Honeywell AutoSet 1500 User Manual
®
AutoSet 1500
Wintriss Two-channel Load Analyzer
1088500
Rev. C1 June 1998
®
Tech Support Hotline 800-586-8324 8-5 EST
®
Wintriss Controls Group
100 Discovery Way
Acton MA 01720-3648 USA
Phone (978) 264-9550 (800) 586-8324
Fax (978)263-2491
PRINTED IN USA DA45897
www.wintriss.com
Thank you for purchasing a Honeywell 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.
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• Expedited Repair Program
Rush service providing 48 hour turnaround is available for most products upon request. An Expedite
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If your needs are urgent, you can take advantage of our Board Exchange (EX) program. Call our
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fee does apply to this service. Contact Wintriss Technical Support at 800-586-8324 for details.
• Service Center
Our Service Center for product repairs 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 Service Manager at
800-586-8324, ext. 1949 or Wintriss Technical Support group at 800-586- 8324.
• Product Training
We also offer both product training and maintenance/troubleshooting courses at our Acton, MA and
Chicago-area facilities. On-site training is available from the factory or through your local Wintriss
representative.
• Restocking Charge
Returned goods are subject to a 20% restocking charge if returned for credit. The minimum charge
is $50, not to exceed $250 per item.
Whatever the product, we are committed to satisfying you with innovative engineering, quality
construction, reliable performance, and ongoing, helpful support. Call us whenever you need assistance.
Changes for Revision C1 of the
AutoSet 1500 User Manual
(1088500)
Revision C1 of the AutoSet 1500 User Manual covers all AutoSet 1500
models.
Change(s) for Revision C1 include:
Label Switch 2 in location figure. (Figure 2-2, Chapter 2)
•
• Designate correct switch for “Zero Set”. (”Zeroing strain links”,
Chapter 3)
PROVIDE IMPORTANT INFO
DURING TROUBLESHOOTING WITH DI TECH SUPPORT!
Whenever you need to contact Data Instruments for technical assistance, be
ready to provide some important information to expedite a resolution to the
problem. Please supply: product name (e.g. AutoSet); model (e.g. 1500 or
1504); type (e.g. standard or plus); 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).
Table of Contents
Chapter 1 The AutoSet® 1500.........................................................................1
How AutoSet will benefit your operation..................................................................1
The AutoSet 1500 front panel....................................................................................2
How tonnage is recorded on the AutoSet displays....................................................3
Strain links.................................................................................................................3
Calibration .................................................................................................................3
How AutoSet 1500 works..........................................................................................4
Specifications.............................................................................................................6
Chapter 2 AutoSet 1500 Installation...............................................................7
Mounting the AutoSet control enclosure...................................................................7
Connecting AC wiring and stop circuit .....................................................................8
Mounting and connecting strain links........................................................................12
Connecting AC wires to power source ......................................................................16
Optional wiring connections......................................................................................17
Wiring a remote reset switch to AutoSet (optional)..................................................21
Wiring a strip chart recorder to AutoSet (optional)...................................................21
Final checkout for AutoSet 1500...............................................................................22
Chapter 3 AutoSet 1500 Calibration...............................................................23
Calibration .................................................................................................................23
Types of calibration kits you can use.........................................................................24
How many load cells to use.......................................................................................24
How to begin..............................................................................................................24
Zeroing strain links....................................................................................................24
Setting up and adjusting a Wintriss Load Analyzer (WLA) calibration kit..............26
Setting up and adjusting an AutoSet 1500 calibration kit .........................................29
Calibrating your AutoSet 1500..................................................................................33
Setting up the press..............................................................................................33
Setting full scale tonnage.....................................................................................35
Adjusting AutoSet to read the correct tonnage....................................................37
Linearity check ..........................................................................................................40
Chapter 4 AutoSet 1500 Operation.................................................................41
How to make settings on AutoSet..............................................................................41
Selecting the sample period.................................................................................41
Setting the percent tolerance selector ..................................................................42
Creating setpoints for the job....................................................................................44
When you may want to change the setpoint percentage.............................................................46
When you must recalculate setpoints.........................................................................46
When power is turned off and restored......................................................................46
Disabling AutoSet......................................................................................................46
AutoSet 1500 User Manual i TOC 1088500
Table of Contents
Chapter 5 AutoSet 1500 Troubleshooting .....................................................47
AutoSet Alarms..........................................................................................................47
Before you reset AutoSet...........................................................................................47
When AutoSet displays a high setpoints fault...........................................................48
When AutoSet displays an offset error......................................................................49
Resetting AutoSet ......................................................................................................49
AutoSet Troubleshooting...........................................................................................50
When none of the load or setpoint LEDs are displayed ......................................50
When either of the load displays shows no tonnage............................................50
When the tonnage is lower than it should be.......................................................50
What happens when power is turned off and restored.........................................50
Appendix A AutoSet 1500 Panel Mount.........................................................51
Standard Enclosure versus Optional Panel Mount ....................................................51
Preparation for mounting AutoSet using your enclosure.............................................................51
Final assembly ...........................................................................................................51
Appendix B Modification for Selectable Sampling .......................................53
Index .................................................................................................................55
AutoSet 1500 User Manual ii TOC 1088500
Table of Contents
How to use this manual
This is the installation and reference manual for AutoSet 1500. It has information about
how to install and use AutoSet 1500 to monitor load.
Chapter 1 introduces you to AutoSet 1500, tells how it works, lists features, and
explains how to use AutoSet.
Chapter 2 is the installation chapter. Use it to install AutoSet 1500 if you are
installing AutoSet yourself. Note that the 1500 processor board has changed. This is
covered in Chapter 2.
Chapter 3 talks about calibration. Read this chapter to calibrate AutoSet properly.
Chapter 4 explains how to use AutoSet. Use it to create and adjust setpoints.
Chapter 5 talks about what happens when AutoSet stops the press and what to do to
remedy the situation. It displays the alarms that AutoSet will provide, explains what
they mean, and how to correct them. This chapter also discusses how to troubleshoot
certain situations that may occur during normal press operation.
Appendix A explains how to install AutoSet 1500 as a panel mount. Mounting and
"cutout" dimensions are provided.
Appendix B is specifically included for specially modified AutoSet monitors with
custom selectable sampling. It explains how to use stroke sampling for 1, 15, 30,
and 60 strokes.
AutoSet 1500 User Manual iii TOC 1088500
Table of Contents
Warranty
Data Instruments Inc. (D.I.) warrants that Data Instruments / 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 (PACNet and RSR), 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. D.I.'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 D.I. freight prepaid, and which are, after examination,
disclosed to the satisfaction of D.I., 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 D.I. No other warranty is expressed or implied. D.I.
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. Data Instruments manufactures its products to meet stringent
specification and cannot assume responsibilities for those consequences arising from
their misuse. SmartPAC, AutoSet load monitors, DiPro 1500, IC Controllers,
ProCam 1500, Sensors, Spectrum Systems, and Wintriss Load Analyzers are not
designed or intended for use as personnel protection devices.
DATA INSTRUMENTS® AUTOSET® 1500
Wintriss® Controls Group USER MANUAL
75 Discovery Way Revision C1
Acton, MA 01720-3648 June 1998
Telephone: (800) 586-TECH (8234) ©1998, Data Instruments Inc.
(508)264-9550
Fax: (978) 263-2491
Internet: http://www.wintriss.com
AutoSet 1500 User Manual iv TOC 1088500
Chapter 1
The AutoSet® 1500
Your AutoSet 1500 load monitor from Data Instruments is a simple, easy-to-use load
monitor. It protects your press and dies from overloads without the need to change or
readjust settings from die to die. That is because the AutoSet 1500 creates load limits (or
setpoints) automatically—for any job. You never have to calculate and enter settings
yourself. With AutoSet, you get overload protection, and you are freed from the
repetitive process of calculating and setting new setpoints every time you change dies.
How AutoSet will benefit your operation
AutoSet provides these benefits for any press operation:
1. It identifies machine overloading. AutoSet helps reduce unnecessary wear on
load bearing components.
2. While AutoSet cannot anticipate a bad stroke, it can signal the press to stop
after a bad stroke occurs. This eliminates successive bad hits that can cause
catastrophic damage.
3. Tooling setups are more accurate because of the actual tonnage information
AutoSet provides. The correct information about tonnage can be stamped on
the die shoe, per OSHA regulation 1910.217 (d) (6) (i).
4. AutoSet can detect die malfunctions through tonnage variations and can therefore monitor misfeeds, slug stacking, misuse of stop blocks, increases in material thickness and hardness, broken stripper springs, and broken punches in
the die. AutoSet makes it possible for one operator to monitor several presses
because it stops the press when these malfunctions are detected.
5. AutoSet helps you keep track of tonnage and tool wear so repairs to dies and
punches can be made on a schedule which permits more efficient use of the
press. This results in faster parts production and higher quality parts. You
know the tool is wearing if tonnage increases as the die is used again and
again.
6. AutoSet enables better matching of dies to press capacity since it tells you the
exact tonnage produced for each die. Therefore you can avoid using large capacity presses for smaller jobs.
AutoSet 1500 User Manual 1 Ch 1 1088500
AutoSet 1500
The AutoSet 1500 front panel
Tonnage
displays (for
forward or
reverse)
Zero
cam
LED
LEFT
LOAD
ZERO CAM
SETPOINTS
RIGHT
Setpoint
displays
®
1500
RESET
Cover latches
(keylock in between)
Reset button
AutoSet
WINTRISS LOAD ANALYZER
Figure 1-1. AutoSet front panel
Tonnage displays. Three-digit tonnage displays show the tonnage at each strain link.
Tonnage displays flash when an overload occurs.
Setpoint displays. Three-digit setpoint displays show the the upper load limits (or
setpoints). AutoSet creates setpoints automatically based on the load. AutoSet stops the
press if these limits are exceeded.
Reset button. This button has two functions. Pushing it momentarily (less than two sec-
onds) resets AutoSet after it signals an overload and stops the press. When an overload
occurs, the tonnage display for the strain link where the overload occurred will flash.
(Both displays will flash if an overload occurs on both sides of the press.) The press
stops. Once AutoSet is reset, the displays stop flashing. You can once again run the press.
Be sure to check for the cause of the overload first.
Holding the button down for more than two seconds signals AutoSet to recalculate
setpoints the next time the press is started. (This can be done while the press is running.)
To recalculate, the button should always be held down until the numbers in the setpoint
display blink once and change to 120% of the full scale tonnage set on AutoSet.
Complete instructions for using the reset button are in Chapter 4.
Zero Cam LED (optional). Illuminates when the zero cam is closed, generally through top
of stroke.
Keylock. AutoSet 1500 has a lock and key so the cover can be locked. This prevents
unauthorized changes to settings.
Cover latches. The two cover latches keep the AutoSet front panel door firmly closed. To
make settings on AutoSet, you unlock the box and loosen the two latches. Then swing the
front panel door open. All settings are made inside the box.
AutoSet 1500 User Manual 2 Ch 1 1088500
AutoSet 1500
How tonnage is recorded on the AutoSet displays
The way AutoSet displays tonnage depends on the full scale tonnage of your press. (You
make the full scale tonnage setting during calibration.)
200 tons or less
If AutoSet is set to a full scale tonnage of 200 tons or less, it displays tonnage up to 100
tons in tenths of a ton ( 5.5, 6.0, 45.5, 90.1, 99.9, etc). Over 100 tons, it displays tonnage
in whole numbers only.
Between 200 and 1500 tons
For presses with full scale tonnage between 200 and 1500 tons, AutoSet displays only
whole numbers for tonnage (5, 10, 200 750, etc).
Over 1500 tons
For presses with full scale tonnage over 1500 tons, you must multiply the displayed tonnage by 10. For instance, a display of 5.5 tons would be 55 tons, a display of 105 tons
would be 1050 tons, and so on. (See "setting full scale tonnage" in Chapter 2 for more
details on how AutoSet displays tonnage.)
Strain links
Strain links are the sensors used by AutoSet to measure press tonnage. Strain links are
mounted to the press frame, or other structural members, where strain is proportional to
load and are wired to AutoSet. Two strain links are used. The strain links convert press
frame deflection into an electrical signal. They detect and measure the forces -- tension or
compression -- acting on the press frame.
When the press is loaded, the strain link is either stretched or compressed. On straight
side presses, strain links measure tension (stretching of the frame). On gap frame presses
(OBI or OBG), strain links can measure either tension (front mounted) or compression
(rear mounted). The tensile (or compressive) force changes the output signal of the
resistance bridge located inside the strain link body. The electrical signal sent to the
AutoSet 1500 is proportional to the force being exerted by the press.
The two strain links provided with the AutoSet 1500 are called differential strain links.
The part number on your links should be 9641601 (30' cable), 9641602 (100' cable), or
9641801 (with Hirschmann connector), depending on the cable length or connector you
choose. Contact Data Instruments before trying to use any other strain link.
Strain link mounting is described in Chapter 2– Installation.
Calibration
AutoSet must be calibrated before use. To calibrate, you first load the press to a certain
tonnage using load cells. You measure tonnage on an independent load monitor you
know will give correct readings. You then adjust the tonnage readings on AutoSet until
they match the tonnage readings of the independent load monitor. Calibration is covered
in Chapter 3.
AutoSet 1500 User Manual 3 Ch 1 1088500
AutoSet 1500
How AutoSet 1500 works
AutoSet is so easy to use because it creates and displays load setpoints automatically.
You never have to calculate and enter setpoints.
Once AutoSet is installed and properly calibrated, there are only two settings you have to
make. You set the sample period and a percentage (the percent tolerance setting). The
sample period can be set to 1 or 15 strokes. The percentage tolerance setting tells AutoSet
how high above the load the setpoints should be. The percentages of load you can select
are 2%, 5%, 10%, 15%, 20%, 25%, 35%, 50%, or 100%. Settings are made using a
switch and dial indicator inside the box.
Once selected, these same settings can be used for any die (in most cases). You do not
have to change the setting from job to job. (See Chapter 4 for more details on when
changing settings may be necessary).
AutoSet calculates setpoints automatically based on a sample of the load just like you
would figure out setpoints yourself on paper. Here is how it does it:
1. Once the press is running, AutoSet begins measuring and recording the load (in
tons) at each strain link. It records the load for each stroke in the sample period.
2. After the sample period ends, AutoSet determines the highest load at each strain
link. It ends up with two numbers: the highest measured load at the right strain
link and the highest measured load at the left strain link.
3. It then calculates the setpoints using this formula:
highest measured load on each strain link during sample period +
percentage of load selected = high setpoint.
4. This calculation is performed for both strain links. The results are the setpoints for
each side of the press. See the following example. The setpoints are displayed in
the setpoint displays.
During the sample period (while AutoSet is recording tonnage), setpoints are maintained
at 120% of the full scale capacity of the press. Therefore, AutoSet offers protection from
overloads even during the sample period.
NOTE
AutoSet will not create setpoints greater than
120% of the full scale capacity of the press.
AutoSet will calculate new setpoints when you press the reset button and hold it for two
seconds or more. Afterwards, it will also change setpoints when you change the high
percentage setting switch. Complete instructions for making settings on AutoSet, how to
use the reset button, and a discussion of when you need to change settings is in Chapter
4—AutoSet 1500 Operation.
AutoSet 1500 User Manual 4 Ch 1 1088500
AutoSet 1500
Example of how setpoints are calculated
To better understand how AutoSet 1500 automatically creates setpoints, let's look at an
example. Let's say AutoSet is installed on a 50 ton press. The percent tolerance setting is
at 10%, indicating that AutoSet will create setpoints 10% higher than the highest
measured load during the sample period. The sample period is set to 15 strokes.
The press is started. Then the reset button is pushed and held for at least two seconds.
This signals AutoSet to begin the calculation. It also changes the setpoint displays to 30.0
tons each (120% of 25 tons). 25 tons is the full scale tonnage on each side of the press.
Next, the press is run for 15 strokes. The highest measured tonnage on the left is 16 tons
and on the right is 10 tons. See Figure 1-2.
TONS
30
20
10
0
LEFT CHANNEL
30 tons
16 tons
1
23456789101112131415161718
STROKES
17.6 tons
TONS
30
20
10
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
RIGHT CHANNEL
30 tons
10 tons
STROKES
Figure 1-2. Tonnage produced at each strain link in example.
Highest load is on stroke 7 for left strain link and stroke 5 for right strain link. Tonnage
at far right on each graph is setpoint calculated by AutoSet after sample period.
Instantaneously after the 15 stroke sample period ends, setpoints are calculated as follows:
The setpoint for the left strain link is: 16 tons + (16 tons x 10%)
or 16 tons + 1.6 tons
or 17.6 tons
The setpoint for the right strain link is: 10 tons + (10 tons x 10%)
or 10 tons + 1 ton
or 11 tons
These setpoints are now shown in the setpoint display.
11 tons
Figure 1-3. Setpoints AutoSet created in example.
AutoSet 1500 User Manual 5 Ch 1 1088500
15.1
17.6 11.0
LOAD
RIGHTLEFT
SETPOINTS
RESET
9.6
AutoSet 1500
Specifications
Equipment System enclosure 12" x 10.25" x 4"
(30.5 x 26 x 10.2 cm), NEMA 12,
shockmounted
Power 115 or 220 Vac ±15%, 50-60 Hz, 15 W
Operating temperature 32
Relay contact rating 5 amps @ 120 or 240 Vac
Normally open, held closed
Speed To 400 SPM without zero cam,
to 2000 SPM with optional zero cam
Display 2 3-digit .43" (1.1 cm) high for tonnages
2 3-digit .30" (.76 cm) high for setpoints
Strain links (two provided)
Size 3.75" x 1.19" x 0.75" (9.5 x 3 x 1.9 cm)
Cable 30 ft (9.1m) standard, other lengths optional
Drill fixture One provided
o
to 122o F (0o to 50o C)
AutoSet 1500 User Manual 6 Ch 1 1088500
Chapter 2
AutoSet 1500 Installation
Installation of AutoSet involves mounting the AutoSet control box and connecting wiring
for power, strain links, and other devices. This chapter covers:
• Mounting the control box
• Connecting AC wiring and stop circuit
• Mounting and connecting strain links
• Connecting AC wires to power source
• Zero cam wiring (In some cases, installation of a zero cam switch is necessary)
• Optional connections.
Mounting the AutoSet control enclosure
IMPORTANT!
If you have a panel mount, go to Appendix A for special installation
instructions, and mounting and cutout dimensions.
1. Determine a convenient place for the control box. Ideally it should be close to the
press control so operators and setup personnel can easily see the readouts and
reach the reset button. Also make sure the strain link cables will reach to the
mounting site selected. Leave enough room to open the door at least 120°. The
box can be mounted to the press or on a free-standing pedestal.
2. Drill holes for mounting (see dimensions in Figure 2-1). Shockmount studs are
1/4–20. Tap holes (if necessary) and mount the box using the enclosed shock
mounts. Use a No. 7 drill and 1/4–20 tap.
8 (20.32 )
LOAD
LEFT RIGHT
ZERO CAM
12.75
(32.39)
SETPOINTS
RESET
Figure 2-1. AutoSet mounting dimensions
AutoSet 1500 User Manual 7 Ch 2 1088500
AutoSet
WINTRISS LOAD ANALYZER
®
1500
Installation
Connecting AC wiring and stop circuit
Wiring connections for AC power and for the stop circuit are on the same connector. To
wire the connector, follow these steps.
WARNING! PREVENT SHOCK!
Disconnect main power before installation. All power to the press, press control,
and other equipment used with the press must be off during installation. Also
"tag out" per OSHA 1910.147 Control of Hazardous Energy (Lockout/ Tagout).
Installation must be performed by qualified personnel only.
1. Determine how you will bring wiring from your 115 Vac power source (or 230V
source if applicable) to the control box. For 115 Vac, you need three wires—high
(black), neutral (white) and ground (green). No. 16 wire is recommended (No. 14
if local codes require it). For 230 Vac, wires are black and red with green or
green/yellow for ground.
2. Determine how you will connect the wires from AutoSet to your press control
stop circuit. You need two wires (No. 16 recommended, No. 14 if local codes require it). You should wire the AutoSet into the top stop circuit to avoid sticking
the press on bottom if AutoSet stops the press due to an overload.
NOTE: Top stop circuits are active only in continuous (automatic) operations on most
press controls. If overload protection is required during inch or single stroke mode,
you may have to install an additional control relay so AutoSet will stop the press.
3. Open the cover of the control box. See Figure 2-2 for a drawing of the inside of
the box. Near the top of the enclosure, you will see a metal cover. This cover
protects the power supply. Remove it by first unsnapping the two white plastic
plugs at the bottom of the cover (pull plug straight up). Then loosen the screw on
top. Remove the cover. You will see the connector for AC power and the stop
circuit at right.
WARNING! SHOCK HAZARD!
Never apply power to AutoSet when the power supply cover is removed.
To prevent shock, always replace the cover before applying power.
4. Find the 115V-230V voltage selector switch. It's just below the power connection
to the left . It is a black rectangular box with a red handle and a cavity in the
middle. At the bottom of the cavity, you should see "115V." This is the factory
setting. This means AutoSet is set for 115 V operation.
If your AutoSet will be used with 230 Vac, push the red handle extending out of
the cavity towards you (away from top of the box). You will see 230 V displayed.
With the switch in this position, AutoSet will only work with 230 Vac power.
5. Run power and stop circuit wires through flexible liquid tight conduit to the box.
The AutoSet box is rated NEMA 12 (protected against dust and oil). You must
use conduit of the same rating and make proper connections to ensure NEMA 12
protection. Wires go through top right knockout hole. Leave a small service loop
inside box.
AutoSet 1500 User Manual 8 Ch 2 1088500
Installation
Figure 2-2. Location of components in AutoSet 1500 (important components
shown and labeled)
CAUTION
POWER
POWER
TB3
TRANSFORMER
LINE
STOP CIRC.
FUSES
FOR
CALIBRATION
S2
COMMS
LED
DS2
MODE
SELECTOR
S1
VOLTAGE
SELECTOR
S7
% Tolerance
Selector
SETUP
TB1
Chart
Recorder
Zero
Cam
Power
COMMS
TB4
Zero LED
DS1
Remote Reset
LED
DS3
1
Notch
FIRMWARE
U8 U15
CPU NO.
S9
S8
RAM CHIP
J6
R17
J7
R25
Gain
Settings
Tonnage
Settings
Dialog
Station
TB8
LEFT INPUT
TB6
RIGHT INPUT
TB7
S5
S4
S3
AutoSet 1500 User Manual 9 Ch 2 1088500
Installation
6. First connect the ground (green or green/yellow) wire. It must be connected to the
ground block as shown in Figure 2-3, not to "GND" terminal on the connector.
The ground block is located on the wall of the box at top right. To connect to
ground block, strip ground wire about 1/4" (6.4 mm) from end, loosen screw on
block, slide wire in hole, and tighten screw to pin wire in place.
ground wire (green)
Ground block
Connect ground
(green) wire here.
factory installed
ground wire to
case lug
HI NEU GND N/0 CGND
TB3
12345 6
Figure 2-3. Wiring connector and ground block for AC power and stop circuit.
7. Now find the connector TB3 for the other AC wires and stop circuit. It is at top
right. The connector consists of an L-shaped top section and base. Pull the Lshaped part away from its base. This is the part you will connect wiring to.
NOTE: A ground wire is attached from the connector to a case lug as shown in
Figure 2-3. Leave the ground wire attached to the connector while making
connections. If you remove this wire in order to pull the connector all the way out
of the box, be sure to replace it when done.
8. Connect wires to the L-shaped top section as shown in Figure 2-3. For 115 Vac,
connect black wire to HI slot and white wire to NEU. (For 230 Vac connect black
wire to HI slot and red wire to NEU). To connect a wire, find the correct slot and
loosen the screw over that slot by turning it counterclockwise (see Figure 2-4).
Strip the correct wire for this slot 1/4" (6.4 mm) from end. Insert bare wire into
slot 90% of the way. Tighten the screw. Metal tooth inside slot will clamp down
on the bare wire for a tight connection. Make sure the metal tooth is clamped
down on the bare part of the wire, not on the insulation. If on the insulation, you
will have a bad connection.
Connect both wires and double check connections when done.
NOTE: The connector can only plug in one way. Make sure you don't start at
the wrong end when connecting AC wires. Put the connector over the base the
way it will plug in and note wire marking next to base before starting.
AutoSet 1500 User Manual 10 Ch 2 1088500
Installation
tightening screw
clamps wire in slot
slot for wire
Figure 2-4. Inserting wires into connector
9. Connect one of the wires from the press control stop circuit to the terminals
marked N/O (normally open) and the other wire to C (common). It does not
matter which wire goes to which terminal.
10. Plug the connector back into its terminal. Double check connections with
markings at the connector base to make sure you did not wire it backwards. (Note:
first "GND" from left in Figure 2-3 is not used).
11. Make all necessary conduit connections to ensure NEMA 12 protection.
12. Replace the power supply cover removed earlier. Snap in the white plastic plugs
at the bottom of the cover and tighten down screw at top.
13. Do not connect wires to AC power source until you are done with all other
installation procedures. Also make sure you number all wires in a way consistent
with your press's electrical prints.
WARNING
PREVENT SHOCK
Do not connect AC wires to the power source until
after all other installation procedures are finished.
14. Go on to the next procedure, mounting strain links.
AutoSet 1500 User Manual 11 Ch 2 1088500
Installation
Mounting and connecting strain links
The two strain links provided with the AutoSet 1500 are called differential strain links.
The part number on your links should be 9641601, 9641602, or 9641603, depending on
the cable length or connector you chose. If you plan to use other strain links, contact Data
Instruments to find out if they will work with the AutoSet 1500.
To install strain links, follow these steps:
1. Select mounting sites on the press for the strain links. On straight side presses,
strain links are typically mounted on diagonal corners (one on front left, one on
back right). They measure tension (stretching of the frame). For gap frame (OBI
or OBG) presses, strain links can be mounted on the front of the press to measure
tension or on the back of the press to measure compression. Usually mounting on
back is better because the strain links are away from the work area. Typical strain
link locations for most gap frame and straight side presses are shown in Figures
2-5 and 2-6.
D
D
C
C
A – Side of frame (arrow indicates second link D – Rear face of frame (similar to "A" but on rear of
mounted opposite) machine)
B – Front face of frame E – Similar to B but on rear face of frame
(A and B—forward load read as tension) (D and E—forward load read as compression)
Figure 2-5. Strain link mounting options on OBI/OBG presses
AutoSet 1500 User Manual 12 Ch 2 1088500
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