Wintriss WPC 1000 User manual

WPC 1000
®
Wintriss Clutch/Brake Control
1125100
Rev. R August 2015
UserUserUser
ManualManualManual
User
Manual
Tech Su ort Hotline [phone] EST
www.wintriss.com
®
®
Wintriss Controls Group, LLC
100 Discovery Way
Unit 110
Acton MA 01720 USA
Phone [phone]
Fax [phone]
PRINTED IN USA DA69447

Requirements You Must Meet
When Installing and Using the Wintriss Clutch/Brake Control
The Wintriss Clutch/Brake Control (WPC 1000) is designed solely for controlling operation of part-revolution metal
stamping presses. Before installing or using WPC 1000, be sure you understand and follow these requirements:
DANGER
!
FULL REVOLUTION MECHANICAL POWER PRESSES AND OTHER MACHINES CANNOT BE STOPPED IN MID-
STROKE OR MID-CYCLE
DO NOT use WPC 1000 clutch/brake control on full-revolution clutched machinery or other equipment that cannot be
stopped at any point in its stroke or cycle.
Use WPC 1000 clutch/brake control only on part-revolution clutched mechanical power presses as defined in OSHA
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.
DANGER
!
IMPROPER SAFEGUARDING
Ensure that the press on which WPC 1000 clutch/brake control is used meets all of the OSHA and ANSI regulations
for safeguarding press systems in installation and use. WPC 1000 is not in itself a safeguarding device. Wintriss
takes no responsibility for injury if safeguarding devices are not installed or working properly.
Install any two-hand control used as a safety device at least the safety distance away from the hazardous area; safety
distance is defined in the OSHA and ANSI regulations. Verify at each shift change that any moveable two-hand
control used as a safety device is located at least the safety distance away from the hazardous area.
Install any light curtain or curtains at least the safety distance away from the hazardous area; safety distance is
defined in the OSHA and ANSI regulations.
Install other safeguarding devices as needed to ensure operator safety. Follow the machine guarding requirements of
OSHA standard 1910.217 and any other regulations and standards that apply. Test safeguarding devices for correct
installation and operation after installation and after any modification or repair.
Ensure that guarding is properly installed to prevent access to the machine over, under or around any guarding
device.
Failure to comply with these instructions will result in death or serious injury.
DANGER
!
MORE OPERATORS THAN OPERATOR STATIONS
Ensure that there are the same number of active Operator Stations as there are operators, if the press is not equipped
with properly installed and operating light curtains.
During setup, lockout/tagout the press if there are more operators than Operator Stations.
Verify at every shift change that there are the same number of active Operator Stations as there are operators, if the
press is not equipped with properly installed and operating light curtains.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS WILL RESULT IN DEATH OR SERIOUS INJURY.
DANGER
!
NON-SAFETY OUTPUTS USED FOR SAFETY FUNCTIONS
Use auxiliary outputs and cam channels for non-safety functions only. They cannot protect personnel from a moving
hazard.
Failure to comply with these instructions will result in death or serious injury.
Read additional DANGER
!and
WARNING
!notices on following pages.

DANGER
!
IMPROPER INSTALLATION, USE OR MAINTENANCE
Ensure that the machinery complies with OSHA regulations 1910.217 and ANSI B11.1-2009.
Follow all procedures in this manual. Perform only the tests and repairs listed in this manual. Use only factory-
supplied replacement parts. Ensure that all safety procedures are followed during installation and operation of WPC
1000.
Wire and install WPC 1000 and other equipment according to the requirements of OSHA 1910.147 Control of
Hazardous Energy (Lockout/ Tagout).
Lockout/Tagout the press during all installation, modification, repair or maintenance procedures.
Ensure that the dual safety valve used on the press complies with OSHA 1910.217 (b) (7) (xi). Contact manufacturer
to verify compliance of your model.
Ensure that any foot control complies with OSHA 1910.217 (b) (7) (x).
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. Carry
out all inspection procedures in OSHA 1910.217
Install and maintain your machine guarding system according to OSHA standard 1910.217, ANSI B11.1, ANSI B11.19
and any other regulations and standards that apply. Ensure that guarding is properly installed to prevent access to the
machine over, under or around any guarding device.
Perform all installation verification and checkout tests after installation and after any modification or repair of the WPC
1000 clutch/brake control. Correct any problems before using the press.
Maintain all presses as stated in the applicable regulations. Wintriss takes no responsibility in cases where stopping
mechanisms of machinery or other devices are not maintained or do not meet the applicable regulations or standards.
Ensure that supervisors, die-setters, maintenance persons, machine operators, foremen, and any others responsible
for operation of the machinery have read and understood all instructions for use of the WPC 1000 clutch/brake control.
DO NOT use touch buttons for any safeguarding use.
Failure to comply with these instructions will result in death or serious injury.
x
WARNING
!
MACHINERY NOT CONFIGURED OR WORKING PROPERLY
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.
Failure to comply with these instructions could result in death or serious injury.
WARNING
!
OTHER EQUIPMENT CONTINUING TO OPERATE
Ensure that all operators and other affected personnel know which equipment may continue to operate and which will
not. Equipment that operates with the machinery connected to WPC 1000 clutch/brake control may continue to
operate after the press has received a stop signal.
Failure to comply with these instructions could result in death or serious injury.
WARNING
!
ELECTRIC SHOCK HAZARD
Turn off and disconnect power from WPC 1000 clutch/brake control, the press and any other machinery it is
connected to before making any wiring connections. This includes power to the press’s motor.
Failure to comply with these instructions could result in death or serious injury.
The enforcement of the above requirements is beyond Wintriss’s ability to control. For proper WPC 1000
operation, it is your responsibility to follow these requirements and any other requirements that may be
specific to your machinery.

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)

Thank you for purchasing a 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. We would like to share with you a list of
service options–probably the largest number of service options offered in the industry.
• Technical Assistance
We offer a toll-free line for technical assistance. Call our Wintriss Technical Support Hotline at
1-800-586-TECH (8324) should you have any questions about your equipment. Our technical
staff is ready to assist you Monday through Friday, 8 a.m. to 5 p.m. EST. In many cases our
experienced technical staff can resolve your inquiry right over the phone.
• Return Authorization
Please call our “800” number for a return authorization (RMA) number to return a product for
repair. Returned goods must arrive freight prepaid. In order to process your return quickly, we ask
that you provide us with the following pertinent information when you call: purchase order
number, shipping address, contact name and telephone number, and product type. The assigned
RMA number should appear on all packages returned to Wintriss Controls Group to ensure prompt
service.
At the time of requesting an RMA, you will be quoted a flat-rate repair price for the product you
are returning. We ask that you either fax us a PO for that amount or enclose the PO with the
returned item. This will enable us to ship the item back to you as soon as the repair has been
completed. If the item cannot be repaired or there are additional charges, you will be contacted for
approval.
Please be sure to carefully pack all returned items and ship to our Acton, MA location.
• Expedited Repair Program
Rush service providing 48 hour turnaround is available for most products upon request. An
Expedite Fee will be applied to our standard repair rate.
• Board Exchange Program
If your needs are urgent, you can take advantage of our Board Exchange (EX) program. Call our
“800” number between 8 a.m. and 5 p.m. EST and we will send a replacement to you overnight. A
fee does apply to this service. Contact Wintriss Technical Support at 800-586-8324 for details.
• Service Center
Our Service Center for product service is located at our headquarters in Acton MA. If your
equipment requires repair, please contact us at 800-586-8324 to obtain a return authorization
number.
Nationwide field service is also available. Contact the Wintriss Technical Support group at
800-586-8324.
• Product Training
We also offer both product training and maintenance/troubleshooting courses at our Acton, MA
and Chicago-area facilities. On-site training is available from the factory or through your local
Wintriss representative.
• Restocking Charge
Returned goods are subject to a 20% restocking charge if returned for credit. The minimum charge
is $50, not to exceed $250 per item.
Whatever the product, we are committed to satisfying you with innovative engineering, quality
construction, reliable performance, and ongoing, helpful support. Call us whenever you need
assistance.

Table of Contents i
Table of Contents
Chapter 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
WPC 1000 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Resolver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operator Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Other Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Dual-monitored Safety Valve (DSV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Clutch Air Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Shadow Light Curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Optional Counter and Crank-angle Clock Display . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Chapter 2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Installation Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Connecting Wires to Terminal Block Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Terminating Cable Shields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Mounting the Control Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Wiring the Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Slide Adjust Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Connecting AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Installing a Dual Safety Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Installing Clutch and Counterbalance Air Pressure Switches. . . . . . . . . . . . . .2-11
Installing Operator Station(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Wiring a Pre-wired Operator Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Checking Pre-wired Operator Station Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Making Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Wiring an Unwired Operator Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Wiring a User-built Operator Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Installing Multiple Operator Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Installing a Light Curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
Installing Shadow Light Curtains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Setting Jumpers for Shadow VII and Shadow 8 Light Curtains . . . . . . . . . . . . . . 2-19
Installing Non-Shadow Light Curtains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Installing the Resolver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Mounting the Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Wiring the Resolver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Checking the Resolver’s Direction of Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

1125100 WPC 1000 User Manual
ii Table of Contents
Replacing the Resolver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
Installing the Overrun Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Planning Your Overrun Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Mounting the Overrun Sensor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Wiring the Overrun Sensor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
Wiring WPC 1000 User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Wiring the Lockout Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Wiring the Auxiliary Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Connecting Multiple Controls to the Resolver . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Connecting Other Wintriss Products to WPC 1000. . . . . . . . . . . . . . . . . . . . . 2-32
Wiring Micro-inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Disabling Top-stop in Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Wiring a Remote Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Installing 2-channel Programmable Cam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Mounting and Wiring the Cam Output Assembly . . . . . . . . . . . . . . . . . . . . . . . . .2-34
Making Wiring Connections to Cam Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37
Wiring Zero Cam Output to AutoSet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Wiring Foot Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Installing One-hand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Mounting the One-hand Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41
Wiring One-hand Control to WPC 1000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43
Mounting and Wiring the Bar Control Enclosure . . . . . . . . . . . . . . . . . . . . . . 2-45
Installing Revised Firmware in WPC 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Installing WPC 1000 without Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Installing the WPC 1000 Mounting Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
Installing the Panel-mount Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49
Mounting the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49
Connecting the Panel-mount Display to the WPC 1000 Control Board . . . . .2-50
Installing Selector Switches and Final Assembly . . . . . . . . . . . . . . . . . . . . . .2-51
Installing Display Board Kit with Selector Switches . . . . . . . . . . . . . . . . . . . . . . .2-52
Installing the Display Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55
Installing the Multicolored Ribbon Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55
Installing the Shielded Gray Ribbon Cable . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Installation Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
Checking Safeguarding Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66
Checking Dual Safety Valve (DSV) Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67
Checking for Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68
Checking the Emergency-stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68
Installation Verification Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68
Wiring Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

WPC 1000 User Manual 1125100
Table of Contents iii
Chapter 3. Initialization, Setup, and Checkout . . . . . . . . . . . . . .3-1
Viewing and Setting Press Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Initializing the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Re-zeroing the Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Initializing Only the Start-time Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Viewing the Start-time Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Viewing the Last Start Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Installing the Overrun Sensor Magnet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Setting the Top-stop “On” Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Mounting the Overrun Sensor Magnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Adjusting the Top-stop Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Setting the Auto Carry-up Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Running Brake Monitor Tests and Making Settings. . . . . . . . . . . . . . . . . . . . .3-15
Determining the Stopping Time of Your Press . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Calculating the Stop-time Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Setting the Stop-time Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Determining the 90° Stop Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Performing the 90° Stop Test (Continuous Mode) . . . . . . . . . . . . . . . . . . . . . 3-18
Performing the 90° Stop Test (Single-stroke Mode) . . . . . . . . . . . . . . . . . . . . 3-19
Calculating the Safety Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
ANSI and OSHA Safety Distance Formulas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
ANSI Safety Distance Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
OSHA Safety Distance Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Adding to Safety Distance for Blanking Windows . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Setting Micro-Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
Setting Press Option Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
Switches 1 and 2 – Top-stop “On” Angle Range . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Switch 3 – One-hand Control and Foot Switch Settings. . . . . . . . . . . . . . . . . . . . 3-28
Enabling Light Curtain Break Mode in a One-hand Control . . . . . . . . . . . . . 3-28
Enabling Foot Control in a Foot Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Switch 4 – Enabling Auto Compensated Top Stop (ACTS) . . . . . . . . . . . . . . . . . 3-29
Switch 5 – Selecting Concurrent Time for Multiple Op. Stations. . . . . . . . . . . . . 3-30
Switch 6 – Enabling Access to Cam Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Switch 7 – Disabling Access to Stop-time Limit and Auto Carry-up Angle
Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Switch 8 – Top-stop Mode for F and H Errors and Auxiliary Output 1
Response to Interrupted Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Selecting Top-stop Mode for F and H Errors . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Auxiliary Output 1 Response to Interrupted Stroke . . . . . . . . . . . . . . . . . . . . 3-32
Setting Programmable Cams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33
Final Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
Checking the Emergency-stop Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Checking the Top-stop Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Checking for Faults When the Press Is Running. . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Power Supply Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Shadow Light Curtain Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
System Static Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

1125100 WPC 1000 User Manual
iv Table of Contents
Single-stroke Mode Test with Light Curtain(s) . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
Single Stroke Mode Test Without Light Curtain(s) . . . . . . . . . . . . . . . . . . . . . . . .3-44
Anti-tiedown Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
Anti-repeat Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46
Continuous Mode Test with Light Curtain(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
Continuous Mode Test without Light Curtain(s) . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
Foot Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50
One-hand Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
Bar Mode Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53
Checking Operation of the User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54
Chapter 4. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Responding to an Interrupted Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Responding to a Brake Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Displaying and Clearing the Stroke Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Viewing the Counter Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Resetting the Counter Value to Zero. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Setting and Maintaining the Counter Preset Value . . . . . . . . . . . . . . . . . . . . . . 4-5
Setting the Counter Preset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Disabling the Counter Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Forcing the Counter Preset Value to 999999 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Operating the Press in Inch Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Top-stop in Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Top-stop Bypass (Top-stop in Inch Disabled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Micro-inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Dead Motor Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Operating the Press in Single-stroke Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Single-stroke, Two-hand Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Single-stroke, One-hand Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Single-stroke, One-hand Control Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Single-stroke, Foot Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Operating the Press in Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Continuous, Two-hand Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Continuous, Foot Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
Operating the Press in Bar Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Multiple Operator Stations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Chapter 5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Responding to WPC 1000 Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Lockout Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Brake Monitor Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Brake Warning LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Stop Time Exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

WPC 1000 User Manual 1125100
Table of Contents v
E, F, and H Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Resolver Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Operational Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Inter-processor Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Input Buffer Test Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Component Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Customized Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Light Curtain Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Emergency-stop Circuit Driver Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Top-stop Circuit Driver Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
DSV Interface and Lockout Relay Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Loss of Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Internal Timing Input Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Top-stop and Overrun Setting Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Overrun Limit Switch Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Overrun Limit Switch Test Angle Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Overrun Limit Switch Setting Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Internal Memory Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Resetting Ross DM2 DSV Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
Appendix A. Extracts from OSHA Regulations and ANSI
Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Extracts from OSHA Regulation 1910.217. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Extracts from ANSI Standards for Presence-sensing Devices and Two-hand
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Appendix B. Specifications for User-built Operator Stations. . . .B-1
Run Button Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Switch Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Appendix C. Old Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Wintriss Manuals

1125100 WPC 1000 User Manual
vi Table of Contents
Figures at End of Manual
Figure 1. WPC 1000 Operator Station, Foot Switch and Bar Control Wiring
Figure 2. WPC 1000 Shadow VI and Cam Output Wiring
Figure 3. WPC 1000 Resolver and Interlock Wiring
Figure 4. WPC 1000 Stroke Select Wiring, Herion and Ross DSV Wiring
Figure 5. WPC 1000 Unwired Operator Station Wiring Diagram
Figure 6. WPC 1000 Shadow V Wiring
Figure 7. WPC 1000 Shadow VI Integrated and Cam Output Wiring
Figure 8. WPC 1000 and Shadow VII Wiring
Figure 9. Shadow VII DIN Module WPC 1000 Wiring
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. WPC 1000 Control Panels .............................................................................................1-2
Figure 1-2. Operator Station Components (Side-mounted Run/Inch Palm Buttons) ....................... 1-3
Figure 1-3. WPC 1000 Displays ....................................................................................................... 1-5
Figure 2-1. WPC 1000 Wiring Overview .........................................................................................2-4
Figure 2-2. Correct Way to Attach Wires to Terminal Block Connectors ....................................... 2-5
Figure 2-3. Cable Shield Termination .............................................................................................. 2-6
Figure 2-4. WPC 1000 Mounting Dimensions .................................................................................2-7
Figure 2-5. AC Input Wiring Connections ....................................................................................... 2-9
Figure 2-6. Pre-wired Operator Stations Showing Mute Lamp Connections ................................2-13
Figure 2-7. Wiring Steps to Modify Operator Station for WPC 1000 ...........................................2-14
Figure 2-8. Pre-wired Operator Station with Side Run Buttons: Mounting Dimensions ...............2-15
Figure 2-9. Pre-wired Operator Station with Top Run Buttons: Mounting Dimensions ...............2-15
Figure 2-10. Unwired Operator Station: Mounting Dimensions ......................................................2-16
Figure 2-11. WPC 1000 Control Board with DSV/Lockout Relay Board: Location of
Important Components ................................................................................................2-20
Figure 2-12. WPC 1000 Control Board with DSV/Lockout Relay Board Removed: Location
of Important Components ............................................................................................ 2-21
Figure 2-13. Resolver: Mounting Dimensions .................................................................................2-23
Figure 2-14. Overrun Sensor Magnet Placement: Dwell as a Function of Shaft Diameter .............2-26
Figure 2-15. Overrun Sensor Magnetic Switch: Installation Example .............................................2-27
Figure 2-16. WPC 1000 Display Board: Location of Important Components ................................. 2-33
Figure 2-17. Cam Output Enclosure: Mounting Dimensions ...........................................................2-35
Figure 2-18. Cam Output Board: Mounting Dimensions .................................................................2-36
Figure 2-19. Connectors TB2 and TB3 on Cam Output Board ........................................................ 2-37
Figure 2-20. Installing a Suppressor across an AC Load .................................................................2-38
Figure 2-21. Installing a Diode across a DC Load ...........................................................................2-39
Figure 2-22. One-hand Control Switch: Mounting Dimensions ......................................................2-42
Figure 2-23. One-hand Control Switch Base: Mounting Dimensions ............................................. 2-43
Figure 2-24. Wiring Connections in One-hand Control Switch .......................................................2-44
Figure 2-25. Bar Control Enclosure: Mounting Dimensions ...........................................................2-45

WPC 1000 User Manual 1125100
Table of Contents vii
Figure 2-26. WPC 1000 Mounting Plate: Mounting Dimensions ....................................................2-48
Figure 2-27. WPC 1000 Panel Mount Display: Mounting and Cutout Dimensions ........................2-50
Figure 2-28. Selector Switch: Cutout Dimensions ...........................................................................2-51
Figure 2-29. WPC 1000 Display Board Kit: Mounting and Cutout Dimensions .............................2-53
Figure 2-30. Reset/Select Button Wiring Connections .....................................................................2-54
Figure 2-31. Multicolored Ribbon Cable with Connector ................................................................2-55
Figure 2-32. Display Cable (Multicolored) with Gray Stripes Indicating Flat Area ........................2-56
Figure 2-33. Display Cable Jacket with Multicolored Ribbon Cable Exposed ................................2-57
Figure 2-34. Ribbon Cable Connector Assembly .............................................................................2-57
Figure 2-35. Connector Top with Multicolored Ribbon Cable Conductors .....................................2-58
Figure 2-36. Multicolored Ribbon Cable Conductors Being Laid on Connector Top .....................2-58
Figure 2-37. Connector Halves Brought Together (Multicolored Conductors) ...............................2-59
Figure 2-38. Strain Relief Installed on Connector (Multicolored Conductors) ................................2-60
Figure 2-39. Gray Ribbon Cable with Connector and Insulated Shield ...........................................2-61
Figure 2-40. Display Cable Jacket with Gray Ribbon Cable and Shield Exposed ...........................2-62
Figure 2-41. Connector Top with Gray Ribbon Cable Conductors and Shield ................................2-63
Figure 2-42. Gray Ribbon Cable Conductors Being Laid on Connector Top ..................................2-63
Figure 2-43. Connector Halves Brought Together (Gray Conductors) ............................................2-64
Figure 2-44. Strain Relief Installed on Connector (Gray Conductors) .............................................2-65
Figure 3-1. WPC 1000 Displays Showing Indicator Segments ........................................................3-2
Figure 3-2. WPC 1000 Displays Showing “System Initialized” (“Int”) Message ............................3-4
Figure 3-3. WPC 1000 Displays Showing “Resolver Zeroed” (“rES”) Message .............................3-5
Figure 3-4. WPC 1000 Displays Showing “Initializing Start-time Limit” (“Str”) Message ............3-6
Figure 3-5. Setting Overrun Timing: Example ...............................................................................3-10
Figure 3-6. WPC 1000 Displays Showing Overrun Sensor “On” Angle .......................................3-11
Figure 3-7. WPC 1000 Displays Showing Stop-time Limit Value .................................................3-17
Figure 3-8. WPC 1000 Displays Showing Results of 90° Stop-time Test .....................................3-18
Figure 3-9. Safety Distance: Distance between Pinch Point and Light Curtain .............................3-20
Figure 3-10. WPC 1000 Displays Showing Micro-inch Time Setting .............................................3-26
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. WPC 1000 Optional Counter Display with “Counter” Value Shown ............................4-4
Figure 4-2. WPC 1000 Optional Counter Display with “Counter Preset” Value Shown .................4-6
Figure 5-1. WPC 1000 Displays Showing Fault Code .....................................................................5-2
Figure 5-2. WPC 1000 Displays Showing Lockout Message ...........................................................5-3
Figure 5-3. WPC 1000 Display Showing Stopping Time Fault .......................................................5-4
Figure 5-4. Ross DM2 DSV Showing Reset Button .......................................................................5-18
Figure C-1. Old WPC 1000 Control Board with DSV/Lockout Relay Board: Location of
Important Components ..................................................................................................C-1

1125100 WPC 1000 User Manual
viii Table of Contents
List of Tables
Table 1-1. WPC 1000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Table 2-1. Shadow VII and Shadow 8 Light Curtain Jumper Settings . . . . . . . . . . . . . . . . . . . . . 2-19
Table 2-2. Overrun Sensor Switch Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Table 2-3. WPC 1000 User Inputs: Stop Types, Fault Codes, and Wiring Connections . . . . . . . 2-29
Table 2-4. Lockout Relay Wiring Connections (DSV/Lockout Relay Board) . . . . . . . . . . . . . . . 2-30
Table 2-5. Auxiliary Output 1 Wiring Connection and Change Conditions . . . . . . . . . . . . . . . . . 2-30
Table 2-6. Option Switch 8 Settings for Auxiliary Output 1 State Changes . . . . . . . . . . . . . . . . . 2-31
Table 2-7. Micro-inch Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Table 2-8. Remote Reset Switch Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Table 2-9. WPC 1000 Control Board to Cam Output Assembly (TB1) Wiring Connections . . . 2-36
Table 2-10. Zero Cam Output Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Table 2-11. Foot Switch Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Table 2-12. One-hand Control Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Table 2-13. Bar Control Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Table 2-14. Selector Switch Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Table 2-15. Reset Button, Settings Key Switch, and Mute Lamp Wiring Connections . . . . . . . . . 2-54
Table 2-16. WPC 1000 Control Board: TB101 and TB102 Wiring Connections . . . . . . . . . . . . . . 2-69
Table 2-17. WPC 1000 Control Board: Resolver (TB103) Wiring Connections . . . . . . . . . . . . . . 2-70
Table 2-18. WPC 1000 Control Board: DSV/Lockout Relay Board Wiring Connections . . . . . . . 2-70
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. WPC 1000 Standard Display Default Parameters (Press Running) . . . . . . . . . . . . . . . . 3-2
Table 3-2. WPC 1000 Optional Counter Display Default Parameters (Press Running) . . . . . . . . . 3-3
Table 3-3. Overrun Sensor Magnet Location and Option Switch Settings . . . . . . . . . . . . . . . . . . . 3-9
Table 3-4. Shadow Light Curtain Response Time and Object Sensitivity . . . . . . . . . . . . . . . . . . 3-22
Table 3-5. Switches 1 and 2 Settings: Top-stop “On” Angle Range . . . . . . . . . . . . . . . . . . . . . . . 3-27
Table 3-6. Switch 3 Settings: Enabling Light Curtain Break Mode . . . . . . . . . . . . . . . . . . . . . . . 3-28
Table 3-7. Switch 3 Settings: Enabling Foot Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Table 3-8. Switch 4 Settings: Enabling ACTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Table 3-9. Switch 5 Settings: Selecting Concurrent Time for Multiple Operator Stations . . . . . . 3-30
Table 3-10. Switch 6 Settings: Enabling Cam Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Table 3-11. Switch 7 Settings: Disabling Access to Stop-time Limit and Auto Carry-up Angle . . 3-31
Table 3-12. Switch 8 Settings: Top-stop Mode for F and H Errors . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Table 3-13. Switch 8 Setting: Auxiliary Output 1 Response to Interrupted Stroke . . . . . . . . . . . . 3-32
Table 5-1. Fault Codes: Significance of Initial Letter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Table 5-2. Fault Codes for User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Table B-1. Operator Station Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Table B-2. Specifications for Operator Station Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Table C-1. Differences between New and Old Control Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

WPC 1000 User Manual 1125100
Table of Contents ix
How To Use This Manual
This manual shows you how to install, set up, operate, and troubleshoot the WPC 1000
Wintriss Clutch/Brake Control.
Chapter 1 provides an overview of WPC 1000 features and components, describes the
locations and functions of the switches and LEDs on the front panel and display, and lists
WPC 1000 specifications.
Chapter 2 shows you how to install both enclosure and non-enclosure versions of WPC 1000,
including optional components, and perform installation verification tests.
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.
Chapter 5 shows you how to respond to and correct the fault codes that appear on the display
when WPC 1000 detects an error.
Appendix A provides OSHA regulations and ANSI standards pertaining to the use of
presence-sensing devices for point-of-operation guarding on mechanical power presses.
Appendix B provides the safety standards you must meet when building your own Operator
Station.
Appendix C provides a drawing of the old WPC 1000 Control board and explains differences
between the old and new boards.
The Glossary explains some terms that may be unfamiliar to you.
Figures at the back of the manual provide wiring diagrams that you can use in conjunction
with the instructions in Chapter 2 to wire WPC 1000 and its components.

1125100 WPC 1000 User Manual
xTable of Contents
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.
A CAUTION symbol indicates a potentially hazardous situation, which, if not avoided, may result in
property damage.
A NOTICE symbol indicates important information that you should remember, including tips to aid
you in performance of your job.
DANGER
!
WARNING
!
CAUTION
NOTICE

WPC 1000 User Manual 1125100
Table of Contents xi
Wintriss Controls Group, LLC WPC 1000 CLUTCH/BRAKE CONTROL
100 Discovery Way USER MANUAL
Unit 110 1125100
Acton, MA 01720 ©2015 Wintriss Controls Group, LLC
Telephone: (800) 586-TECH (8324)
[phone]
Fax: [phone]
Internet: http://www.wintriss.com
WARRANTY
Wintriss Controls warrants that Wintriss electronic controls are free from defects in
material and workmanship under normal use and service for a period of one year (two
years for Shadow light curtains) from date of shipment. All software products (LETS/
SFC and SBR), electro-mechanical assemblies, and sensors are warranted to be free
from defects in material and workmanship under normal use and service for a period
of 90 days from date of shipment. Wintriss’s obligations under this warranty are
limited to repairing or replacing, at its discretion and at its factory or facility, any
products which shall, within the applicable period after shipment, be returned to
Wintriss Controls freight prepaid and which are, after examination, disclosed to the
satisfaction of Wintriss to be defective. This warranty shall not apply to any equipment
which has been subjected to improper installation, misuse, misapplication, negligence,
accident, or unauthorized modification. The provisions of this warranty do not extend
the original warranty of any product which has either been repaired or replaced by
Wintriss Controls. No other warranty is expressed or implied. Wintriss accepts no
liability for damages, including any anticipated or lost profits, incidental damages,
consequential damages, costs, time charges, or other losses incurred in connection
with the purchase, installation, repair or operation of our products, or any part thereof.
Please note:
It is solely the user’s responsibility to properly install and maintain Wintriss controls
and equipment. Wintriss Controls manufactures its products to meet stringent
specifications and cannot assume responsibility for consequences arising from their
misuse.

1125100 WPC 1000 User Manual
xii Table of Contents

Introduction 1-1
Chapter 1. Introduction
WPC 1000 Wintriss Clutch/Brake Control is an easy-to-use, dual-microprocessor-based
system that controls part-revolution mechanical power presses. Housed in a single modular
enclosure, both microprocessors function independently, have different power supplies, and
provide separate information to the operator. As a result of its “dual diverse redundancy,”
WPC 1000 is able to provide optimum clutch/brake control and improved operator safety
while increasing productivity.
WPC 1000 meets or exceeds all ANSI B11.1-2009 standards and OSHA 1910.217 regulations
for Control Reliability, the benchmarks that govern the operation of mechanical power
presses. Control Reliability demands that a single component failure in a clutch/brake control
circuit not prevent the normal stopping action of the press, not create an unintended stroke,
and not allow initiation of a subsequent stroke until the failure has been corrected.
WPC 1000 Components
WPC 1000 can be configured as a complete system with all the components necessary to
operate a pneumatic clutch/brake system.
Resolver
The resolver, which is mounted on the press, turns one-to-one (1:1) with the crankshaft,
allowing WPC 1000 to know the exact position of the crankshaft on every stroke.
The resolver is similar to an electrical generator and works on the principle of inductance.
The resolver’s two outputs vary in amplitude and phase as the resolver turns. WPC 1000
translates these analog signals to a number that indicates the position of the resolver (and
press crankshaft) in degrees.
The resolver eliminates the need for a mechanical rotary limit switch. Operators no longer
have to climb on top of the press to make timing adjustments. In addition, the resolver on the
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). Three selector key switches are available:
•Stroke Select (Standard)–Provides settings for selection of either Inch, Single-stroke, or
Continuous operation or Inch or Single-stroke.
•Mode Select (Optional)–Provides settings for selection of One-hand, Two-hand, or Foot
operation. Optional One-hand/Two-hand/Foot firmware is required for use of One-hand
and Foot settings.

1125100 WPC 1000 User Manual
1-2 Introduction
•Micro-inch (Optional)–Provides a setting for turning on the Micro-inch feature (see
Standard Features, page 1-7).
There are two display options: standard and optional counter/crank-angle clock (see Displays,
page 1-4).
Figure 1-1. WPC 1000 Control Panels
MICRO INCH
O
N
O
F
F
MODE SELECT
1
H
A
N
D
2
H
A
N
D
F
O
O
T
WPC SETTINGSRESET/SELECT MUTE
INTERRUPTED STROKE
BRAKE WARNING
TOP STOP ANGLE
AUTO CARRYUP
ANGLE / SPM
90° STOP TEST
STOP TIME LIMIT
MICRO-INCH
STOPPING TIME
STOPPING ANGLE
CAM 1
off
on
CAM 2
off
on
WPC 1000
Wintriss Clutch/Brake Control
WPC 1000 Center Mount
Standard Displa
WPC 1000 Center Mount with Optional
Counter/Crank Angle Clock Displa
WPC 1000 Left-side Mount
Standard Displa
WPC SETTINGSRESET/SELECT MUTE
INTERRUPTED STROKE
BRAKE WARNING
TOP STOP ANGLE
AUTO CARRYUP
ANGLE / SPM
90° STOP TEST
STOP TIME LIMIT
MICRO-INCH
STOPPING TIME
STOPPING ANGLE
CAM 1
off
on
CAM 2
off
on
WPC 1000
Wintriss Clutch/Brake Control
STROKE SELECT
O
F
F
I
N
C
H
S
I
N
G
L
E
C
O
N
T
MODE SELECT
1
H
A
N
D
2
H
A
N
D
F
O
O
T
MICRO INCH
O
N
O
F
F
WPC 1000
Wintriss Clutch/Brake Control
WPC SETTINGSRESET/SELECT MUTE
BRAKE WARNING
INTERRUPTED STROKE
TOP STOP ANGLE
AUTO CARRYUP
STOP TIME LIMIT
MICRO-INCH
STOPPING TIME
STOPPING ANGLE
90° STOP TEST
COUNTER
COUNTER PRESET
ANGLE / SPM
MODE SELECT
1
H
A
N
D
2
H
A
N
D
F
O
O
T
MICRO INCH
O
N
O
F
F
Micro Inch
Key Switch
(optional)
MICRO INCH
O
N
O
F
F
Mode Select
Key Switch
(optional)
MODE SELECT
1
H
A
N
D
2
H
A
N
D
F
O
O
T
Stroke Select
Key Switch
available as
OFF/INCH/SINGLE
and
OFF/INCH/SINGLE/CONT
STROKE SELECT
O
F
F
I
N
C
H
S
I
N
G
L
E
C
O
N
T
STROKE SELECT
O
F
F
I
N
C
H
S
I
N
G
L
E
STROKE SELECT
O
F
F
I
N
C
H
S
I
N
G
L
E
C
O
N
T
STROKE SELECT
O
F
F
I
N
C
H
S
I
N
G
L
E
C
O
N
T

WPC 1000 User Manual 1125100
Introduction 1-3
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).
Figure 1-2 shows the switches and indicator lamps on an Operator Station with side-mounted
Run/Inch palm switches. Functions of these components are shown below.
•Run/Inch Palm Switches (2)–Initiate press action when both switches are pressed at the
same time (Two-hand mode) or when only the left switch is pressed (One-hand mode).
•Prior Act Lamp and Switch–An arming device that must be pressed in Continuous Two-
hand and Continuous Foot operating modes before a stroke can be initiated. When the
switch is pressed, the lamp illuminates for 8 seconds, indicating the interval within which
the operator must press the Run/Inch buttons or Foot Switch in order to stroke the press.
•Emergency Stop Switch–Stops the press immediately when you push it. The switch is not
spring-loaded, so you must pull it back to its original position to clear the emergency stop
(F13) fault (see page 5-7).
•Top Stop Switch–Stops the press at the top of its stroke when pressed during Continuous
operation.
•Palm Time Lamp–Illuminates when one Run/Inch palm button is depressed, turning off
after the 1/2 second palm time (“synchronous” time in ANSI terminology) on a standalone
Operator Station or the 5 second concurrent time on multiple Operator Stations. The other
palm button on a standalone Op. Station or all pairs of buttons on multiple Operator
Stations must be pressed before the lamp turns off in order to initiate a stroke. The palm/
concurrent time setting is made on option switch 5 (see page 3-30).
•Mute Lamp–Illuminates during muting of the light curtain on the upstroke. Requires
installation of a Shadow light curtain and optional light curtain muting firmware.
Figure 1-2. Operator Station Components (Side-mounted Run/Inch Palm Buttons)
PRIOR ACT
switch
PALM TIME
lamp
MUTE
lamp
TOP STOP
switch
EMERGENCY STOP
switch
RUN / INCH
palm switches
RUN/
INCH
RUN/
INCH
PALM
TIME
PRIOR
ACT
MUTE
TOP
STOP
WINTRISS
E
M
E
R
G
E
N
C
Y
S
T
O
P