Wintriss autoset 1500 User manual

AutoSet
Wintriss Load Analyzers
including 1500 and 1500 Plus Two-channel Models
and 1504 and 1504 Plus our-channel Models
1137200
Rev. L November 2016
UserUserUser
ManualManualManual
User
Manual
Tech Support Hotline [phone] EST
www.wintriss.com
®
®
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Wintriss Controls Group, LLC
100 Discovery Way
Unit 110
Acton MA 01720 USA
Phone [phone]
Fax [phone]
PRINTED IN USA DA71510

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.

Changes for Revision L of the
AutoSet User Manual (1137200)
This revision of the AutoSet user manual covers AutoSet software version 2.28 and higher.
The changes include:
•Removed obsolete references.

Table of Contents i
Table of Contents
Chapter 1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Standard AutoSet Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
AutoSet Plus Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
AutoSet Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Strain Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
AutoSet Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
AutoSet Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
AutoSet Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Chapter 2. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mounting AutoSet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Mounting an AutoSet Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installing an AutoSet Panel Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Connecting AC and Stop Circuit Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Installing Strain Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
Mounting Strain Links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Wiring Strain Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Installing a Zero Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
Using a Zero Cam on Standard AutoSets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Using a Zero Cam on AutoSet Plus Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Installing the Latching Magnetic Cam Switch (LMCS) . . . . . . . . . . . . . . . . . . . . 2-17
Optional Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
Wiring a Remote Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Wiring an Oscilloscope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Wiring a Setup Mode Circuit (AutoSet Plus Only) . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Connecting an AutoSet to SmartPAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
Connecting an AutoSet to SmartPAC 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Connecting an AutoSet to SmartPAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Connecting AC Wires to Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
Powering Up AutoSet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
Chapter 3. Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Zeroing Strain Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Using a Voltmeter to Zero Strain Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Recording Tonnage on an AutoSet Calibration Kit. . . . . . . . . . . . . . . . . . . . . . .3-5
Setting Up and Adjusting the Calibration Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Applying Full-scale Tonnage to the Calibration Kit . . . . . . . . . . . . . . . . . . . . . . . 3-11
Setting Full-scale Tonnage on Your AutoSet . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

1137200 AutoSet User Manual
ii Table of Contents
Adjusting AutoSet to Read the Correct Tonnage. . . . . . . . . . . . . . . . . . . . . . . 3-15
Checking Linearity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Final Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Chapter 4. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
AutoSet’s Setpoint Calculation Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Setting the Sample Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Setting the Percent High Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Setting the Percent Repeatability Tolerance (AutoSet Plus Only). . . . . . . . . . . 4-6
Determining the Correct High Tolerance Setting (Standard AutoSet) . . . . . . . 4-8
Determining the Correct High Tolerance and Repeatability Settings (AutoSet
Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Changing Setpoint Percentage Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Recalculating Setpoints after a Tool Change . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Displaying Reverse Load (AutoSet Plus Only) . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Four-Channel to Two-Channel Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Disabling AutoSet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Turning Off and Restoring Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Chapter 5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Responding to AutoSet Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
High Tonnage Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Repeatability Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
High Setpoint and Repeatability Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Offset Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Troubleshooting Common AutoSet Problems . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Load or Setpoints LED Displays Are Blank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Front Load and Setpoints LED Displays Are Blank (4-Channel Units). . . . . . . . . . 5-6
Load LED Display(s) Shows Zero Tonnage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Tonnage Shown in Load LED Displays Is Too Low . . . . . . . . . . . . . . . . . . . . . . . . 5-6
New Installation or Calibration 6
Existing Installation 6
Using LEDs As Diagnostic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Remote Reset, Zero Cam, and Setup LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Reset, Repeatability Select, and Reverse Select LEDs. . . . . . . . . . . . . . . . . . . . . . . 5-7
Power Supply LEDs, +5V and ±12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Relay Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

AutoSet User Manual 1137200
Table of Contents iii
Appendix A. Wiring and Settings Tables. . . . . . . . . . . . . . . . . . . . .A-1
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Wintriss Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1
List of Figures
Figure 1-1. AutoSet 1500 Front Panel ..............................................................................................1-3
Figure 1-2. AutoSet 1504 Plus Front Panel ......................................................................................1-3
Figure 2-1. AutoSet 1500 Mounting Dimensions .............................................................................2-2
Figure 2-2. AutoSet 1504 Mounting Dimensions .............................................................................2-2
Figure 2-3. AutoSet Panel Mount: Mounting and Cutout Dimensions ............................................2-4
Figure 2-4. AutoSet 1500 Processor Board: Location of Important Components ............................2-6
Figure 2-5. AutoSet 1504 Processor Board: Location of Important Components ............................2-7
Figure 2-6. AC Power Connections ..................................................................................................2-8
Figure 2-7. Correct Way To Make Terminal Block Connections ....................................................2-9
Figure 2-8. Strain Link: Mounting Dimensions ..............................................................................2-10
Figure 2-9. Strain Link Mounting Options on Gap-frame Presses .................................................2-11
Figure 2-10. Strain Link Mounting Options on Straight-side Presses ..............................................2-12
Figure 2-11. Strain Link Drill Jig: Mounting Dimensions ...............................................................2-13
Figure 2-12. Shield Drain Wire Connected to Ground Stud on Enclosure .......................................2-16
Figure 2-13. LMCS Installation ........................................................................................................2-18
Figure 2-14. AutoSet 1504 Processor Board: Mode Switch #2 Set to ON (Zero Cam Enabled) .....2-20
Figure 2-15. AutoSet 1504 Processor Board: Mode Switch #6 Set to OFF (AutoSet 1) .................2-24
Figure 3-1. Potentiometer Adjustment Screw on Strain Links without Access Hole in Cover ........3-2
Figure 3-2. AutoSet 1500 Calibration Kit Processor Board: Old Style ............................................3-6
Figure 3-3. AutoSet 1500 Calibration Kit Processor Board: New Style ..........................................3-7
Figure 3-4. Tonnage Dial Indicators: Old-style Board (Left), New-style Board (Right) .................3-9
Figure 3-5. Mode Switch #3 Set to “Decimal Point Off” Position (Old-style Processor Board) .....3-9
Figure 3-6. Load Cell Gain Adjustment Potentiometer with Adjustment Screw ...........................3-10
Figure 3-7. AutoSet 1504 Processor Board: Tonnage Dial Indicators ...........................................3-13
Figure 3-8. AutoSet 1504 Processor Board: Mode Switch #3 Set to OFF (Decimal Point On) .....3-14
Figure 3-9. AutoSet 1504 Processor Board: High/Low Gain Jumper and Gain Potentiometer .....3-16
Figure 3-10. AutoSet Label Showing Locations for Recording Calfactors and Jumper Settings ....3-19
Figure 4-1. Setpoint Calculation Example: Tonnage Produced at Each Strain Link ........................4-2
Figure 4-2. AutoSet 1504 Processor Board: Mode Switch #1 Set to OFF .......................................4-4
Figure 4-3. AutoSet 1504 Plus Processor Board: Percent High Tolerance Dial ..............................4-5
Figure 4-4. AutoSet 1504 Plus Processor Board: Percent Repeatability Dial ..................................4-7
Figure 4-5. AutoSet 1504 Plus Front Panel Showing Reverse Tonnage LED Displays ................4-13
Figure 4-6. AutoSet 1504 Processor Board: Mode Switch #7 Set to ON (2-Ch. Operation) .........4-14
Figure 5-1. AutoSet 1504 Plus Front Panel Displaying High Setpoint Faults ..................................5-2
Figure 5-2. AutoSet 1504 Plus Front Panel Displaying Repeatability Fault ....................................5-3
Figure 5-3. AutoSet 1504 Plus Front Panel Displaying High Setpoint and Repeatability Faults ....5-4

1137200 AutoSet User Manual
iv Table of Contents
Figure 5-4. AutoSet 1504 Plus Front Panel Displaying Offset Error ............................................... 5-5

AutoSet User Manual 1137200
Table of Contents v
List of Tables
Table 1-1. AutoSet Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Table 2-1. AC Power and Stop Circuit Wiring Connections, TB103 . . . . . . . . . . . . . . . . . . . . . . . .2-8
Table 2-2. Strain Link Part Numbers with Cable Length or Connector Type . . . . . . . . . . . . . . . .2-10
Table 2-3. Strain Link Connections on AutoSet Processor Board . . . . . . . . . . . . . . . . . . . . . . . . .2-14
Table 2-4. Strain Link Wiring Connections, TB105 - TB108: Tension . . . . . . . . . . . . . . . . . . . . .2-15
Table 2-5. Strain Link Wiring Connections, TB105 - TB108: Compression . . . . . . . . . . . . . . . . .2-15
Table 2-6. LMCS (Zero Cam) Wiring Connections, TB101B or TB101A . . . . . . . . . . . . . . . . . .2-19
Table 2-7. Remote Reset Switch Wiring Connections, TB101B or TB101A . . . . . . . . . . . . . . . .2-21
Table 2-8. Oscilloscope Wiring Connections, TB101B or TB101A . . . . . . . . . . . . . . . . . . . . . . .2-22
Table 2-9. Setup Mode Circuit Wiring Connections, TB101B or TB101A . . . . . . . . . . . . . . . . . .2-23
Table 2-10. Communications Wiring Connections: AutoSet and SmartPAC 2 . . . . . . . . . . . . . . . .2-24
Table 2-11. Communications Wiring Connections: AutoSet and SmartPAC . . . . . . . . . . . . . . . . .2-27
Table 3-1. Strain Link Potentiometer: Direction of Screw* Adjustment . . . . . . . . . . . . . . . . . . . . .3-3
Table 3-2. AutoSet Load Cell Tonnage Display Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Table 3-3. AutoSet 1500 and 1500 Plus Tonnage Display Formats . . . . . . . . . . . . . . . . . . . . . . . .3-14
Table 3-4. AutoSet 1504 and 1504 Plus Tonnage Display Formats . . . . . . . . . . . . . . . . . . . . . . . .3-15
Table 3-5. Gain Adjustment Potentiometer and High/Low Gain Jumper Identifiers . . . . . . . . . . .3-16
Table 3-6. AutoSet Load Readings: Ratio of Calibration Unit Readings . . . . . . . . . . . . . . . . . . . .3-17
Table 4-1. Percent High Tolerance Selector Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Table 4-2. Percent Repeatability Selector Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Table A-1. AC Power and Stop Circuit Wiring Connections, TB103 . . . . . . . . . . . . . . . . . . . . . . . A-1
Table A-2. Strain Link Wiring Connections, TB105 - TB108: Tension . . . . . . . . . . . . . . . . . . . . . A-1
Table A-3. Strain Link Wiring Connections, TB105 - TB108: Compression . . . . . . . . . . . . . . . . . A-1
Table A-4. TB101A and TB101B Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Table A-5. Mode Switch (S101) Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Table A-6. Percent High Tolerance Selector (S107) Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Table A-7. Percent Repeatability Selector (S106) Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

1137200 AutoSet User Manual
vi Table of Contents
How To Use This Manual
This manual shows you how to install, calibrate, operate, and troubleshoot AutoSet 1500,
AutoSet 1500 Plus, AutoSet 1504, and AutoSet 1504 Plus load analyzers.
Chapter 1 provides an overview of the operation and features of AutoSet.
Chapter 2 shows you how to mount and wire AutoSet.
Chapter 3 shows you how to calibrate AutoSet.
Chapter 4 shows you how to make the settings AutoSet uses to calculate setpoints and how to
establish setpoints for your press.
Chapter 5 shows you how to respond to AutoSet faults, troubleshoot common AutoSet
problems, and use the LEDs on the AutoSet processor board as diagnostic tools.
Appendix A provides tables of wiring connections and AutoSet processor board settings.
The Glossary provides definitions of some of the terms used in the manual that may be
unfamiliar to you.

AutoSet User Manual 1137200
Table of Contents vii
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

1137200 AutoSet User Manual
viii Table of Contents
Wintriss Controls Group, LLC AUTOSET
100 Discovery Way USER MANUAL
Unit 110 1137200
Acton, MA 01720 ©2016 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.

Introduction 1-1
Chapter 1. Introduction
The AutoSet family of load analyzers provides overload protection for your press and dies
without the need to update settings on each die change. AutoSet creates load limits, or
setpoints, automatically for every job. Setpoints can be changed immediately based upon the
actual load of your press.
Four AutoSet models are available: AutoSet 1500, AutoSet 1504, AutoSet 1500 Plus, and
AutoSet 1504 Plus. AutoSet 1500s are two-channel load analyzers. AutoSet 1504s are four-
channel units. Standard AutoSets allow you to establish setpoints for high tonnage. On
AutoSet Plus units, you can also establish setpoints for stroke-to-stroke tonnage variation, or
repeatability. In addition, with AutoSet Plus you can display reverse tonnage.
Standard AutoSet Benefits
Standard AutoSet 1500 and 1504 load analyzers provide the following benefits:
•Identify machine overloading, enabling you to prevent unnecessary wear on load-bearing
components
•Stop the press after a bad stroke, preventing successive bad hits and, possibly, catastrophic
damage to the die
•Allow more accurate tool setups by providing actual tonnage information. Information can
be stamped on the die shoe per OSHA regulation 1910.217 (d) (6) (i).
•Enable better matching of dies to press capacity. Since AutoSet displays the exact tonnage
produced by each die, you can avoid using large-capacity presses for smaller jobs or
overloading a small-capacity press with too large a job.
•Monitoring of tonnage variations allows you to detect misfeeds, slug stacking, misuse of
stop blocks, changes in material thickness and hardness, broken stripper springs, and
broken punches in the die. One operator can monitor several presses at a time because
AutoSet stops the press when these and other malfunctions are detected.
•Diagnose tool wear by monitoring tonnage increases as a die is re-used. This monitoring
capability enables you to schedule repairs to dies and punches, resulting in more efficient
use of the press, faster parts production, and higher quality parts.
AutoSet Plus Benefits
AutoSet 1500 Plus and 1504 Plus load analyzers deliver the following benefits in addition to
those offered by standard AutoSets:
•Provide repeatability, or stroke-to-stroke, tonnage monitoring. When variation in tonnage
from one stroke to the next exceeds the repeatability setpoint, AutoSet displays an error and
stops the press. 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. Repeatability setpoints also allow you to relax the high setpoint tolerance,
thus avoiding nuisance stops due to acceptable variance in material thickness and hardness.

1137200 AutoSet User Manual
1-2 Introduction
•Display reverse tonnage, which helps you to avoid excessive “snap through” overloads.
Press manufacturers typically recommend that reverse loads not exceed 15% to 25% of
total press capacity.
AutoSet Front Panel
AutoSet 1500 and AutoSet 1504 Plus front panels are shown in Figure 1-1 and Figure 1-2,
page 1-3. The front panels of the AutoSet 1500 Plus and standard 1504 units are similar.
Controls and displays appearing on the AutoSet front panel are described below.
•Channel Load LED Display. Each of these three-digit LED displays shows the tonnage
measured at the corresponding strain link. On AutoSet 1500 units, there are two displays,
one for each strain link; on 1504 AutoSets, there are four. Each Load display can be set to
show tonnage in tenths of a ton up to 100 tons. Channel Load LED displays flash when a
fault occurs on that channel.
•Total Load LED Display. This four-digit LED display, which appears only on AutoSet
1504 and 1504 Plus units, shows the sum of the tonnages on all four strain link channels.
This display can be set to show tonnage in tenths of a ton up to 400 tons. The Total Load
LED display flashes when a fault occurs on any channel.
•Channel Setpoints LED Display. Each of these three-digit LED displays shows the load
limit, or setpoint, that has been established for the corresponding strain link. On AutoSet
1500 units, there are two displays; on 1504 AutoSets there are four.
Setpoints displays on standard 1500 and 1504 AutoSets show setpoints for high tonnage.
Setpoints displays on AutoSet 1500 Plus and 1504 Plus units may show either high tonnage
or repeatability setpoints, depending on the position (i.e., HIGH or REPEATABILITY) to
which the DISPLAY switch (see page 1-4) is set.
AutoSet creates setpoints automatically based on the measured load and stops the press if
one of these limits is exceeded. Setpoints LED displays flash when a fault occurs on that
channel and show an abbreviation indicating the type of fault (e.g., HI, rEP, etc.).
•RESET Button. This button is found only on standard AutoSet 1500 and 1504 load
analyzers. It has two functions.
Depressing the button briefly (i.e., for less than two seconds) resets the load analyzer after a
fault.
Depressing the button (and holding it down) for more than two seconds signals AutoSet to
recalculate setpoints. The button should be depressed until the values shown in the
Setpoints displays blink once and change to 120% of the full-scale tonnage.

AutoSet User Manual 1137200
Introduction 1-3
Figure 1-1. AutoSet 1500 Front Panel
Figure 1-2. AutoSet 1504 Plus Front Panel
LOAD
RIGHLEF
ZERO CAM
SE POIN S
RESE
AutoSet 1500
®
WIN RISS LOAD ANALYZER
RESET button
Right channel
load LED
display
Zero cam LED
Left channel
setpoint LED
display
Keylock
Left channel
load LED
display
Right channel
setpoint LED
display
Screws (2) to
secure cover
to enclosure
AutoSet 1504
®
WIN RISS LOAD ANALYZER
PLUS
Rear channel
load LED
displays (Left
and Right)
Rear channel
setpoint LED
displays (Left
and Right)
Zero cam LED
Keylock
DISPLAY switch
Total load
LED display
REVERSE
button
Front channel
setpoint LED
displays (Left
and Right)
Front channel
load LED
displays (Left
and Right)
SE POIN S
RIGHLEF
ZERO CAM
REAR LOAD
SE POIN S
FRON LOAD
O AL
DISPLAY
HIGH
RESE
REPEA ABILI Y
REVERSE
Latches (2) to
secure cover
to enclosure

1137200 AutoSet User Manual
1-4 Introduction
•DISPLAY Switch. This switch is found only on AutoSet 1500 Plus and 1504 Plus models.
It has three settings: from left to right, REPEATABILITY, HIGH, and RESET.
When the switch is set to “HIGH,” the Setpoints LED displays show setpoints for high
tonnage.
When the switch is turned to the “REPEATABILITY” position, repeatability setpoints
appear in the Setpoints displays.
The “RESET” position has the same functionality as the RESET button on standard
AutoSet 1500 and 1504 units. Turning the switch briefly to “RESET” (i.e., for less than
two seconds) resets the load analyzer after a fault. Turning the switch to the “RESET”
position (and holding it there) for more than two seconds signals AutoSet to recalculate
setpoints.
•Zero Cam LED. Illuminates when the zero cam switch is on (i.e., between 240oand 30o).
The zero cam, which is standard on AutoSet 1500 Plus and 1504 Plus analyzers but
optional on standard 1500 and 1504 AutoSets, clears the tonnage reading for the previous
stroke so the tonnage reading for the current stroke can be displayed.
•REVERSE Button. This button appears only on AutoSet 1500 Plus and 1504 Plus units.
Pressing the REVERSE button causes reverse tonnage values to replace forward tonnage
readings in the Load LED displays. The abbreviation “rEV” appears in the Setpoints LED
displays to indicate that reverse tonnage is being shown. Pressing the REVERSE button
again returns the Load LED displays to forward tonnage values.
•Keylock and Screws (AutoSet 1500 and 1500 Plus). The keylock enables the AutoSet
enclosure to be locked and the key removed, preventing unauthorized changes to settings.
In addition, the cover can be secured to the enclosure with two Phillips screws. To make
settings inside the enclosure, simply loosen the screws, turn the keylock to its “open”
position, and swing the cover open.
•Keylock and Cover Latches (AutoSet 1504 and 1504 Plus). The keylock on AutoSet
1504 and 1504 Plus units is located on the right side of the enclosure rather than on the
cover but, otherwise, functions identically to the keylock on AutoSet 1500 and 1500 Plus
load analyzers. The cover can be secured to the enclosure with two latches, located on the
enclosure’s right side. To make settings inside the enclosure, simply release the latches,
turn the keylock to its “open” position, and swing the cover open.
Strain Links
AutoSet receives its tonnage information from strain links, which are mounted to the press
frame or other structural members and wired to the load analyzer. Strain links measure the
forces acting on the press frame, converting press frame deflection into an electrical signal.
This signal is proportional to the load being generated by the press.
Two strain links are used with AutoSet 1500 and 1500 Plus models, four strain links with
AutoSet 1504 and 1504 Plus units. Instructions on how mount and wire strain links are
provided starting on page 2-10. Zeroing strain links is covered starting on page 3-1.

AutoSet User Manual 1137200
Introduction 1-5
Calibration
AutoSet must be calibrated before use. To calibrate the unit, you first load the press to a
known tonnage, using load cells connected to an independent load monitor that you know will
give correct readings. You then adjust the tonnage readings on AutoSet until they match the
tonnage readings on the independent load monitor. Instructions for calibrating AutoSet are
provided in Chapter 3.
AutoSet Operation
AutoSet creates and displays setpoints automatically based on settings you make inside the
AutoSet enclosure. On standard AutoSet 1500 and 1504 units, you make two settings: sample
period and percent high tolerance. On AutoSet 1500 Plus and 1504 Plus models, you make
three settings: sample period, percent high tolerance, and percent repeatability tolerance.
The sample period is the number of strokes during which AutoSet collects tonnage
information to use in calculating setpoints. Percent high tolerance is the percentage above the
measured load at which AutoSet establishes high tonnage setpoints. Percent repeatability
tolerance is the percent of stroke-to stroke variation in the measured load at which AutoSet
establishes repeatability setpoints.
AutoSet uses the settings you specify for percent high tolerance and percent repeatability
tolerance to calculate setpoints for all dies used on the press. (If you want different settings
used for individual dies, you must change settings.) AutoSet displays the results of its
calculations in the Setpoints LED displays on the front panel. Two setpoints are shown for
1500 and 1500 Plus AutoSets, four setpoints for 1504 and 1504 Plus units.
Only high setpoints are displayed on standard AutoSet 1500 and 1504 units. On AutoSet
1500 Plus and 1504 Plus models, either high or repeatability setpoints are displayed,
depending on the position to which you set the DISPLAY switch (i.e., “HIGH” or
“REPEATABILITY”).
During the sample period, setpoints are maintained at 120% of the full-scale capacity of the
press to provide overload protection.
AutoSet calculates new setpoints whenever the RESET button is depressed for at least two
seconds (1500 and 1504 AutoSets) or the DISPLAY switch is turned to “RESET” and held for
at least two seconds (1500 Plus and 1504 Plus units). Setpoints are displayed after the sample
period is completed. AutoSet also calculates new setpoints whenever you change the percent
high tolerance or percent repeatability tolerance setting.
Complete instructions for setting the sample period, percent high tolerance, and percent
repeatability tolerance on AutoSet are provided in Chapter 4.
AUTOSET SETPOINTS NEVER EXCEED 120%
AutoSet will not create setpoints greater than 120% of the full-scale capacity of the press.
NOTICE

1137200 AutoSet User Manual
1-6 Introduction
AutoSet Faults
AutoSet stops the press whenever the measured tonnage exceeds the high setpoint or the
stroke-to-stroke tonnage variation exceeds the repeatability setpoint for one or more of the
strain links.
To clear the error condition, you press the RESET button (AutoSet 1500) or turn the
DISPLAY switch to the RESET position (AutoSet 1504). The button or switch should be
held for less than two seconds; otherwise, AutoSet will recalculate setpoints.
AutoSet fault conditions are covered in Chapter 5.
AutoSet Specifications
AutoSet specifications are shown in Table 1-1.
Table 1-1. AutoSet Specifications
Equipment System enclosure 10.25” (260.4 mm) x 12” (304.8 mm) x 4”
(101.6 mm), NEMA 12, shock-mounted
Power 115 or 230 Vac ±15%, 50-60 Hz, 30 W
Operating temperature 32oto 122oF (0oto 50oC)
Relay contact rating 4 amps @ 120 or 240 Vac
Normally open, held closed
Speed to 2000 SPM
Display AutoSet 1500/1500+
Two 3-digit .43” (10.9 mm) high for tonnages
Two 3-digit .30” (7.6 mm) high for setpoints
AutoSet 1504/1504+
Four 3-digit .43” (10.9 mm) high for tonnages
Four 3-digit .30” (7.6 mm) high for setpoints
One 4-digit .43” (10.9 mm) high for total tonnage
Strain links
Size
Cable
Two (1500/1500+) or four (1504/1504+) provided
3.75” (95.3 mm) x 1.19” (30.2 mm) x 0.75” (19.1 mm)
30 ft. (9.1 m) standard, other lengths optional
Drill jig One provided