTANT Adjustments you make on this screen change the Program settings for the currently loaded tool.

  • Page 103: Low Setpoint Limits

    AutoSetPAC User Manual 1101600 Low Setpoint Limits To display low setpoint values (see Figure 4-10), press the F3 (Low Setpoint) function key. Figure 4-10. Adjust Setpoints Screen: Low Setpoint Limits Display The Low Setpoint Limits display shows the current low setpoint percentage, the most recently calculated low tonnage setpoints for each strain link using the displayed percentage, and the actual tonnage recorded for each strain link.

  • Page 104: Recalculating Setpoints

    1101600 AutoSetPAC User Manual Figure 4-11. Adjust Setpoints Screen: Repeatability Setpoint Limits Display To adjust the repeatability setpoint percentage up or down, press the Up Arrow () or Down Arrow () cursor key. Each keystroke increases or decreases the displayed value by 1 percent. As you adjust the repeatability setpoint percentage, the repeatability setpoint values for each strain link are updated, allowing you to see the results of your adjustments and to compare them with actual stroke- to-stroke tonnage values.
  • Page 105 AutoSetPAC User Manual 1101600 Figure 4-12. Main Program Menu with “RECALCULATE SETPOINTS” Warning Displayed 2. Press ENTER to confirm that you want to recalculate setpoints. The message SETPOINTS WILL BE RECALCULATED displays briefly on top of the warning message, and you are returned to the Main Program Menu.
  • Page 106 1101600 AutoSetPAC User Manual Chapter 4 Using AutoSetPAC in Program Mode...

  • Page 107: Chapter 5 Using Autosetpac In Run Mode

    Chapter 5 Using AutoSetPAC in Run Mode This chapter shows you how to use the screens in Run mode to adjust Program tool settings, recalculate setpoints, display setpoints and current tonnage information, and load a tool. The chapter is organized in the following sections: Accessing the Tonnage Monitor Run Menu ....................
  • Page 108 1101600 AutoSetPAC User Manual NOTICE A tool number must be loaded before switching to Run mode. If you attempt to switch to Run mode without a tool number loaded, the following message will display: NO TOOL NUMBER HAS BEEN LOADED To clear the message, turn the Program/Run key to “PROG,”...

  • Page 109: Displaying Tonnage In Plan View

    AutoSetPAC User Manual 1101600 Figure 5-2. Tonnage Monitor Run Menu Displaying Tonnage in Plan View When you select SHOW “PLAN” VIEW on the Tonnage Monitor Run Menu, the screen shown in Figure 5-3 displays. Figure 5-3. Tonnage “Plan” View Screen (4-channel AutoSetPAC Shown) The Tonnage Plan View screen displays the current tonnage at each strain link as a colored column filling some fraction of a graduated rectangular container.

  • Page 110: Displaying Tonnage In Bargraph View

    1101600 AutoSetPAC User Manual Yellow–Tonnage is within 25% of high or low setpoint • Red–Tonnage exceeds high or low setpoint • Tonnage is also shown in numerical form next to each rectangular container. Tonnage readings are shown in tenths of a ton (e.g., 27.8 tons) if the full-scale capacity of the press is less than 100 tons per channel, as whole numbers (e.g., 28 tons) if full-scale capacity is 100 tons or greater.

  • Page 111: Viewing And Adjusting Setpoints

    AutoSetPAC User Manual 1101600 Green–Tonnage is safely below high setpoint and safely above low setpoint • Yellow–Tonnage is within 25% of high or low setpoint • Red–Tonnage exceeds high or low setpoint • The scale of the bar graph (for instance, 7.0 through 20.1 in Figure 5-4) is determined by the tonnages recorded during the sample period and the setpoint calculations performed when the sample period has expired.

  • Page 112: High Setpoint Limits

    1101600 AutoSetPAC User Manual NOTICE If the ADJUST SETPOINTS function has been locked out of Run mode (see Locking Run Mode Actions, page 69), the following message displays at the bottom of the Adjust Setpoints screen, and you will not be able to adjust setpoints: THE TONNAGE MONITOR ADJUST MODE IS LOCKED OUT.

  • Page 113: Repeatability Setpoint Limits

    AutoSetPAC User Manual 1101600 To recalculate setpoints based on your change(s), refer to Recalculating Setpoints, page 114.. Figure 5-6. Adjust Setpoints Screen: Low Setpoint Limits Display Repeatability Setpoint Limits To display repeatability setpoint values (see Figure 5-7), press the F4 (Rep Setpoint) function key. Figure 5-7.

  • Page 114: Setpoint Calculation Period

    1101600 AutoSetPAC User Manual adjust the repeatability setpoint percentage, the repeatability setpoint values for each strain link are updated, allowing you to see the results of your adjustments and to compare them with actual stroke- to-stroke tonnage values. To recalculate setpoints based on your change(s), refer to Recalculating Setpoints, page 114.. Setpoint Calculation Period To display the sample period setting (see Figure 5-8), press the F5 (Sample Period) function key.

  • Page 115: Viewing Tonnage History

    AutoSetPAC User Manual 1101600 Press ENTER to confirm that you want to recalculate setpoints. The message SETPOINTS WILL BE RECALCULATED displays briefly on top of the warning message, and you are returned to the Adjust Setpoints screen. Setpoints are recalculated the next time you run the press and will appear on the appropriate Adjust Setpoints display (e.g., High Setpoint Limits, Low Setpoint Limits, etc.) the next time you access it.
  • Page 116 1101600 AutoSetPAC User Manual Figure 5-11. Tonnage History Display for “Left Rear” Input (#1) Chapter 5 Using AutoSetPAC in Run Mode...

  • Page 117: Table 5-1. Tonnage History Information For Each Strain Link Input

    AutoSetPAC User Manual 1101600 Table 5-1. Tonnage History Information for Each Strain Link Input Field Description # OF HITS The period of time, measured in number of strokes, during which AutoSetPAC has collected the displayed historical data. HIGHEST The highest tonnage recorded during the data collection period. LOAD This value is useful in cases of catastrophic damage, or when you need to determine whether tooling components failed due to...

  • Page 118: Viewing History For The Total Strain Link Tonnage

    1101600 AutoSetPAC User Manual Viewing History for the Total Strain Link Tonnage To view history for the total tonnage on all strain link inputs, select the TOTAL TONNAGE item on the Tonnage History Menu. A screen like the one shown in Figure 5-12 displays. Figure 5-12.

  • Page 119: Clearing Tonnage History

    AutoSetPAC User Manual 1101600 Clearing Tonnage History To delete all the information in tonnage history, press the F6 (Clear History) function key on the Tonnage History for Total Tonnage display. The following warning message (see Figure 5-13) displays, asking you to confirm that you want to clear tonnage history. Figure 5-13.

  • Page 120: Viewing Reverse Tonnage

    1101600 AutoSetPAC User Manual You should always recalculate setpoints when you have used the COPY TOOL function to create a new tool number. The copied tool will have the same percentages and the same setpoints as the original tool. If you create a new tool (not copying from an existing one), you do not have to recalculate setpoints.

  • Page 121: Loading A New Tool

    AutoSetPAC User Manual 1101600 Loading a New Tool NOTICE In order to load a new tool in Run mode, the LOAD TOOL # item on the Security Access Menu in Initialization mode must be set to “PROGRAM AND RUN MODES.” If this item has been set to “PROGRAM MODE ONLY,”...
  • Page 122 1101600 AutoSetPAC User Manual Figure 5-18. Tool Loading Message Chapter 5 Using AutoSetPAC in Run Mode...

  • Page 123: Chapter 6 Troubleshooting

    Chapter 6 Troubleshooting This chapter shows you how to respond to AutoSetPAC faults and perform troubleshooting on a few common AutoSetPAC problems. It is organized in the following sections: Responding to AutoSetPAC Faults ......................123 Setpoint Faults ............................125 Offset Errors ............................126 Troubleshooting Common AutoSetPAC Problems ..................

  • Page 124: Table 6-1. Common Causes Of Tonnage Faults

    1101600 AutoSetPAC User Manual Only one faulted channel is identified in an AutoSetPAC message, but setpoints for other strain link inputs may have been exceeded as well and other types of faults may have occurred. You can check to see if other channels are at fault by accessing the Adjust Setpoints screen (see Viewing and Adjusting Setpoints, page 111) and comparing the setpoint and tonnage value for each strain link.

  • Page 125: Setpoint Faults

    IMPORTANT INFORMATION TO PROVIDE WHEN CONTACTING WINTRISS TECH. SUPPORT When you contact Wintriss Tech. Support for technical assistance, be ready to provide the following information to expedite a resolution to the problem: product name (e.g. SmartPAC 2 standard); installed options (e.g. AutoSetPAC, etc.); and firmware version number (e.g. Vs. 2.00).

  • Page 126: Offset Errors

    1101600 AutoSetPAC User Manual 4. When the problem has been corrected, press RESET and restart the press. Table 6-2. Setpoint Faults: Possible Causes Setpoint Fault Possible Cause(s) Type Repeatability Change in the die due to: Slug stacking Misfeed End of stock Broken punch Change in material thickness or hardness Material feed problems...

  • Page 127: Troubleshooting Common Autosetpac Problems

    AutoSetPAC User Manual 1101600 Troubleshooting Common AutoSetPAC Problems The following sections show you how to troubleshoot problems you may encounter as you run the press with AutoSetPAC. Tonnage/WaveForm Menu Option Does Not Display at Power-up (Communications Error) 1. Verify that the AutoSetPAC processor board has power by testing both sides of fuse F102 (see Figure 2-6, page 37, or Figure 2-7, page 38).

  • Page 128: Displayed Tonnage Is Lower Than It Should Be

    • link connectors. e. If you are still having difficulty, contact Wintriss Tech. Support. Displayed Tonnage Is Lower Than It Should Be If the tonnage displayed for one or more strain links is lower than you think it should be, do the...

  • Page 129: Glossary

    Glossary NOTICE Cross-references to other glossary entries are shown in italics. high setpoint The tonnage limit above which AutoSetPAC generates a high tonnage fault, stopping the press and displaying a fault message. To calculate the high setpoint, AutoSetPAC multiplies the high setpoint percentage specified in Program mode by the reference tonnage and adds this value to the reference tonnage.
  • Page 130 1101600 AutoSetPAC User Manual setup mode A press operating mode that enables the press to be run in Inch without generating low setpoint or repeatability faults. With this setting enabled, AutoSetPAC disables low and repeatability setpoints whenever the press is operated in Inch.

  • Page 131: Index

    Index AC power gain potentiometers connecting to power source, 53 adjusting in AutoSetPAC, 89 powering up AutoSetPAC, 57 setting on AutoSet 2-Channel calibration kit, 84 wiring to AutoSetPAC, 36 AutoSet connecting to original SmartPAC, 56 high setpoints connecting to SmartPAC PRO or SmartPAC 2, 54 adjusting in Run mode, 112 viewing in Run mode, 110, 112 viewing/adjusting in Program mode, 102...

  • Page 132: Autosetpac User Manual

    (24 Vdc) strain links installing, 35 changing default input names, 66 mounting dimensions, 35 models available from Wintriss, 41 processor board (no enclosure), installing, 34 mounting, 42 processor board, location of components using a voltmeter to zero, 76...

This manual is also suitable for:

Autosetpac 24 vdc

Table of Contents