Wintriss AutoSet PAC 120 VAC User manual

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www.wintriss.com
Wintriss Controls Group, LLC
100 Discovery Way
Unit 110
Acton MA 01720 USA
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PRINTED IN USA DA46021
®
AutoSet PAC
®
Wintriss Load Analyzer
A SmartPAC Module
1101600
Rev. N December 2018
®
®

Changes for Revision N of the
AutoSetPAC User Manual (1101600)
This revision of the AutoSetPAC user manual covers AutoSetPAC software version 2.28 and higher.
The changes include:
•Addition of SmartPAC PRO installation, usage information, and wiring diagrams 8 – 12.
•AutoSetPAC 1500 and 1504 references changed to 2-channel and 4-channel, respectively.

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.

AutoSetPAC User Manual 1101600
Table of Contents 7
Table of Contents
Chapter 1 Introduction........................................................................................................19
AutoSetPAC Benefits....................................................................................................................................20
SmartPAC PRO, SmartPAC 2, and Original SmartPAC ..............................................................................20
Original SmartPAC and SmartPAC 2 Front Panels ......................................................................................22
SmartPAC PRO Front Panel .........................................................................................................................23
Strain Links ...................................................................................................................................................25
Calibration.....................................................................................................................................................25
AutoSetPAC Operation .................................................................................................................................26
AutoSetPAC Faults .......................................................................................................................................26
AutoSetPAC Specifications ..........................................................................................................................27
Chapter 2 Installation..........................................................................................................29
Mounting AutoSetPAC .................................................................................................................................29
Mounting the AutoSetPAC Enclosure without Display .........................................................................30
Mounting the AutoSetPAC Enclosure with AutoSet 2-Channel/4-Channel Display .............................31
Installing the AutoSetPAC Panel Mount................................................................................................32
Installing the AutoSetPAC Processor Board, 85 to 264 Vac Version (No Enclosure)...........................34
Installing the AutoSetPAC Processor Board (24 Vdc Version) .............................................................35
Connecting AC and Stop Circuit Wiring.......................................................................................................36
Installing Strain Links ...................................................................................................................................41
Mounting Strain Links ...........................................................................................................................42
Wiring Strain Links................................................................................................................................46
Connecting the Zero Cam Signal to SmartPAC 2 or SmartPAC PRO ..........................................................48
Connecting Communications Wiring to SmartPAC 2 or SmartPAC PRO....................................................50
Wiring an Oscilloscope (Optional)................................................................................................................51
Connecting AC Wires to Power Source ........................................................................................................53
Connecting a New AutoSetPAC to Original SmartPAC ...............................................................................53
Connecting an AutoSet to SmartPAC ...........................................................................................................54
Connecting AutoSet to SmartPAC Pro or SmartPAC 2 .........................................................................54
Connecting an AutoSet to Original SmartPAC ......................................................................................56
Powering Up AutoSetPAC............................................................................................................................57
Installing New AutoSetPAC Firmware .........................................................................................................58
Chapter 3 Initialization and Calibration.............................................................................61
Making Settings on Switch Block S101........................................................................................................61
Accessing the SmartPAC Main Initialization Menu .....................................................................................63
Making Tonnage/Waveform Initialization Settings ......................................................................................65
Initializing Parameters ...........................................................................................................................65
Setting Input Names...............................................................................................................................66
Disabling/Enabling AutoSetPAC Parameters ........................................................................................68
Setting Reverse Setpoint % of Press Capacity .......................................................................................68
Locking Run Mode Actions ..........................................................................................................................69
Viewing Communications.............................................................................................................................71
Calibrating AutoSetPAC ...............................................................................................................................72
Zeroing Strain Links ..............................................................................................................................73
Recording Tonnage on an AutoSet Calibration Kit................................................................................77
Setting Full-scale Tonnage on Your AutoSetPAC.................................................................................85
Adjusting AutoSetPAC To Read the Correct Tonnage..........................................................................87
Checking Linearity ........................................................................................................................................91
Final Checkout ..............................................................................................................................................92

8 Table of Contents
Chapter 4 Using AutoSetPAC in Program Mode..............................................................93
AutoSetPAC’s Setpoint Calculation Process................................................................................................ 93
Startup Counter............................................................................................................................................. 95
Accessing the Tonnage Monitor Programming Menu.................................................................................. 96
Making Tonnage Monitor Settings............................................................................................................... 98
Loading Tonnage Monitor Settings.............................................................................................................. 99
Copying Tonnage Monitor Settings ............................................................................................................100
Changing Tonnage Monitor Settings...........................................................................................................101
Viewing and Adjusting Setpoints ................................................................................................................101
High Setpoint Limits ............................................................................................................................102
Low Setpoint Limits.............................................................................................................................103
Repeatability Setpoint Limits...............................................................................................................103
Recalculating Setpoints ...............................................................................................................................104
Chapter 5 Using AutoSetPAC in Run Mode ...................................................................107
Accessing the Tonnage Monitor Run Menu................................................................................................107
Displaying Tonnage in Plan View...............................................................................................................109
Displaying Tonnage in Bargraph View .......................................................................................................110
Viewing and Adjusting Setpoints ................................................................................................................111
High Setpoint Limits ............................................................................................................................112
Low Setpoint Limits.............................................................................................................................112
Repeatability Setpoint Limits...............................................................................................................113
Setpoint Calculation Period..................................................................................................................114
Recalculating Setpoints ........................................................................................................................114
Viewing Tonnage History ...........................................................................................................................115
Viewing Tonnage History for a Selected Strain Link Input .................................................................115
Viewing History for the Total Strain Link Tonnage ............................................................................118
Clearing Tonnage History ....................................................................................................................119
Recalculating Setpoints ...............................................................................................................................119
Viewing Reverse Tonnage ..........................................................................................................................120
Loading a New Tool....................................................................................................................................121
Chapter 6 Troubleshooting ..............................................................................................123
Responding to AutoSetPAC Faults .............................................................................................................123
Setpoint Faults......................................................................................................................................125
Offset Errors.........................................................................................................................................126
Troubleshooting Common AutoSetPAC Problems .....................................................................................127
Glossary.............................................................................................................................129
Index...................................................................................................................................131
Wiring Diagrams at End of Manual
Figure 1. 120 VAC AutoSetPAC 2 Channel with SmartPAC 2
Figure 2. 120 VAC AutoSetPAC 4 Channel with SmartPAC 2
Figure 3. SmartPAC 2 Loopback Wiring Connections
Figure 4. 120 VAC AutoSetPAC 2 Channel with SmartPAC 1
Figure 5. 120 VAC AutoSetPAC 4 Channel with SmartPAC 1
Figure 6. 24 VDC AutoSetPAC 4 Channel with SmartPAC 2
Figure 7. 24 VDC AutoSetPAC 2 Channel with SmartPAC 2
Figure 8. 120 VAC AutoSetPAC 2 Channel with SmartPAC PRO
Figure 9. 120 VAC AutoSetPAC 4 Channel with SmartPAC PRO
Figure 10. SmartPAC PRO Loopback Test Wiring
Figure 11. 24 VDC AutoSetPAC 4 Channel with SmartPAC PRO
Figure 12. 24 VDC AutoSetPAC 2 Channel with SmartPAC PRO

AutoSetPAC User Manual 1101600
Table of Contents 9
List of Figures
Figure 1-1. SmartPAC 2 and Original SmartPAC................................................................................ 21
Figure 1-2. SmartPAC PRO ................................................................................................................. 23
Figure 2-1. AutoSetPAC Enclosure: Mounting Dimensions................................................................ 30
Figure 2-2. AutoSetPAC Enclosure with AutoSet 4-Channel Display: Mounting Dimensions .......... 31
Figure 2-3. AutoSetPAC Panel Mount: Mounting and Cutout Dimensions ........................................ 33
Figure 2-4. AutoSetPAC 4-Channel Processor Board (85 to 264 Vac Version): Mounting
Dimensions ........................................................................................................................ 34
Figure 2-5. AutoSetPAC Processor Board (24 Vdc Version): Mounting Dimensions ........................ 35
Figure 2-6. AutoSetPAC 2-Channel Processor Board: Location of Important Components ............... 37
Figure 2-7 AutoSetPAC 4-Channel Processor Board: Location of Important Components. ............... 38
Figure 2-8. AC Power Connections...................................................................................................... 39
Figure 2-9. Strain Link: Mounting Dimensions ................................................................................... 42
Figure 2-10. Strain Link Mounting Options on Gap-frame Presses..................................................... 43
Figure 2-11. Strain Link Mounting Options on Straight-side Presses.................................................. 44
Figure 2-12. Strain Link Drill Jig: Mounting Dimensions ................................................................... 45
Figure 2-13. Shield Drain Wire Connected to Ground Stud on Enclosure .......................................... 47
Figure 3-1. Switch Block S101 (Default Settings Shown)................................................................... 62
Figure 3-2. SmartPAC 2 Main Initialization Menu.............................................................................. 64
Figure 3-3. SmartPAC PRO Initialization Menu.................................................................................. 64
Figure 3-4. Tonnage/Waveform Initialization Menu ........................................................................... 65
Figure 3-5. Initialize Parameters Warning Message ............................................................................ 66
Figure 3-6. Load Monitor Input Name Menu with “INPUT 1” Highlighted ....................................... 67
Figure 3-7. Load Monitor Input Name Menu with Alphabetic Entry Window Displayed .................. 67
Figure 3-8. Numeric Entry Window Superimposed on Tonnage Monitor Initialization Menu ........... 69
Figure 3-9. Security Access Menu with Load Monitor Setting Highlighted........................................ 70
Figure 3-10. COMMUNICATIONS Item on Diagnostic Menu in Initialization Mode....................... 71
Figure 3-11. Communication Data Viewer Screen .............................................................................. 71
Figure 3-12. Communications Transmit/Receive Screen..................................................................... 72
Figure 3-13. Calibration Screen: Current Zero Offsets Display........................................................... 73
Figure 3-14. Potentiometer Adjustment Screw on Strain Links without Access Hole in Cover.......... 74
Figure 3-15. AutoSet 2-Channel Calibration Kit Processor Board: Old Style ..................................... 79
Figure 3-16. AutoSet 2-Channel Calibration Kit Processor Board: New Style.................................... 80
Figure 3-17. AutoSet 2-Channel Calibration Kit Processor Board: AutoSet V2.0 Board.................... 81
Figure 3-18. Tonnage Dial Indicators: Old-style Board (Left), New-style Board (Right)................... 82
Figure 3-19. Mode Switch #3 Set to “Decimal Point Off” Position (Old-style Processor Board) ....... 82
Figure 3-20. Load Cell Gain Adjustment Potentiometer with Adjustment Screw ............................... 84
Figure 3-21. Tonnage/Waveform Initialization Menu with Numeric Entry Window Displayed......... 86
Figure 3-22. Calibration Screen ........................................................................................................... 87
Figure 3-23. AutoSetPAC 4-Channel Processor Board: High/Low Gain Jumper and Gain
Adjustment Potentiometer for Left Rear Strain Link ...................................................... 89
Figure 3-24. Calibration Screen: Calfactors Display............................................................................ 91
Figure 4-1. Tonnages Produced on Left Strain Link during Sample Period: Example ........................ 95
Figure 4-2. Main Program Menu.......................................................................................................... 96
Figure 4-3. Tool Manager Screen......................................................................................................... 97
Figure 4-4. Tool Programming Menu .................................................................................................. 97
Figure 4-5. Tonnage Monitor Programming Menu .............................................................................. 98
Figure 4-6. Load Tool Warning Message........................................................................................... 100
Figure 4-7. Tool Loading Message .................................................................................................... 100

10 Table of Contents
Figure 4-8. Tool Manager Screen with Copy Tool Message and Numeric Entry Window
Displayed ........................................................................................................................ 100
Figure 4-9. Adjust Setpoints Screen: High Setpoint Limits Display ................................................. 102
Figure 4-10. Adjust Setpoints Screen: Low Setpoint Limits Display ................................................ 103
Figure 4-11. Adjust Setpoints Screen: Repeatability Setpoint Limits Display .................................. 104
Figure 4-12. Main Program Menu with “RECALCULATE SETPOINTS” Warning Displayed...... 105
Figure 5-1. SmartPAC Main Run Menu ............................................................................................ 108
Figure 5-2. Tonnage Monitor Run Menu........................................................................................... 109
Figure 5-3. Tonnage “Plan” View Screen (4-channel AutoSetPAC Shown) .................................... 109
Figure 5-4. Tonnage Bargraph View Screen ..................................................................................... 110
Figure 5-5. Adjust Setpoints Screen: High Setpoint Limits Display ................................................. 111
Figure 5-6. Adjust Setpoints Screen: Low Setpoint Limits Display .................................................. 113
Figure 5-7. Adjust Setpoints Screen: Repeatability Setpoint Limits Display .................................... 113
Figure 5-8. Adjust Setpoints Screen: Sample Period Display............................................................ 114
Figure 5-9. Adjust Setpoints Screen: Recalculate Setpoints Warning Message ................................ 114
Figure 5-10. Tonnage History Menu.................................................................................................. 115
Figure 5-11. Tonnage History Display for “Left Rear” Input (#1) .................................................... 116
Figure 5-12. Tonnage History for “Total Tonnage” Display............................................................. 118
Figure 5-13. “Clear Tonnage History” Warning Message................................................................. 119
Figure 5-14. Tonnage Monitor Run Menu: Recalculate Setpoints Warning Message ...................... 119
Figure 5-15. Reverse Tonnage Plan View Screen ............................................................................. 120
Figure 5-16. Tool Manager Screen .................................................................................................... 121
Figure 5-17. Load Tool Warning Message ........................................................................................ 121
Figure 5-18. Tool Loading Message .................................................................................................. 122
Figure 6-1. AutoSetPAC Tonnage Fault Message: High Setpoint Exceeded .................................... 123
List of Tables
Table 1-1. Original SmartPAC and SmartPAC 2 Panel Features ........................................................ 22
Table 1-2. SmartPAC PRO Panel Features.......................................................................................... 24
Table 1-3. AutoSetPAC Specifications................................................................................................ 27
Table 2-1. AutoSetPAC AC Power and Stop Circuit Wiring Connections, TB103 ............................ 40
Table 2-1. AutoSetPAC 24 VDC Power Wiring Connections, TB109 ............................................... 40
Table 2-1. AutoSetPAC 24 VDC Stop Circuit Wiring Connections, TB103 ...................................... 40
Table 2-2. Strain Link Part Numbers with Cable Length or Connector Type ..................................... 41
Table 2-3. Strain Link Connections on AutoSetPAC Processor Board ............................................... 46
Table 2-4. Strain Link Wiring Connections, TB105 - TB108: Tension .............................................. 47
Table 2-5. Strain Link Wiring Connections, TB105 - TB108: Compression ...................................... 47
Table 2-6. Zero Cam Wiring Connections to SmartPAC PRO............................................................ 48
Table 2-7. Zero Cam Wiring Connections to SmartPAC 2 ................................................................. 49
Table 2-8. Communications Wiring Connections................................................................................ 50
Table 2-9. Oscilloscope Wiring Connections, 120 VAC AutoSetPAC ............................................... 52
Table 2-10. Oscilloscope Wiring Connections, 24 VDC AutoSetPAC ............................................... 52
Table 2-11. Communications Wiring Connections: AutoSet and SmartPAC 2 or SmartPAC PRO ... 55
Table 2-12. Communications Wiring Connections: AutoSet and Original SmartPAC ....................... 57
Table 3-1. Switch Block S101 Settings ............................................................................................... 62
Table 3-2. Strain Link Potentiometer: Direction of Screw* Adjustment............................................. 75
Table 3-3. AutoSet Load Cell Tonnage Display Formats.................................................................... 83
Table 3-4. AutoSetPAC 2-Channel and 4-Channel Tonnage Display Formats................................... 86
Table 3-5. Gain Adjustment Potentiometer and High/Low Gain Jumper Identifiers .......................... 88
Table 3-6. AutoSetPAC Load Readings: Ratio of Calibration Unit Readings .................................... 89