Wintriss AutoSet PAC 120 VAC User manual

Tech Support 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 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

AutoSetPAC User Manual 1101600
Table of Contents 11
Table 4-1. Tonnage Monitor Programming Menu Settings ................................................................. 99
Table 5-1. Tonnage History Information for Each Strain Link Input................................................. 117
Table 5-2. Tonnage History Information for Total Tonnage.............................................................. 118
Table 6-1. Common Causes of Tonnage Faults ................................................................................. 124
Table 6-2. Setpoint Faults: Possible Causes....................................................................................... 126

12 Table of Contents

13
How to Use This Manual
This manual shows you how to install, calibrate, program, run, and troubleshoot AutoSetPAC 2-
Channel and 4-Channel load analyzers. In some places, this manual assumes that you are running
AutoSetPAC with a SmartPAC 2 control, but the instructions also apply to AutoSetPACs connected
to an original SmartPAC or SmartPAC PRO.
Chapter 1 provides an overview of AutoSetPAC features and operation.
Chapter 2 shows you how to mount and wire AutoSetPAC.
Chapter 3 shows you how to enter AutoSetPAC settings in SmartPAC Initialization mode and
calibrate AutoSetPAC.
Chapter 4 shows you how to establish AutoSetPAC setpoint percentages and a sample period for
each tool in SmartPAC Program mode.
Chapter 5 shows you how to view and adjust programmed AutoSetPAC settings in SmartPAC
Run mode.
Chapter 6 shows you how to respond to AutoSetPAC faults and troubleshoot common
AutoSetPAC problems.
The Glossary provides definitions of some of the terms used in the manual that may be unfamiliar
to you.
Wiring diagrams at the end of the manual show connections between AutoSetPAC and all three
versions of SmartPAC (original SmartPAC, SmartPAC 2, SmartPAC PRO) and the connections
necessary to conduct a loopback test.
NOTICE
DOWNLOAD WINTRISS DOCUMENTS
Download any needed Wintriss documents from www.wintrissdocs.com

14

15
Important Highlighted Information
Important danger, warning, caution and notice information is highlighted throughout the manual as
follows:
A DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result
in death or serious injury.
A WARNING symbol indicates a potentially hazardous situation, which, if not avoided, could
result in death or serious injury.
CAUTION
A CAUTION symbol indicates a potentially hazardous situation, which, if not avoided, may result
in property damage.
NOTICE
A NOTICE symbol indicates important information that you should remember, including tips to aid
you in performance of your job.

16

17
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.
Wintriss Controls Group, LLC AUTOSETPAC
100 Discovery Way USER MANUAL
Unit 110 1101600
Acton, MA 01720 ©2018 Wintriss Controls Group, LLC
Telephone: (800) 586-TECH (8324)
[phone]
Fax: [phone]
Internet: http://www.wintriss.com

18

AutoSetPAC User Manual 1101600
Chapter 1 Introduction 19
Chapter 1 Introduction
NOTICE
THE NAME “AUTOSETPAC”
The name “AutoSetPAC” as used in this manual refers to the original SmartPAC, SmartPAC 2, or
SmartPAC PRO Press Automation Control with the AutoSetPAC option.
“SmartPAC” refers to original SmartPAC, SmartPAC 2, and SmartPAC PRO, unless otherwise
indicated.
NOTICE
AUTOSETPAC 2 AND 4 CHANNEL UNITS
AutoSetPAC 2 and 4 channel units were previously called 1500 and 1504, respectively.
NOTICE
USING YOUR AUTOSETPAC WITH DIFFERENT VERSIONS OF SMARTPAC
You can use your AutoSetPAC with
•original SmartPAC
•SmartPAC 2
•SmartPAC PRO
Figures 1-1 and 1-2 show the front panels of the three SmartPAC versions. They are similar, but
have the following differences:
•Original SmartPAC:separate entry keypad, 8 separate function (F) keys
•SmartPAC 2: separate entry keypad, 6 separate function keys
•SmartPAC PRO: entry keys and function keys appear on the touch screen display
Be sure to read the instructions on the display and the labels for the function keys.
This manual shows original SmartPAC screens. SmartPAC 2 and SmartPAC PRO screens are
similar. The menu organization is the same on all versions.
Chapter 2 gives instructions for installing AutoSetPAC on a SmartPAC. Refer to the appropriate
wiring diagrams at the end of the manual.
Chapters 3 through 6 tell how to initialize, program, run, and troubleshoot your
AutoSetPAC/SmartPAC system. Refer to your SmartPAC manual.
Download any needed Wintriss documents from www.wintrissdocs.com
SmartPAC with AutoSetPAC is a reliable, easy-to-use load monitoring system that provides overload
and underload protection for your press and dies without the need to change settings manually on
each die change. AutoSetPAC creates load limits, or setpoints, automatically for any job. Setpoints
can be changed immediately based upon the actual load of your press.
AutoSetPAC also includes the repeatability feature that provides more precise, reliable stroke-to-
stroke protection on your press. AutoSetPAC reduces unnecessary downtime and improves process
control. SmartPAC with AutoSetPAC comes in 2- or 4-input options.

1101600 AutoSetPAC User Manual
20 Chapter 1 Installation
AutoSetPAC Benefits
AutoSetPAC provides the following benefits:
•Identifies machine overloading, enabling you to prevent unnecessary wear on load-bearing
components
•Provides repeatability, or stroke-to-stroke, tonnage monitoring. Repeatability setpoints allow you
to monitor your stamping process more precisely, enabling you to detect punch breakage, quality
problems, and loss of tonnage due to end of stock. Repeatability setpoints also allow you to relax
the high and low setpoint tolerances, thus avoiding nuisance stops due to acceptable variance in
material thickness and hardness.
•Displays and monitors 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.
•Stops the press after a bad stroke, preventing successive bad hits and, possibly, catastrophic
damage to the die.
•Allows 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).
•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 AutoSetPAC stops the
press when these and other malfunctions are detected.
•Diagnoses tool wear by monitoring tonnage increases as a die is re-used. This enables you to
schedule repairs to dies and punches, resulting in more efficient use of the press, faster parts
production, and higher quality parts. In addition, SmartPAC keeps track of the number of hits on
the tool being run, helping you determine when the die requires maintenance.
•Enables better matching of dies to press capacity. Since AutoSetPAC 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.
SmartPAC PRO, SmartPAC 2, and Original SmartPAC
Your AutoSetPAC can be used with the SmartPAC PRO, SmartPAC 2, and original SmartPAC.
To install AutoSetPAC on a SmartPAC, follow the instructions in Chapter 2 and refer to the
appropriate wiring diagrams at the end of the manual. (Wiring diagrams show connections for
original SmartPAC, SmartPAC 2, and SmartPAC PRO.)
AutoSetPAC menu organization in SmartPAC 2 and SmartPAC PRO is similar to that in original
SmartPAC, and the AutoSetPAC screens are similar in all SmartPACs. As a result, you can refer to
the screens and follow the steps provided in chapters 3-6 of this manual to initialize, program, run,
and troubleshoot AutoSetPAC in original SmartPAC, SmartPAC 2, and SmartPAC PRO. The main
differences among the three SmartPACs are in their panel displays, as shown in Figure 1-1 and
Figure 1-2.
SmartPAC 2 and SmartPAC PRO operate much like the original SmartPAC, which you may already
have in your plant.