Wintriss wpc 2000 User manual

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Changes for Revision F of the WPC 2000 Option 2
User Manual (1130700)
This revision of the WPC 2000 Option 2 User Manual covers software version 2.00 and higher. This
manual also reflects the following associated product versions:
•SmartPAC PRO firmware version 10.40 or higher
•SmartPAC 2 firmware version 16.26 or higher
•WPC 2000 version 6.39 or higher.
The changes include:
•Added SmartPAC PRO screens and functions
•Revised Lube 1 Frequency maximum value to 65535 strokes or 283 minutes on the Press
Lubrication Setup screen (Chapter 3 –Setting Option 2 Initialization Parameters)
•Added ACTUATIONS setting for Monitor Switch Count on the Press Lubrication Setup
screen (Chapter 3 –Setting Option 2 Initialization Parameters)
•Revised documentation of fault code F160 (Chapter 6 –Troubleshooting)
•Added new fault code F149 (Chapter 6 –Troubleshooting)
•Added new fault code F163 (Chapter 6 –Troubleshooting)

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 number for technical support assistance. Call 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. Eastern Time. 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 email us a PO to o[email protected] 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. Eastern Time 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.

WPC 2000 Option 2 User Manual 1130700
Table of Contents 7
Table of Contents
Chapter 1 –Introduction...................................................................................................17
Expanded User Inputs....................................................................................................................17
Hydraulic Overload Control ..........................................................................................................18
Flywheel Brake Control.................................................................................................................19
Other Standard Features.................................................................................................................20
Motor Current Readout ...........................................................................................................20
Top-Stop Output Relay for Auxiliary Devices........................................................................20
Dual Safety Valve (DSV) Reset..............................................................................................20
Lube Control..................................................................................................................................20
Lube 1......................................................................................................................................20
Monitor 1 and 2.......................................................................................................................21
Speed Control ................................................................................................................................21
Specifications.................................................................................................................................22
Chapter 2 –Installation.....................................................................................................23
Installing the Option 2 Board.........................................................................................................23
Replacing Option 2 Firmware........................................................................................................26
Wiring User Inputs.........................................................................................................................28
Wiring Hydraulic Overload Inputs and Outputs............................................................................31
Wiring Flywheel Brake Inputs and Outputs ..................................................................................32
Wiring Top Stop Outputs...............................................................................................................32
Wiring Lube Control Inputs and Outputs ......................................................................................32
Wiring Analog Speed Control Inputs and Outputs........................................................................34
Installing and Wiring a Motor Current Transducer .......................................................................35
Installing the Transducer.........................................................................................................35
Wiring the Transducer.............................................................................................................35
Chapter 3 –Setting Option 2 Initialization Parameters...................................................39
Accessing the SmartPAC PRO Main Initialization Menu.............................................................39
Making and Viewing User Input Settings......................................................................................39
Setting User Input Stop Type and Name.................................................................................39
Viewing the Status of User Inputs...........................................................................................42
Accessing the Lube/Speed/Flywheel Brake Init. Menu.................................................................43
Making Flywheel Brake and Related Settings...............................................................................44
Setting Flywheel Brake Initialization Parameters...................................................................46
Enabling the “Dead Motor Inch” Feature................................................................................46
Setting Top Stop Output Mode................................................................................................47
Setting Maximum Transducer and Motor Current..................................................................47
Making Lube Control Settings.......................................................................................................48
Setting Lube 1 Initialization Parameters .................................................................................52
Setting Monitor 1 and 2 Initialization Parameters...................................................................54
Making Speed Control Settings.....................................................................................................58
Resetting a Dual Safety Valve (DSV)............................................................................................60
Viewing the Status of Option 2 Inputs and Outputs ......................................................................61
Chapter 4 –Setting Press Speeds in Program Mode......................................................63
Chapter 5 –Using Option 2 in Run Mode ........................................................................67
Calibrating Speed Control Settings................................................................................................67

1130700 WPC 2000 Option 2 User Manual
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Adjusting Press Speed................................................................................................................... 71
Monitoring Motor Current............................................................................................................. 72
Operating the Press in “Dead Motor Inch”.................................................................................... 74
Chapter 6 –Troubleshooting ...........................................................................................75
General Faults................................................................................................................................ 75
User Input Faults........................................................................................................................... 78
Hydraulic Overload Faults ............................................................................................................ 79
Flywheel Brake Faults................................................................................................................... 82
DSV Faults.................................................................................................................................... 82
Lube Faults.................................................................................................................................... 83
Speed Control Faults ..................................................................................................................... 85
Appendix A –Option 2 User Input Setup Sheet.............................................................87
Appendix B –Lube Control Setup Guide.......................................................................89
Index..................................................................................................................................91
Figures at End of Manual
Figure 1. WPC 2000 Plus Option 2 User Input External Wiring
Figure 2. WPC 2000 Option 2 External Wiring
List of Figures
Figure 2-1. Option 2 Board Installed on WPC 2000 Main Processor Board....................................... 24
Figure 2-2. Option 2 Board: Location of Important Components ....................................................... 29
Figure 2-3. Option 2 Board: LED Map................................................................................................ 37
Figure 3-1. SmartPAC PRO Main Initialization Menu........................................................................ 39
Figure 3-2. WPC Initialization Menu .................................................................................................. 40
Figure 3-3. Change User Interlocks Screen......................................................................................... 40
Figure 3-4. Press Control User Interlock Menu for Group 2 User Inputs............................................ 41
Figure 3-5. WPC Initialization Menu .................................................................................................. 42
Figure 3-6. Display WPC Input Status Screen..................................................................................... 42
Figure 3-7. WPC Interlock Group 2 Input Status Screen..................................................................... 43
Figure 3-8. SmartPAC PRO Main Initialization Menu........................................................................ 43
Figure 3-9. Lube/Speed/Flywheel Brake Initialization Menu.............................................................. 44
Figure 3-10. Flywheel Brake Setup Screen ......................................................................................... 44
Figure 3-11. Lube/Speed/Flywheel Brake Initialization Menu............................................................ 48
Figure 3-12. View or Change Lubrication Setup Menu....................................................................... 49
Figure 3-13. Press Lubrication Setup Screen....................................................................................... 49
Figure 3-14. Press Lubrication Setup Screen, INTERVAL................................................................. 55
Figure 3-15. Press Lubrication Setup Screen, ACTUATIONS ........................................................... 55
Figure 3-16. Press Lubrication Setup Screen with Monitor Switch Count Interval ............................ 55
Figure 3-17. Press Lubrication Setup Screen with Monitor Switch Count Actuations........................ 56
Figure 3-18. Lube/Speed/Flywheel Brake Initialization Menu............................................................ 58
Figure 3-19. Press Speed Setup Screen................................................................................................ 59
Figure 3-20. Dual Safety Valve Reset Function on WPC Initialization Menu.................................... 60
Figure 3-21. Display WPC Input Status Screen................................................................................... 61

WPC 2000 Option 2 User Manual 1130700
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Figure 3-22. WPC 2000 Option 2 I/O Status Screen............................................................................62
Figure 4-1. Edit Tool Program Menu...................................................................................................64
Figure 4-2. Press Control Parameters Screen.......................................................................................64
Figure 5-1. Main Run Menu.................................................................................................................68
Figure 5-2. Press Control Run Screen..................................................................................................68
Figure 5-3. Run Screen Showing PRESS SPEED While Press Is Running.........................................69
Figure 5-4. Press Control Run Screen Displaying Maximum Speed Values.......................................70
Figure 5-5. Press Control Run Screen Displaying Minimum Speed Values........................................70
Figure 5-6. Press Control Run Screen Displaying Motor Speed..........................................................71
Figure 5-7. Press Control Screen in Run..............................................................................................73
Figure 5-8. Motor Current Readings on Press Control Run Screen.....................................................73
Figure 6-1. Error Code Message ..........................................................................................................75
List of Tables
Table 1-1. Option 2 Specifications.......................................................................................................22
Table 2-1. Option 2 Board: CAN Bus Wiring Connections (TB605)..................................................25
Table 2-2. Option 2 Board: User Input Wiring Connections (TB601)................................................30
Table 2-3. Option 2 Board: Lube Control and Other Input Connections (TB603) ............................33
Table 2-4. Option 2 Board: Lube Control and Other Output Connections (TB606)..........................33
Table 2-5. Option 2 Board: Speed Control Connections (TB604).....................................................36
Table 3-1. Flywheel Brake Setup Screen Settings ...............................................................................45
Table 3-2. Press Lubrication Setup Screen Settings.............................................................................50
Table 3-3. Actuations Check Frequency ..............................................................................................57
Table 3-4. Press Speed Setup Screen Settings......................................................................................59
Table 4-1. Press Control Parameters Screen Settings...........................................................................65
Table 5-1. Press Control Run Screen Settings......................................................................................72
Table 6-1. WPC 2000 Option 2 User Input Fault Codes......................................................................78

1130700 WPC 2000 Option 2 User Manual
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