Wintriss dipro 1500 User manual

DiPro 1500
Die Protection
Programmable Cam Switch
1092000
Rev. B5 July 2010
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 DA45930

Changes for Revision B5 of the
DiPro 1500 User Manual
Revision B5 of the DiPro 1500 User Manual covers all DiPro 1500 versions,
except where noted.
The changes for Revision B5 include:
• Circuit board illustrated in Chapter 2 ("location of components") has been
modified to show important components only (components have been
labeled).
PROVIDE IMPORTANT INFO
DURING TROUBLESHOOTING WITH DI TECH SUPPORT!
Whenever you need to contact Wintriss Controls for technical assistance, be
ready to provide some important information to expedite a resolution to the
problem. Please supply: product name (e.g. DiPro 1500); installed options
(e.g. 8-channel cam.); and firmware version number (e.g. Vs. 2.00). You
can determine firmware version number from the chip on the processor board
(see "location of components" in Chapter 2).

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 out Board Exchange (EX) program. Call our
“800” number between 8 a.m. to 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.

DiPro 1500 User Manual i TOC 1092000
Table of Contents
Chapter 1 Introduction to DiPro 1500 ............................................................1
How DiPro 1500 will benefit your operation ............................................................1
DiPro 1500 Front Panel .............................................................................................2
How DiPro 1500 works .............................................................................................3
Sensors for DiPro 1500..............................................................................................4
Connecting sensors to DiPro 1500.............................................................................5
Connection boxes for sensors ....................................................................................6
Connecting DiPro cam channels to your equipment .................................................7
Settings you can make on DiPro..........................................................................7
Understanding sensor terminology............................................................................9
DiPro three modes of operation.................................................................................12
Guidelines for setting sensors....................................................................................13
Considerations for setting sensor stop type .........................................................13
Specifications.............................................................................................................14
Chapter 2 DiPro 1500 Installation...................................................................15
Before you start..........................................................................................................15
Installation Guidelines...............................................................................................16
Overview of the installation.......................................................................................17
Mounting the DiPro 1500 control enclosure..............................................................19
Mounting the resolver................................................................................................20
If you replace your resolver.................................................................................23
Multiple controls connected to a single resolver.................................................24
Wiring a remote reset switch or setup mode disable circuit......................................25
Installing the DiPro Remote Connection Box (RCB)................................................26
Connecting DiPro Sensor Interface or Wintriss Sensor Interface to DiPro 1500......27
Connecting AC wiring, stop circuits and input check circuit....................................28
Connecting programmable cam channels (if installing cam) ....................................31
Important change about the cam outputs assembly/enclosure.............................31
Making the connections.......................................................................................31
Connecting Spectrum-style programmable cam channels (if installing cam)...........36
Power-up prechecks...................................................................................................40
Connect AC power wires from DiPro to power source.............................................40
Turn on power to DiPro and check display ...............................................................40
Zero Resolver.............................................................................................................41
How to replace and rezero the resolver ...............................................................43
Install position sensor (optional) ...............................................................................43
Installing high speed version of DiPro 1500 (optional).............................................46
Final checkout............................................................................................................47
Wiring the Top Stop with your mechanical cam switch (optional)...........................49

Table of Contents
DiPro 1500 User Manual ii TOC 1092000
Chapter 3 About the keyboard and displays.................................................51
Why using DiPro is easy............................................................................................51
Your starting point in each mode...............................................................................51
Selecting an item on a display ...................................................................................54
Using the keyboard....................................................................................................55
Chapter 4 Using DiPro 1500 in Initialization mode.......................................61
About Initialization mode..........................................................................................61
The first display—the Initialization menu.................................................................61
Resolver zero .............................................................................................................62
Position sensor...........................................................................................................62
Communications........................................................................................................63
Select cam names.......................................................................................................64
Security access...........................................................................................................66
Locking Reset mode ............................................................................................67
Chapter 5 Using DiPro 1500 in Program mode.............................................69
About Program mode.................................................................................................69
The first display—the programming menu................................................................69
Setting Sensors...........................................................................................................70
Bringing up the display of sensors and selecting a sensor to set.........................70
Naming the sensor................................................................................................71
Setting sensor type...............................................................................................72
Setting stop type...................................................................................................72
Setting the ready signal for a green sensor..........................................................73
Setting counter value for green special sensor.....................................................74
Setting the other sensors for the tool ...................................................................75
Going back to the programming menu ................................................................75
What to do about sensor inputs that are not used ................................................75
Going back to the sensor list using the RESET key............................................76
Fine tuning the settings for green sensors............................................................76
Set Cams ....................................................................................................................76
Selecting a channel and making an on-off setting...............................................77
Selecting a channel and making a timed output setting.......................................78
Setting other channels for the tool.......................................................................79
Delete channel settings ........................................................................................79
Set counters................................................................................................................80
Load the tool information..........................................................................................81
Delete the tool information........................................................................................82
Disable (enable) sensors ............................................................................................83
Modify the tool information ......................................................................................84
Modifying sensor settings....................................................................................85
Modifying cam channels......................................................................................86
Modifying counters..............................................................................................86

Table of Contents
DiPro 1500 User Manual iii TOC 1092000
Chapter 6 Using DiPro 1500 in Run mode.....................................................87
About Run mode........................................................................................................87
The first display in Run mode—the Run menu.........................................................88
Disable (enable) sensors ............................................................................................90
Counters.....................................................................................................................91
Show sensors..............................................................................................................91
Adjust sensors............................................................................................................93
Adjust cams................................................................................................................96
Load tool number.......................................................................................................97
Chapter 7 DiPro 1500 Fault Messages...........................................................99
Messages displayed when a sensor signals a fault.....................................................99
Fault messages for green sensors.........................................................................99
Fault message for yellow sensors ........................................................................102
Fault message for red sensors..............................................................................103
Fault message for green special sensors..............................................................103
Messages displayed when a counter preset is reached ..............................................104
Messages displayed for equipment or software problems.........................................105
Appendix A DiPro 1500 Panel Mount.............................................................111
Standard Enclosure versus Optional Panel Mount ....................................................111
Preparationfor mountingDiProusingyourenclosure ...............................................................111
Final assembly ...........................................................................................................111
Index.................................................................................................................113

Table of Contents
DiPro 1500 User Manual iv TOC 1092000
How to use the manual
This is the installation and reference manual for DiPro 1500. It has information about
how to install DiPro 1500 and how to use all the displays to make die protection sensor
settings and cam settings.
Chapter 1 introduces you to DiPro 1500, lists features, and explains key terms
required to use DiPro.
Chapter 2 is the installation chapter. Use it to install DiPro 1500 if you are installing
DiPro yourself.
Chapter 3 is an introduction to the DiPro displays and keyboard. Read this chapter to
get started using DiPro. It shows you how to select items on the DiPro displays and
how to perform key tasks. It also explains the keyboard. This chapter is the place to
start for learning how to use the DiPro 1500 displays and keyboard.
Chapter 4 explains how to use DiPro 1500 in Initialization mode. Use it to look up
things you need to know about using DiPro in Initialization mode.
Chapter 5 explains how to use DiPro 1500 in Program mode. Use it to look up things
you need to know about Program mode.
Chapters 6 explains how to use DiPro 1500 in Run mode. You can look up things you
need to know about Run mode.
Chapter 7 shows you fault messages or other types of messages you will see on your
display when DiPro sends a stop command to the press or when there is an equipment
or software problem. What the message means and how to correct the problem is
explained. Use this chapter to learn about all the DiPro 1500 fault and error messages.
Appendix A explains how to install DiPro 1500 as a panel mount. Mounting and
"cutout" dimensions are provided.
The headings in Chapters 4, 5, and 6 are, in general, the same as the menu items listed on
your screen. To learn about a menu item in one of the modes (Initialization, Program,
Run), go to the chapter for that mode and find the page showing the menu item. Topic
headings are set to the left of the text.

Table of Contents
DiPro 1500 User Manual v TOC 1092000
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
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 DIPRO 1500
100 Discovery Way USER MANUAL
Unit 110 1092000
Acton, MA 01720 ©2010 Wintriss Controls Group, LLC
Telephone: (800) 586-TECH (8324)
[phone]
Fax: [phone]
Internet: http://www.wintriss.com

Table of Contents
DiPro 1500 User Manual vi TOC 1092000

DiPro 1500 User Manual 1 Ch 1 1092000
Chapter 1
Introduction to DiPro 1500
DiPro®1500 is an easy-to-use die protection controller which will protect your dies and
press from damage. It allows unattended press operation and eliminates the tedious
settings and adjustments necessary with other units.
You make all settings for your sensors at the keyboard. And because DiPro is a
microprocessor, you can save all your settings for up to 200 tools in DiPro's electronic
memory. You just recall the settings when you use the tool again.
If you have the optional DiPro programmable cam switch installed, you can also set
timing for your feed, lubricator, part blowoff, transfer devices, etc. You set the portion of
the stroke these devices will activate. The programmable cam switch will then turn these
devices on during the portion of the stroke you set.
How DiPro 1500 will benefit your operation
The DiPro 1500 operates in theory like other die protection systems in use today. You
place sensors on and around your tooling to detect malfunctions such as stock buckling,
misfeeds, die overload, and improper part ejection. The DiPro controller stops the press
whenever any sensor signals a malfunction, protecting your press and die from damage
(see "Theory of Operation" for a complete explanation of how DiPro works).
Here are some of the benefits you will come to appreciate when using your DiPro 1500.
• You make all settings for sensors and cam channels (if installed) right at the
operator console using DiPro's liquid crystal display (LCD) and keyboard.
• There are no complicated instructions to learn. The messages that appear in the
LCD display screen tell you what to do next.
• You can turn unused sensors off at the console and DiPro will ignore them.
• All timing for green (cyclic) sensors is set individually. Timing signals are called
ready signals. DiPro makes a decision to stop the press at the end of each sensor's
individual ready signal. You do not run the risk of delaying a "stop" decision for
all sensors until so late in the stroke that the press cannot be stopped before bottom
dead center (BDC).
• All settings for a die are automatically saved in DiPro 1500's non-volatile memory
(with battery back-up). To use the same settings when you run the same job again,
you simply re-load your stored tool number and you are ready to go. DiPro can
save up to 200 tool numbers.
• DiPro gives you specific error messages on its display screen when a malfunction
occurs, telling you the sensor that signalled the malfunction, stroke angle where it
occurred (when appropriate), and even the name of the sensor in question.

Introduction to DiPro 1500
DiPro 1500 User Manual 2 Ch 1 1092000
DiPro 1500 Front Panel
Contrast
CURSORANGLE
ON
OFF RESET
ENTER
WINTRISS DIE PROTECTION
DiPro 15 0 0
®
ANGLE/
SPM
0° 90° 180° 270° 360°
RUN
PROGRAM
100 Discovery Way, ACTON, MA 01720 USA
DATA INSTRUMENTS
WINTRISS CONTROLS GROUP
LCD display
screen
Screen
contrast
adjust
LED display
(shows RPM,
stroke angle
when press
stops
Program/run key
(set to program to
make settings; set
to run to operate
press)
keys for making settings
Figure 1-1. DiPro front panel
LCD display A 40-character, 8-line liquid crystal display which you use along
with the keyboard to make and adjust settings, to load tool
numbers, and to view error messages when DiPro stops the press.
Screen contrast This knob adjusts the brightness of the LCD display.
LED Display Three digit display which shows strokes per minute when the
press is running. When the press stops, the display shows the an-
gle of the stroke, in degrees, where the press stopped. For in-
stance, it would show 0° for top dead center.
Program/run key Allows you to lock the Program mode so settings cannot be
changed. Settings for sensors (or cam channels) can only be made
when the key is set at "program". The key must be at RUN to
operate the press. Minor adjustments can be made in Run mode.
Keyboard The keyboard consists of the angle on and angle off keys, the cur-
sor keys, the RESET key, and the ENTER key. You use these
keys along with the LCD display to make settings. The keyboard
is covered in detail in Chapter 3. See "Using the keyboard".

Introduction to DiPro 1500
DiPro 1500 User Manual 3 Ch 1 1092000
How DiPro 1500 works
The resolver lets DiPro 1500 know where the crankshaft is
A key element of DiPro operation is that it always knows the position of the crankshaft
during the stroke. DiPro is connected to a resolver mounted on the press which turns one
to one (1:1) with the crankshaft. The resolver is similar to an electrical generator. It has a
lot of windings inside and works on the principle of inductance. The resolver has two
outputs. As the resolver turns the amplitude and the phase of the two ouptuts varies,
these signals are interpreted by DiPro 1500's electronics to determine the correct angle.
Thus, the purpose of the resolver is to tell DiPro where the crankshaft is at every point in
the stroke.
DiPro converts the resolver signal to the crank angle
DiPro's electronics convert the analog signal from the resolver at any point in its rotation
to a number. This number is the position of the resolver (and press crankshaft) in degrees.
Now let's say you expect to see a part eject from the die between 190° and 270° of every
stroke. You make this setting on DiPro. This is the ready signal—the degrees during the
stroke where you will expect your part ejection sensor to actuate. (We will tell you more
about sensors and ready signals later). Now DiPro knows when during the stroke to
expect a signal from the sensor (between 190° and 270°). You can set a separate ready
signal for each sensor.
DiPro 1500 checks for the sensor signal at the right time
When the press is running and the ram reaches 190°, DiPro checks for the signal from the
sensor. If it does not get a signal from the sensor before the ram reaches 270°, it sends a
stop command to the press.
DiPro 1500 makes many decisions simultaneously
DiPro can make decisions like this for up to six sensors at once. You can use sensors that
actuate on every stroke to signal the proper event has occurred (cyclic sensors). You can
also use sensors that actuate only when a malfunction occurs (static sensors). If you have
the cam timing option installed, DiPro can also simultaneously control four cam
channels. It can turn a channel on and off at the exact point in the stroke you set. Because
DiPro is a microprocessor, it can monitor or control all these different functions during a
press stroke even for very high speed presses. And it saves all your settings so you do not
have to make them over and over. You just reload them when the tool is used again.
DiPro 1500 stops press when a malfunction occurs
When a sensor signals a malfunction, DiPro signals the press to stop (either an
emergency stop or top stop—your choice). The display tells you which sensor signalled
the malfunction. After you correct the problem, you reset DiPro using the RESET key.
Then you can continue to make parts.
DiPro 1500 can also send a stop signal when one of its counters reaches the preset value.

Introduction to DiPro 1500
DiPro 1500 User Manual 4 Ch 1 1092000
Sensors for DiPro 1500
DiPro 1500 is the controller, the part of your die protection system that checks signals
from sensors and sends a stop signal to the press when a malfunction is detected. Sensors
connected to DiPro are mounted to the press or die to monitor what is happening in the
dies.
Any electro-mechanical sensor can be used with DiPro as long as it can switch between
an open state (sensor circuit to DiPro open) and a closed state (sensor circuit closed—
some use the term grounded). All types of electronic sensors (proximity, photoelectric,
fiberoptic) can be used. Simple contact sensors and probes which close by touching the
part, die or press can be used as well. If you have any questions about whether a certain
sensor will work with DiPro, do not hesitate to call Wintriss Controls.
Wintriss Controls makes or sells a wide range of sensors. Below is a partial list of sensors
Wintriss Controls makes for its die protection units, and all can be used with DiPro.
Most sensors made by other manufacturers can also be used. Detailed application
information is available on any of the Wintriss Controls sensors listed below.
• Miniature fiberoptic photoelectric sensors—thru-beam and reflective types with
adjustable sensitivity detect objects as small as .0006 in. (.015 mm). Requires
12 to 24 Vdc for power.
• Proximity sensors—miniature electronic sensors that detect metal objects
passing in front of the the sensor barrel. Sensors have no moving parts and are
not affected by water or oil. Requires 12 to 24 Vdc power source.
• Misfeed detectors—designed to monitor non-working spring loaded pilot punch
position, stripper position, or other material location applications.
• Short feed sensors—for contacting material at the fully advanced position.
• Overload sensors—for preventing expensive die damage due to overload from
slugging, material thickness variations, broken tooling, or other causes.
• Die overload sensors—designed to detect minor changes in shut height.
• Buckling sensor—for detecting material buckle
• End of material sensor—signals when material runs out.
• Probes—Three types available for diverse applications.

Introduction to DiPro 1500
DiPro 1500 User Manual 5 Ch 1 1092000
Connecting sensors to DiPro 1500
Sensors can be plugged into the numbered banana jacks at the left side of the box. A
ground jack is also available if you cannot get a good ground for a sensor at the press.
12
34
56
GND
Low impedance
inputs: 1, 2, 3
High impedance
inputs: 4, 5, 6
SENSOR INPUTS
Figure 1-2. DiPro 1500 inputs on left side of box
Low impedance inputs
Inputs 1, 2, and 3 are low impedance inputs. They recognize a sensor's closure to
ground when the resistance in the circuit drops below 700 ohms. These inputs are
good for use with electro-mechanical sensors located in a wet area. Water (or
water-based lube) on the sensor could act as a conductor, causing current to flow in
the circuit even with the contacts open. False signals would occur. The low
impedance input blocks these false signals. It ensures that only signals from a firm
sensor contact closure are received by the controller.
High impedance inputs
Inputs 4, 5, and 6 are high impedance inputs. They recognize a sensor's closure to
ground when the resistance in the circuit drops below 7000 ohms. These inputs are
good for situations where an oil coating prevents a firm sensor contact closure or
prevents a good ground. Oil can act as an insulator and create resistance in the
sensor circuit even with the sensor contacts closed. But as long as the resistance is
not more than 7000 ohms, these inputs will detect the contact closure.
Using the inputs
You can plug any sensor into any jack whether it is a high impedance or low impe-
dance input. In most cases, which inputs you use will not matter. However, if you
have the problems described above, use the different inputs to correct the problem.
These inputs work the same way even if you use the DiPro Remote Connection Box
or Wintriss Sensor Interface for sensor connections instead of the side jacks.
NOTE: Electronic sensors will not be affected by liquids as described above. Use
them with any input, even in wet or oily areas.

Introduction to DiPro 1500
DiPro 1500 User Manual 6 Ch 1 1092000
Connection boxes for sensors
Instead of using the side panel inputs on DiPro 1500, you can use one of two optional
interface boxes to connect sensors to DiPro—the Remote Connection Box (RCB) or the
DiPro Sensor Interface or Wintriss Sensor Interface. They can be mounted near the die,
eliminating long sensor leads and making it easy to switch sensors between jobs. Refer
to either the DiPro Sensor Interface or Wintriss Sensor Interface user manual for more
information.
The DiPro Remote Connection Box (RCB) has six quick connectors. The RCB is
wired permanently to DiPro.
SENSOR INPUTS
123
456
GND
DiPro RCB
®
®
DATA INSTRUMENTS
WINTRISS CONTROLS GROUP
1
2
3
Figure 1-3. Remote Connection Box (RCB)
RCB Dimensions. Width (does not include width of flanges): 4.56" (11.6 cm);
Depth: 2.56" (6.5 cm); Height: 4.06" (10.3 cm); Overall width (includes width of
both flanges): 5.75" (14.6 cm); Vertical distance between mounting holes (center
to center: 3.25" (8.3 cm); Horizontal distance: 5.25" (13.3 cm).
RCB cable (30 or 100 ft) is attached. Eight wires in cable are factory installed on
RCB end (one for each sensor plus ground connection, one wire not used). Wires
are connected to DiPro I/O Assembly in controller. (See Chapter 2 for wiring.)
1. The RCB has six banana jacks for connecting sensors. It also has three Lumberg
twistlock connectors for use with many types of electronic sensors. You have the
choice of using the banana jacks or Lumberg connectors for inputs 1, 2, and 3.
2. Ground jack on RCB box.
3. Flange and mounting holes for attaching RCB to press.

Introduction to DiPro 1500
DiPro 1500 User Manual 7 Ch 1 1092000
The DiPro Sensor Interface is also an option with DiPro. The DiPro Sensor
Interface has 8 inputs for sensors. It also has its own 24V power supply so you
can use it to power your electronic sensors. LED indicators show the on-off
status of each sensor input. Wiring connections from the DiPro Sensor Interface
to DiPro 1500 are shown in Chapter 2. However, installation of DiPro Sensor
Interface is not covered in this manual. If you purchase DiPro Sensor Interface to
use with your DiPro 1500, you will also receive the DiPro Sensor Interface user
manual. The manual tells how you how to install and use it. Refer to that manual
for details.
Connecting DiPro cam channels to your
equipment
If you purchased the programmable cam option with DiPro, you have received a separate
box for wiring the cam channels to your equipment. The box contains the relay modules
that will open and close on signal from DiPro to turn your equipment on and off. You
wire it to the main DiPro assembly. Different types of relays can be used depending on
the voltages of your equipment and your special needs.
WARNING!
DiPro 1500 should not be used to control clutch / brake timing.
It is designed to be used for auxiliary functions only.
Settings you can make on DiPro
All settings are made using the keys on the DiPro keyboard. Up to six sensors can be
used with DiPro. If the programmable cam switch option is installed, four channels for
controlling press equipment are available. For complete instructions on how to make
settings, see Chapter 4—Programming. Here are settings you can make:
• Assign tool numbers for tools.You assign a tool number to your settings for a
tool. This is how you keep track of all settings you make.
• Set green sensors. You set the ready signal (portion of the stroke where the
sensor must actuate). You also set stop type (top stop or emergency stop) and
sensor function. DiPro signals the press to stop if it does not receive a signal from
the sensor during the portion of the stroke set. There are three types of green
sensors on DiPro—green, green quick check, and green constant. See "Sensor
terminology" for definitions.
• Set green special sensors. You set the maximum number of strokes that the press
can make without this sensor actuating. You also set the sensor function. See
"Sensor terminology" for a description of the sensor.
• Set yellow sensors. You set stop type (top stop or emergency stop) and sensor
function. A yellow sensor is always normally open to ground (ungrounded).
• Set red sensors. You set stop type (top stop or emergency stop) and sensor
function. A red sensor is always normally closed to ground (grounded).

Introduction to DiPro 1500
DiPro 1500 User Manual 8 Ch 1 1092000
• Sensor on–off. Sensor inputs can be turned on or off at the keyboard. You turn a
sensor input on by selecting the type of sensor you want it to be—either red,
yellow or green. You turn a sensor off by naming it NOT USED. When you turn a
sensor input off that has been in use, the settings for that sensor are lost.
• Lock settings.You can lock settings so no one can change settings in Run mode.
This prevents anyone from changing settings without the Program/Run key. You
lock settings in Initialization mode.
• Set timing for cam channels. If the programmable cam switch option is installed,
you can set the on and off angle for each cam channel or set the on angle and time
in milliseconds you want the channel to be on. The channel will close the circuit
to the device it is connected to for that angle of the stroke (or for the time set).
You can activate your feed pilot release, assembly operations, air cylinders,
transfer devices, lubricators, air blow off, cut off, loader/unloader controls and
other equipment that requires precise timing with the press. As with sensors, you
can assign a name to each cam channel (pilot release, blowoff, etc.)
• Load settings by tool number. DiPro saves all sensor settings, counter settings,
and cam switch settings (if cam installed) in its electronic memory. The settings
are stored by tool number. To use the settings for a tool again, you recall them by
selecting the tool number from the tool number display. You never need to make
the same settings for a tool over again. You can save up to 200 tool numbers.
Settings are saved automatically as you make them. You do not have to tell DiPro
to save settings by pressing a key or issuing a command. When you load the
stored tool number, DiPro loads all the settings for the tool. DiPro retains all
settings for a tool even with power off. A lithium battery on the memory chip
supplies power and lasts for up to ten years.
• Set good parts counter. The good parts counter counts good parts while the press
is running. The counter will top stop the press (open the top stop relay) when the
count set is reached. The counter does not count strokes where a sensor signalled
a malfunction.
• Set batch counter. The batch counter top stops the press (opens the top stop
relay) when the preset count is reached. This counter is good for stopping the
press to change bins or chutes.
• Set total hits counter. This counter counts every stroke for the tool number
loaded. In other words, it keeps a running total of hits on the tool. It is useful to
determine when the tool needs regrinding. You can reset this counter after the tool
is reground to start the count again from 0.
• Reset DiPro. You reset the unit after DiPro stops the press when a sensor signals
a malfunction. DiPro gives you specific fault messages for a malfunction. It lists
the name of the sensor that signalled the malfunction, the type of fault, and the
angle of the stroke where the fault occurred. This makes it easy to troubleshoot.
See Chapter 7 for a complete list of fault messages.

Introduction to DiPro 1500
DiPro 1500 User Manual 9 Ch 1 1092000
Understanding sensor terminology
In order to make the proper settings for your sensors using the DiPro display, you have to
know what certain terms mean. You will see words on the display like ready on, ready
off, NC (normally closed), NO (normally open), green, green quick check, green
constant, yellow, and red. If you are familiar with die protection sensors and controllers,
you will know what most of these terms mean already. If you do not, these key words are
explained below.
Normally open, normally closed
These terms refers to the way a sensor operates. A normally open (NO) sensor
actuates (signals DiPro) when the sensor circuit to DiPro switches from open to
closed (ground). Normally open sensors are broadly classified as yellow or green
sensors.
A normally closed (NC) sensor works just the opposite of normally open. The
sensor circuit to DiPro is closed (to ground) in its normal state. The sensor actuates
when the circuit opens. Normally closed sensors are classified as red sensors.
Most contact type sensors can be used as either normally open or normally closed
depending on how they are connected. Most sensors are used as normally open just
because you do not have any current flowing in the normal state, which is the state
the sensor will be in most of the time. Some electronic sensors can be switched to
work either as normally open or normally closed. Usually, these sensors have
amplifiers. You change their output using a switch on the amplifier.
The ready signal
The ready signal is the portion of the stroke where a sensor must actuate. For many
of your sensors, like those that monitor part ejection, blowoff, or feed advance, you
need to be sure that the event occurs during a specific portion of each stroke. If the
event occurs late, or not at all (say a part that did not eject), you are likely to have
tooling damage. The ready signal tells DiPro 1500 when to expect the actuation
from the sensor. A ready signal is set only for sensors classified as cyclic (green)
sensors. These are sensors which monitor events that must occur on every stroke.
The term "ready signal" comes from older die protection systems where you had to
set a mechanical cam switch on the press to send a signal to the die protection unit
during the portion of the stroke where the sensor had to actuate. As we saw earlier
("How DiPro works"), DiPro eliminates all this extra work because it automatically
knows where the ram is at every point in the stroke. But we still use the term "ready
signal" because it is widely understood.
To set a ready signal on DiPro, you just key in the degrees of the stroke where the
sensor must actuate. The beginning point is called ready on. The end point is ready
off. A separate ready signal can be set for each green sensor. If the sensor does not
actuate (closure to ground) during the ready signal, DiPro will send a "stop"
command to the press. The type of stop can be a top stop or emergency stop.

Introduction to DiPro 1500
DiPro 1500 User Manual 10 Ch 1 1092000
Sensor types for DiPro
Sensors used with die protection systems are classified as red, yellow, or green. For
DiPro, there are three types of greens—green, green quick check, and green
constant.
When you make settings for a tool, you select the sensor type for each one of
DiPro's sensor inputs. This allows you to have any combination of reds, yellows, or
greens for a tool. You will see how to select sensor type in Chapter 5 where you
learn how to make sensor settings. Here we discuss what the five types mean.
Green sensors
Any sensor set to green (either green, green quick check or green constant) must be
cyclic. In other words, it must actuate during a portion of each stroke (during the
ready signal). An actuation is a closure to ground. If the sensor does not actuate,
DiPro sends a stop signal to the press. You can select an emergency stop or top
stop.
Green sensors are used to detect events that must occur during a certain portion of
each stroke. Examples are part ejection, stock feed, and part transfer.
DiPro displays the portion of the stroke green sensors actuate when you run the
press. It displays the degrees of the stroke where the sensor turns on and where it
turns off. That makes it easy to set the ready signal for the sensor. You just make
the ready signal a little longer or shorter than the actuation time (depending on the
sensor). See the procedures in Chapter 5 and Chapter 6 for complete instructions
on making and adjusting sensor settings.
The four types of green sensors are described below.
Green
When you set a sensor input to "green," the sensor must turn on at least
momentarily during the ready signal. Also the sensor must be off, at least
momentarily, at any point outside of the ready signal.
TDC
BDC
TDC
BDC
TDC
BDC
TDC
BDC
OK not allowed
(press stops)
Sensor isn't off outside
ready signal. Stop
signal sent at start of
next ready signal.
Sensor never turns on.
Stop signal sent at end
of ready signal.
OK
Sensor stays on after
the end of ready signal
Sensor actuates
inside ready signal
not allowed
(press stops)
= Ready
Signal
KEY
= Sensor
Actuation
Figure 1-4. How DiPro interprets signals from a sensor set to "green."

Introduction to DiPro 1500
DiPro 1500 User Manual 11 Ch 1 1092000
Green quick check
A sensor input set to "green quick check" is almost the same as the "green" setting.
The sensor must turn on at least momentarily within the ready signal. However, a
green quick check sensor cannot stay on or turn on outside the ready signal. The
sensor must turn on, then turn off within the ready signal. Otherwise, DiPro 1500
sends the stop signal to the press.
TDC
BDC
TDC
BDC
TDC
BDC
OK
Sensor stays on after
the end of ready signal.
Stop signal sent just
after ready signal ends.
not allowed
(press stops) not allowed (press stops) not allowed (press stops)
Sensor actuates
inside ready signal Sensor turns on outside ready signal. Stop signal
sent when sensor turns
on.
Sensor never turns on.
Stop signal sent at end
of ready signal.
= Ready
Signal
KEY
= Sensor
Actuation
TDC
BDC
Figure 1-5. How DiPro interprets signals from a sensor set to "green quick check."
Green constant
When you set a sensor input to "green constant," the sensor must turn on before the
ready signal begins and turn off after the ready signal ends. That is, it must stay
actuated constantly during the ready signal. However, the sensor must turn off, at
least momentarily, outside the ready signal.
TDC
BDC
TDC
BDC
TDC
BDC
TDC
BDC
Sensor doesn't turn off
outside ready signal.
Stop signal sent at start
of next ready signal.
Sensor never turns
on. Stop signal sent
at beginning of ready
signal.
OK not allowed
(press stops)
Sensor turns off before
ready signal ends. Stop
signal sent when sensor
turns off.
Sensor stays on dur-
ing complete ready
signal.
not allowed
(press stops) not allowed (press stops)
Figure 1-6. How DiPro interprets signals from a sensor set to "green constant."