Wintriss wpc 2000 User Manual

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Page 1

WPC 2000

Wintriss Clutch/Brake Control 1128500 Rev. P November 2015

UserUserUser

ManualManualManual

User

Manual

Tech Support Hotline 800-586-8324 8-5 EST

www.wintriss.com

Wintriss Controls Group, LLC

100 Discovery Way Unit 110 Acton MA 01720 USA Phone (800) 586-8324 Fax (978) 263-2048

PRINTED IN USA DA70481

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Requirements You Must Meet

When Installing and Using the Wintriss Clutch/Brake Control

The Wintriss Clutch/Brake Control (WPC 2000) is designed solely for controlling operation of part-revolution metal stamping presses. Before installing or using WPC 2000, be sure you understand and follow these requirements:

DANGER

FULL REVOLUTION MECHANICAL POWER PRESSES AND OTHER MACHINES CANNOT BE STOPPED IN MID-

STROKE OR MID-CYCLE

 DO NOT use WPC 2000 clutch/brake control on full-revolution clutched machinery or other equipment that cannot be

stopped at any point in its stroke or cycle.

 Use WPC 2000 clutch/brake control only on part-revolution clutched mechanical power presses as defined in OSHA

1910.217 (b) (7). Refer also to ANSI B11.1-2009.

 Use WPC 2000 clutch/brake control only on rotating machinery that can be stopped at any point in its stroke or cycle.

Failure to comply with these instructions will result in death or serious injury.

DANGER

IMPROPER SAFEGUARDING

 Ensure that the press on which WPC 2000 clutch/brake control is used meets all of the OSHA and ANSI regulations

for safeguarding press systems in installation and use. WPC 2000 is not in itself a safeguarding device. Wintriss takes no responsibility for injury if safeguarding devices are not installed or working pro perly.

 Install any two-hand control used as a safety device at least the safety distance away from the hazardous area; safety

distance is defined in the OSHA and ANSI regulations. Verify at each shift change that any moveable two-hand control used as a safety device is located at least the safety distance away from the hazardous area.

 Install any light curtain or curtains at least the safety distance away from the hazardous area; safety distance is

defined in the OSHA and ANSI regulations.

 Install other safeguarding devices as needed to ensure operator safety. Follow the machine guardi ng requirements of

OSHA standard 1910.217 and any other regulations and standards that appl y. Test safeguarding devices for correct installation and operation after installation and after any modification or repair.

 Ensure that guarding is properly installed to prevent access to the machine over, under or around any guarding

device.

Failure to comply with these instructions will result in death or serious injury.

DANGER

MORE OPERATORS THAN OPERATOR STATIONS

 Ensure that there are the same number of active Operator Stations as there are operators, if the press is not equipped

with properly installed and operating light curtains.

 During setup, lockout/tagout the press if there are more operators than Operator Stations.  Verify at every shift change that there are the same number of active Operator Stations as there are operators, if the

press is not equipped with properly installed and operating light curtains.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS WILL RESULT IN DEATH OR SERIOUS INJURY.

DANGER

NON-SAFETY OUTPUTS USED FOR SAFETY FUNCTIONS

Use auxiliary outputs and cam channels for non-safety functions only. They cannot protect personnel from a moving

hazard.

Failure to comply with these instructions will result in death or serious injury.

Read additional

DANGER

and

WARNING

notices on following pages.

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DANGER

IMPROPER INSTALLATION, USE OR MAINTENANCE

 Ensure that the machinery complies with OSHA regulations 1910.217 and ANSI B11.1-2009.  Follow all procedures in this manual. Perform only the tests and repairs listed in this manual. Use only factory-

supplied replacement parts. Ensure that all safety procedures are followed during installation and operation of WPC

2000.

 Wire and install WPC 2000 and other equipment according to the requirements of OSHA 1910.147 Control of

Hazardous Energy (Lockout/ Tagout).

 Lockout/Tagout the press during all installation, modification, repair or maintenance procedures.  Ensure that the dual safety valve used on the press complies with OSHA 1910.217 (b) (7) (xi). Contact manufacturer

to verify compliance of your model.

 Ensure that any foot control complies with OSHA 1910.217 (b) (7) (x).  Ensure that WPC 2000 clutch/brake control is installed, tested and repaired by qualified personnel.  Wire, install and maintain WPC 2000 clutch/brake control in accordance with the applicable safety standards. Carry

out all inspection procedures in OSHA 1910.217

 Install and maintain your machine guarding system according to OSHA standard 1910.217, ANSI B11.1, ANSI B11.19

and any other regulations and standards that apply. Ensure that guarding is properly installed to pr event access to the machine over, under or around any guarding device.

 Perform all installation verification and checkout tests after installation and after any modification or repai r of the WPC

2000 clutch/brake control. Correct any problems before using the press.

 Maintain all presses as stated in the applicable regulations. Wintriss takes no responsibility in cases where stopping

mechanisms of machinery or other devices are not maintained or do not meet the applicable regulations or standards.

 Ensure that supervisors, die-setters, maintenance persons, machine operators, foremen, and any others responsible

for operation of the machinery have read and understood all instructions for use of the W P C 200 0 clutch/brake control.

 DO NOT use touch buttons for any safeguarding use.

Failure to comply with these instructions will result in death or serious injury.

WARNING

MACHINERY NOT CONFIGURED OR WORKING PROPERLY

 Ensure that the press on which WPC 2000 clutch/brake control is used meets the machine guarding requirements of

OSHA standard 1910.217 and any other regulations and standards that apply.

 DO NOT operate a press equipped with WPC 2000 clutch/brake control if the machine or any of its stopping

mechanisms is not in proper working order.

Failure to comply with these instructions could result in death or serious injury.

WARNING

OTHER EQUIPMENT CONTINUING TO OPERATE

 Ensure that all operators and other affected personnel know which equipment may continue to operate and which will

not. Equipment that operates with the machinery connected to WPC 2000 clutch/brake control may con t inue to operate after the press has received a stop signal.

Failure to comply with these instructions could result in death or serious injury.

WARNING

ELECTRIC SHOCK HAZARD

 Turn off and disconnect power from WPC 2000 clutch/brake control, the press and any other machinery it is

connected to before making any wiring connections. This includes power to the press’s motor.

Failure to comply with these instructions could result in death or serious injury.

The enforcement of the above requirements is beyond Wintriss’s ability to control. For proper WPC 2000 operation, it is your responsibility to follow these requirements and any other requirements that may be specific to your machinery.

Page 4

Changes for Revision P of the

WPC 2000 User Manual (1128500)

This revision of the WPC 2000 user manual covers WPC 2000 software version 6.00 and higher. The changes include:

• Revised mounting dimensions for the WPC 2000 enclosure (see page 2-7)

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Thank you for purchasing a Wintriss Product. We appreciate your business and want to do whatever

we can to ensure your sa ti sf act ion. Wintris s pr oduc ts 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 . Ret urned goods must arri ve freigh t prepaid . In ord er to proc ess your re turn quic kly, 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 al l packages returne d to W i ntriss Co ntrols Group t o ensure p rompt 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 i tem ca nnot be re paire d o r the re a re ad ditio nal c har ges, you will be contac ted f or 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 an d we will send a repl acement to yo u 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 char ge if retur ned for credit. The mini mum 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.

Page 6

Table of Content s

Chapter 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

WPC 2000 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Resolver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Operator Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Other Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Dual-monitored Safety Valve (DSV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

System Air Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Shadow Light Curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

WPC 2000 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

Chapter 2. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Installation Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Connecting Wires to Terminal Block Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Terminating Cable Shields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Mounting the Control Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Wiring the Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Slide Adjust Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Connecting AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Installing a Dual Safety Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Installing Air Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

Installing a Clutch Air Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Installing a Counterbalance Air Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Installing Operator Station(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Wiring a Pre-wired Operator Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Checking Pre-wired Operator Station Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Making Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Wiring an Unwired Operator Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Wiring a User-built Operator Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Installing Multiple Operator Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Installing a Light Curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

Installing Shadow Light Curtains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Setting Jumpers for Shadow VII and Shadow 8 Light Curtains . . . . . . . . . . . . . . 2-19

Installing Non-Shadow Light Curtains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Installing the Resolver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

Mounting the Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Wiring the Resolver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Checking the Resolver’s Direction of Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Table of Contents i

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1128500 WPC 2000 User Manual

Replacing the Resolver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Installing the Overrun Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Planning Your Overrun Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

Mounting the Overrun Sensor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

Wiring the Overrun Sensor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

Wiring WPC 2000 User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Wiring the Lockout Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Wiring Auxiliary Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Auxiliary Output 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

Auxiliary Output 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

Auxiliary Output 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

Connecting Multiple Controls to the Resolver . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Connecting Other Wintriss Products to WPC 2000. . . . . . . . . . . . . . . . . . . . . 2-33

Wiring Micro-inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Disabling Top-stop in Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Wiring a Remote Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Installing 4-channel Programmable Cam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Mounting and Wiring the Cam Output Assembly . . . . . . . . . . . . . . . . . . . . . . . . .2-36

Making Wiring Connections to Cam Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

Enabling Cam Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

Setting Switch S701 on the Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

Setting Switch 1 on S102 on the Main Processor Board . . . . . . . . . . . . . . . . .2-41

Wiring a Remote Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -41

Wiring Zero Cam Output to AutoSet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Wiring a Foot Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Installing a One-hand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

Mounting a One-hand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44

Wiring a One-hand Control to WPC 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

Mounting and Wiring the Bar Control Enclosure . . . . . . . . . . . . . . . . . . . . . . 2-47

Wiring Automatic Single-stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

Wiring Automatic Continuous On-demand. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

Installing Revised Firmware in WPC 2000. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Installing WPC 2000 without Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

Installing the WPC 2000 Mounting Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

Installing the Panel-mount Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

Mounting the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

Connecting the Panel-mount Display to the WPC 2000 Main Processor

Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

Installing Selector Switches and Final Assembly . . . . . . . . . . . . . . . . . . . . . .2-54

Installing Display Board Kit with Selector Switches . . . . . . . . . . . . . . . . . . . . . . .2-55

Installation Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

Checking Safeguarding Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59

Checking Dual Safety Valve (DSV) Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60

Checking for Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

Checking the Emergency-stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

Installation Verification Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

ii Table of Contents

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WPC 2000 User Manual 1128500

Wiring Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -61

Chapter 3. Initialization, Setup, and Checkout . . . . . . . . . . . . . . 3-1

Viewing and Setting Press Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Initializing the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Re-zeroing the Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Initializing Only the Start-time Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Viewing the Start-time Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Viewing the Last Start Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Installing the Overrun Sensor Magnet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Setting the Top-stop “On” Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Mounting the Overrun Sensor Magnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Adjusting the Top-stop Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Setting the Auto Carry-up Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Running Brake Monitor Tests and Making Settings . . . . . . . . . . . . . . . . . . . . .3-14

Determining the Stopping Time of Your Press . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Calculating the Stop-time Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Setting the Stop-time Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Determining the 90° Stop Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Performing the 90° Stop Test (Continuous Mode) . . . . . . . . . . . . . . . . . . . . . 3-17

Performing the 90° Stop Test (Single-stroke Mode) . . . . . . . . . . . . . . . . . . . . 3-18

Calculating the Safety Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

ANSI and OSHA Safety Distance Formulas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

ANSI Safety Distance Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

OSHA Safety Distance Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Adding to Safety Distance for Blanking Windows . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Setting Micro-Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Setting Press Option Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

Making Settings on Switch Block S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Switches 1 and 2 – Top-stop “On” Angle Range . . . . . . . . . . . . . . . . . . . . . . 3-26

Switch 3 – One-hand Control and Foot Switch Settings . . . . . . . . . . . . . . . . 3-27

Switch 4 – Enabling Auto Compensated Top Stop (ACTS) . . . . . . . . . . . . . . 3-28

Switch 5 – Prior Act Time for Automatic Stroke Modes . . . . . . . . . . . . . . . . 3-29

Switch 6 – Enabling Dual Light Curtains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Switch 7 – Disabling Access to Stop-time Limit and Auto Carry-up Angle

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Switch 8 – Top-stop Mode for F and H Errors and Auxiliary Output 1

Response to Interrupted Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Making Settings on Switch Block S102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Switch 1 – Set Cams Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Switch 2 – Auxiliary E-Stop Relay Muting Function . . . . . . . . . . . . . . . . . . . 3-32

Switch 6 – Selecting Concurrent Time for More Than Two Operator

Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Setting Programmable Cams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Final Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35

Checking the Emergency-stop Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

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Checking the Top-stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40

Checking for Faults When the Press Is Running . . . . . . . . . . . . . . . . . . . . . . . . . .3-40

Power Supply Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

Shadow Light Curtain Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

System Static Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

Single-stroke Mode Test with Light Curtain(s) . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

Single Stroke Mode Test without Light Curtain(s). . . . . . . . . . . . . . . . . . . . . . . . .3-47

Anti-tiedown Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48

Anti-repeat Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49

Continuous Mode Test with Light Curtain(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50

Continuous Mode Test without Light Curtain(s) . . . . . . . . . . . . . . . . . . . . . . . . . .3-52

Foot Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54

One-hand Control Tes t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56

Bar Mode Control Tes t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-57

Checking Operation of the User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-58

Chapter 4. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Responding to an Interrupted Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Responding to a Brake Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Stopping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Displaying and Clearing the Stroke Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Viewing the Counter Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Resetting the Counter Value to Zero. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Setting and Maintaining the Counter Preset Value . . . . . . . . . . . . . . . . . . . . . . 4-6

Setting the Counter Preset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Disabling the Counter Preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Forcing the Counter Preset Value to 999999 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Operating the Press in Inch Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Top-stop in Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Top-stop Bypass (Top-stop in Inch Disabled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Micro-inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Dead Motor Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Operating the Press in Single-stroke Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Single-stroke, Two-hand Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Single-stroke, One-hand Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Single-stroke, One-hand Control Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Single-stroke, Foot Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Operating the Press in Automatic Single-stroke Mode . . . . . . . . . . . . . . . . . . 4-16

Operating the Press in Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Continuous, Two-hand Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Continuous, Foot Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

Operating the Press in Automatic Continuous On-demand Mode. . . . . . . . . . 4-19

Operating the Press in Bar Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Multiple Operator Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

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Chapter 5. Troublesh ooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Responding to WPC 2000 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Lockout Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Brake Monitor Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Brake Warning LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Stop Time Exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

E, F, and H Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

Resolver Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Operational Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Inter-processor Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Input Buffer Test Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Component Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Customized Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Light Curtain Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Emergency-stop Circuit Driver Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Top-stop Circuit Driver Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Shadow Light Curtain Input Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

DSV Interface and Lockout Relay Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Loss of Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Internal Timing Input Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Top-stop and Overrun Setting Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Overrun Limit Switch Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Overrun Limit Switch Test Angle Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Overrun Limit Switch Setting Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Internal Memory Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Resetting Ross DM2 DSV Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

Appendix A. Extracts from OSHA Regulations and ANSI

Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Extracts from OSHA Regulation 1910.217. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Extracts from ANSI Standards for Presence-sensing Devices and Two-hand

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Appendix B. Specifications for User-built Operator Stations. . . .B-1

Run Button Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Switch Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Appendix C. Option 1 User Inputs. . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Installing the Option 1 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Wiring Option 1 User Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8

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Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Wintriss Manuals

Figures at End of Manual

Figure 1. WPC 2000 Operator Station and Display Board Wiring Figure 2. WPC 2000 Standalone External Wiring Figure 3. WPC 2000/Shadow V Wiring Figure 4. WPC 2000 Dual Operator Station Wiring Figure 5. WPC 2000 Mode Selector Switches Wiring Figure 6. WPC 2000 Cam Output Wiring Figure 7. WPC 2000 OEM Operator Station with Separate One-hand Control Wiring Figure 8. WPC 2000 Operator Station with Separate One-hand Control Wiring Figure 9. WPC 2000 Cross-checked User Interlocks with Positive Action Interlocks Wiring Figure 10.WPC 2000 Shadow VI Wiring Figure 11.WPC 2000 Shadow VI Integration Wiring Figure 12.WPC 2000 Auxiliary E-stop Outputs Wiring Figure 13.WPC 2000 Herion DSV Wiring Figure 14.WPC 2000 Ross DSV Wiring Figure 15.WPC 2000 and Shadow VII Wiring Figure 16.WPC 2000 and Shadow VII DIN Control Wiring Figure 17.WPC 2000 Ross DM2 DSV Wiring Figure 18.WPC 2000 and Shadow 8 Control Box Wiring Figure 19.WPC 2000 and Shadow 8 Wiring Figure 20.WPC 2000 Plus Option 1 User Input External Wiring

List of Figures

Figure 1-1. WPC 2000 Control Enclosure and Display ...................................................................1-2

Figure 1-2. Operator Station Components (Side-mounted Run/Inch Palm Buttons) ....................... 1-3

Figure 2-1. WPC 2000 Wiring Overview .........................................................................................2-4

Figure 2-2. Correct Way to Attach Wires to Terminal Block Connectors .......................................2-5

Figure 2-3. Cable Shield Termination ..............................................................................................2-6

Figure 2-4. WPC 2000 Enclosure: Mounting Dimensions ...............................................................2-7

Figure 2-5. AC Input Wiring Connections .......................................................................................2-8

Figure 2-6. Pre-wired Operator Stations Showing Mute Lamp Connections ................................2-13

Figure 2-7. Wiring Steps to Modify Operator Station for WPC 2000 ...........................................2-14

Figure 2-8. Pre-wired Operator Station with Side Run Buttons: Mounting Dimensions ............... 2-15

Figure 2-9. Pre-wired Operator Station with Top Run Buttons: Mounting Dimensions ............... 2-15

Figure 2-10. Unwired Operator Station: Mounting Dimensions ......................................................2-16

Figure 2-11. Resolver: Mounting Dimensions .................................................................................2-21

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Figure 2-12. WPC 2000 Main Processor Board (Right or Center Configuration): Location of

Important Components .................................................................................................2-23

Figure 2-13. WPC 2000 Main Processor Board (Left Configuration): Location of Important

Components ..................................................................................................................2-24

Figure 2-14. Overrun Sensor Magnet Placement: Dwell as a Function of Shaft Diameter ..............2-26

Figure 2-15. Overrun Sensor Magnetic Switch: Installation Example .............................................2-27

Figure 2-16. WPC 2000 Display Board: Location of Important Components .................................2-34

Figure 2-17. Cam Output Enclosure: Mounting Dimensions ...........................................................2-37

Figure 2-18. Cam Output Board: Mounting Dimensions .................................................................2-37

Figure 2-19. Connectors TB2 through TB5 on Cam Output Board .................................................2-39

Figure 2-20. Installing a Suppressor across an AC Load ..................................................................2-40

Figure 2-21. Installing a Diode across a DC Load ............................................................................2-40

Figure 2-22. “Set Cams” Switch (S701) Positions ...........................................................................2-41

Figure 2-23. One-hand Control Switch: Mounting Dimensions .......................................................2-44

Figure 2-24. One-hand Control Switch Base: Mounting Dimensions ..............................................2-45

Figure 2-25. Wiring Connections in One-hand Control Switch (Switch Cover, Bottom View) ......2-46

Figure 2-26. Bar Control Enclosure: Mounting Dimensions ............................................................2-47

Figure 2-27. WPC 2000 Mounting Plate: Mounting Dimensions ....................................................2-52

Figure 2-28. WPC 2000 Panel Mount Display: Mounting and Cutout Dimensions ........................2-53

Figure 2-29. Selector Switch: Cutout Dimensions ...........................................................................2-55

Figure 2-30. WPC 2000 Display Board Kit: Mounting and Cutout Dimensions .............................2-56

Figure 2-31. Reset/Select Button Wiring Connections .....................................................................2-57

Figure 3-1. WPC 2000 Display Showing Indicator Segments .........................................................3-2

Figure 3-2. WPC 2000 Display Showing “System Initialized” (“Int”) Message .............................3-3

Figure 3-3. WPC 2000 Display Showing “Resolver Zeroed” (“rES”) Message ..............................3-4

Figure 3-4. WPC 2000 Display Showing “Initializing Start-time Limit” (“Str”) Message ..............3-5

Figure 3-5. Setting Overrun Timing: Example .................................................................................3-9

Figure 3-6. WPC 2000 Display Showing Overrun Sensor “On” Angle .........................................3-10

Figure 3-7. WPC 2000 Display Showing Stop-time Limit Value ..................................................3-16

Figure 3-8. WPC 2000 Display Showing Results of 90° Stop-time Test .......................................3-17

Figure 3-9. Safety Distance: Distance between Pinch Point and Light Curtain .............................3-20

Figure 3-10. WPC 2000 Display Showing Micro-inch Time Setting ...............................................3-25

Figure 3-11. S101 Option Switch OFF and ON Settings ..................................................................3-26

Figure 3-12. Cam Channel Settings Display: Cam 1 ON Angle (270°) Shown ...............................3-34

Figure 3-13. Cam Channel Settings Display: Cam 1 OFF Setting (325°) Shown ............................3-35

Figure 3-14. WPC 2000 LED Indicator Map (Center- or Right-mounted Board) ............................3-37

Figure 3-15. WPC 2000 LED Indicator Map (Left-mounted Board) ...............................................3-38

Figure 3-16. WPC 2000 Display Board LED Indicator Map ...........................................................3-39

Figure 4-1. WPC 2000 Display with “Stopping Angle” Value Shown ............................................4-4

Figure 4-2. WPC 2000 Display with “Counter” Value Shown ........................................................4-5

Figure 4-3. WPC 2000 Display with “Counter Preset” Value Shown ..............................................4-7

Figure 5-1. WPC 2000 Display Showing Fault Code .......................................................................5-2

Figure 5-2. WPC 2000 Display Showing Lockout Message ............................................................5-3

Figure 5-3. WPC 2000 Display Showing Stopping Time Fault .......................................................5-4

Figure 5-4. Ross DM2 DSV Showing Reset Button .......................................................................5-22

Figure C-1. Option 1 Board Installed on WPC 2000 Main Processor Board ...................................C-4

Figure C-2. WPC 2000 Option 1 Board ...........................................................................................C-5

Figure C-3. WPC 2000 Option 1 Board: LED Map .........................................................................C-7

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List of Tables

Table 1-1. WPC 2000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Table 2-1. Shadow VII and Shadow 8 Light Curtain Jumper Settings . . . . . . . . . . . . . . . . . . . . . 2-19

Table 2-2. Overrun Sensor Switch Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Table 2-3. WPC 2000 User Inputs: Stop Types, Fault Codes, and Wiring Connections . . . . . . . 2-29

Table 2-4. Lockout Relay Wiring Connections (DSV/Lockout Relay Board) . . . . . . . . . . . . . . . 2-30

Table 2-5. Auxiliary Output Wiring Connections and Change Conditions . . . . . . . . . . . . . . . . . 2-31

Table 2-6. Option Switch 8 Settings for Auxiliary Output 1 State Change . . . . . . . . . . . . . . . . . 2-31

Table 2-7. Micro-inch Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Table 2-8. Remote Reset Switch Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Table 2-9. WPC 2000 Main Processor Board (TB109) to Cam Output Assembly (TB1):

Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

Table 2-10. Zero Cam Output Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Table 2-11. Foot Switch Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Table 2-12. One-hand Control Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Table 2-13. Bar Control Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Table 2-14. Automatic Single-stroke Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

Table 2-15. Display Cable Wiring Connections, Display Board to Main Processor Board . . . . . . 2-54

Table 2-16. Selector Switch Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

Table 2-17. WPC 2000 Main Processor Board, TB101-TB104: Wiring Connections . . . . . . . . . . 2-62

Table 2-18. Power Supply (TB105) Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Table 2-19. Aux. E-stop Relay Board Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Table 2-20. DSV/Lockout Relay Board Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Table 2-21. Resolver (TB 106) Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Table 2-22. Cam Outputs (TB 109) Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Table 2-23. Display Board Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Table 2-24. AC Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Table 3-1. WPC 2000 Display: Default Parameters (Press Running) . . . . . . . . . . . . . . . . . . . . . . . 3-2

Table 3-2. Overrun Sensor Magnet Location and Option Switch Settings . . . . . . . . . . . . . . . . . . . 3-8

Table 3-3. Shadow Light Curtain Response Time and Object Sensitivity . . . . . . . . . . . . . . . . . . 3-21

Table 3-4. Switches 1 and 2 Settings (S101): Top-stop “On” Angle Range . . . . . . . . . . . . . . . . . 3-27

Table 3-5. Switch 3 Settings (S101): Enabling Light Curtain Break Mode . . . . . . . . . . . . . . . . . 3-27

Table 3-6. Switch 3 Settings (S101): Enabling Foot Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Table 3-7. Switch 4 Settings (S101): Enabling ACTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Table 3-8. Switch 5 Settings (S101): Prior Act Times for Automatic Modes . . . . . . . . . . . . . . . 3-29

Table 3-9. Switch 6 Settings (S101): Enabling Cam Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Table 3-10. Switch 7 Settings (S101): Disabling Access to Stop-time Limit and Auto

Carry-up Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Table 3-11. Switch 8 Settings (S101): Top-stop Mode for F and H Errors . . . . . . . . . . . . . . . . . . 3-30

Table 3-12. Switch 8 Settings (S101): Auxiliary Output 1 Response to Interrupted Stroke . . . . . . 3-31

Table 3-13. Switch 1 Settings (S102): Enabling Set Cams Function . . . . . . . . . . . . . . . . . . . . . . . 3-32

Table 3-14. Switch 2 Settings (S102): Enabling E-Stop Muting Function . . . . . . . . . . . . . . . . . . . 3-32

Table 3-15. Switch 6 Settings (S102): Selecting Concurrent Time for Multiple Op. Stations . . . . 3-33

Table 5-1. Fault Codes: Significance of Initial Letter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Table 5-2. Fault Codes for User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Table B-1. Operator Station Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Table B-2. Specifications for Operator Station Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Table C-1. Option 1 User Inputs: Input Type and Stop Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

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WPC 2000 User Manual 1128500

Table C-2. WPC 2000 Option 1 Board: Wiring Connections, TB601 . . . . . . . . . . . . . . . . . . . . . . C-6

Table C-3. WPC 2000 Option 1 Board: Wiring Connections, TB602 . . . . . . . . . . . . . . . . . . . . . . C-6

Table C-4. WPC 2000 Option 1 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8

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1128500 WPC 2000 User Manual

How To Use This Manual

This manual shows you how to install, set up, operate, and troubleshoot the WPC 2000 Wintriss Clutch/Brake Control.

Chapter 1 provides an overview of WPC 2000 features and components, describes the locations and functions of the switches and LEDs on the front panel and display, and lists WPC 2000 specifications.

Chapter 2 shows you how to install both enclosure and non-enclosure versions of WPC 2000, including optional components, and perform installation verification tests.

Chapter 3 shows you how to initialize and set up WPC 2000 and perform final checkout tests. Chapter 4 shows you how to run the press, using WPC 2000’s Inch, Single-stroke, and

Continuous stroke selections and Two-hand, One-hand, and Foot modes. Chapter 5 shows you how to respond to and correct the fault codes that appear on the display

when WPC 2000 detects an error. Appendix A provides OSHA regulations and ANSI standards pertaining to the use of

presence-sensing devices for point-of-operation guarding on mechanical power presses. Appendix B provides the safety standards you must meet when building your own Operator

Station. Appendix C shows you how to install, wire, and troubleshoot WPC 2000 Option 1 user inputs. The Glossary explains some terms that may be unfamiliar to you. Figures at the back of the manual provide wiring diagrams that you can use in conjunction

with the instructions in Chapter 2 to wire WPC 2000 and its components.

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WPC 2000 User Manual 1128500

DANGER

WARNING

CAUTION

NOTICE

Important Highlighted Information

Important danger, warning, caution and notice information is highlighted throughout the manual as follows:

A DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.

A WARNING symbol indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

A CAUTION symbol indicates a potentially hazardous situation, which, if not avoided, may result in property damage.

A NOTICE symbol indicates important information that you should remember, including tips to aid you in performance of your job.

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1128500 WPC 2000 User Manual

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.

(978) 268-2700 Fax: (978) 263-2048 Internet: http://www.wintriss.com

xii Table of Contents

Page 18

Chapter 1. Introduction

WPC 2000 Wintriss Clutch/Brake Control is an easy-to-use, dual-microprocessor-based system that controls part-revolution mechanical power presses. Housed in a single modular enclosure, both microprocessors function independently, have different power supplies, and provide separate information to the operator. As a result of its “dual diverse redundancy,” WPC 2000 is able to provide optimum clutch/brake control and improved operator safety while increasing productivity.

WPC 2000 meets or exceeds all ANSI B11.1-2009, OSHA 1910.217, and Canadian Z142-02 standards for Control Reliability, the benchmarks that govern the operation of mechanical power presses. Control Reliability demands that a single component failure in a clutch/brake control circuit not prevent the normal stopping action of the press, not create an unintended stroke, and not allow initiation of a subsequent stroke until the failure has been corrected.

WPC 2000 Com ponent s

WPC 2000 can be configured as a complete system with all the components necessary to operate a pneumatic clutch/brake system.

Resolver

The resolver, which is mounted on the press, turns one-to-one (1:1) with the crankshaft, allowing WPC 2000 to know the exact position of the crankshaft on every stroke.

The resolver is similar to an electrical generator and works on the principle of inductance. The resolver’s two outputs vary in amplitude and phase as the resolver turns. WPC 2000 translates these analog signals to a number that indicates the position of the resolver (and press crankshaft) in degrees.

The resolver eliminates the need for a mechanical rotary limit switch. Operators no longer have to climb on top of the press to make timing adjustments. In addition, the resolver on the WPC 2000 can be shared with other Wintriss resolver-based products, such as DiPro 1500.

Control Enclosure

The WPC 2000 control enclosure (see Figure 1-1, page 1-2) can be ordered with the display and controls mounted on the front (center mount) or on the left (left mount) or right side (right mount). Up to three of the following selector key switches can be mounted in the enclosure:

• Stroke Select (Standard)–Provides switch settings for selection of Inch, Single-stroke, or

Continuous operation or Inch or Single-stroke.

• Mode Select (Optional)–Provides switch settings for selection of One-hand, Two-hand, or

Foot operation. Optional One-hand/Two-hand/Foot firmware is required for use of Onehand and Foot settings.

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1128500 WPC 2000 User Manual

STROKE SELECT

WPC SETTINGSRESET/SELECT

BRAKE WARNING

INTERRUPTED STROKE

TOP STOP ANGLE

AUTO CARRYUP

STOP TIME LIMIT MICRO-INCH

STOPPING TIME STOPPING ANGLE

° STOP TEST

COUNTER

COUNTER PRESET

ANGLE / SPM

Digital LED Display

Counter

Press Speed

Error Codes Crank Angle

Crank-angle Clock

Reset/Select

Button

Indicator Segments

WPC Settings Key Switch

Interrupted Stroke LED

Brake Warning LED

cam on angle

cam off angle

MUTE

WPC 2000

Wintriss® Clutch/Brake Control

Mute lamp

Key switch options

Stroke Select

Key Switch

STROKE SELECT

Mode Select

Key Switch

(optional)

MODE SELECT

Micro-Inch

Key Switch

(optional)

MICRO-INCH

Automatic [Single Stroke (External Trip) or Continuous

On-demand]

Key Switch

(optional)

AUTOMATIC

OP STN

Operator

Station Select

Key Switch

(optional)

• Micro-inch (Optional)–Provides a switch setting for turning on the Micro-inch feature (see

Standard Features, page 1-6).

• Automatic (Optional)–Provides a switch setting for turning on the Automatic Single-

stroke (External Trip) or Continuous On-demand feature.

• Operator Station Select (Optional)–Provides switch settings for selection of Operator

Station A, Operator Station B, or both Operator Station A and B in dual Operator Station configurations.

1-2 Introduction

Figure 1-1. WPC 2000 Control Enclosure and Display

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WPC 2000 User Manual 1128500

PRIOR ACT

switch

PALM TIME

lamp

MUTE

lamp

TOP STOP

switch

EMERGENCY STOP

switch

RUN / INCH

palm switches

RUN/ INCH

PAL M

TIME

PRIOR

ACT

MUTE

TOP

STOP

WINTRISS

Operator Station

The Operator Station is normally the d evice used to run the press in all Stroke Selec t positions. Wintriss provides operator stations with Run/Inch palm switches mounted on either the top or sides (see shows the switches and indicator lamps on an Operator Station with side-mounted Run/Inch palm switches. Functions of these compon ents are shown below.

Installing Operator Station(s)

, page 2-12 for available configurations). Figure 1-2

Figure 1-2. Operator S tation Components (Side-mounted Run/I nch Palm Buttons)

• Run/Inch Palm Switches (2)–Initiate press action when both switches are pressed at the

same time (Two-hand mode) or when only the left switch is pressed (One-hand mode).

• Prior Act Lamp and Switch–An arming device that must be pressed in Continuous Two-

hand and Continuous Foot operating modes before a stroke can be initiated. When the switch is pressed, the lamp illuminates for 8 seconds, indicating the interval within which the operator must press the Run/Inch buttons or Foot Switch in order to stroke the press. Also used in Automatic Single-stroke operation (see page 4-16).

• Emergency Stop Switch–Stops the press immediately when you push it. The switch is not

spring-loaded, so you must pull it back to its original position to clear the emergency stop (F13) fault (see page 5-7).

• Top Stop Switch–Stops the press at the top of its stroke when pressed during Continuous

operation.

• Palm Time Lamp–Illuminates when one Run/Inch palm button is depressed, turning off

after the 1/2 second palm time (“synchronous” time in ANSI terminology) on a standalone Operator Station or the 5 second concurrent time on multiple Operator Stations. The other palm button on a standalone Op. Station or all pairs of buttons on multiple Operator Stations must be pressed before the lamp turns off in order to initiate a stroke.

• Mute Lamp–Illuminates during muting of the light curtain on the upstroke. Requires

installation of a Shadow light curtain and optional light curtain muting firmware.

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1128500 WPC 2000 User Manual

Other Components

Dual-monitored Safety Valve (DSV)

The DSV controls the flow of air to the press clutch and brake. Wintriss provides 3/4 in. and 1 in. Ross DM2 DSVs. See Installing a Dual Safety Valve, page 2-9 for further details.

System Air Pressure Switch

This switch monitors the system ai r pressure . See Install ing Air Pressur e Switches, page 2-11 for additional information.

Shadow Light Curtain

The Shadow light curtain is a presence-sensing device that places an infrared light field between the point-of-operation and the operator. When an object, like the operator’s hand, enters the sensing field and blocks a light beam, the light curtain detects the object and issues an Emergency-stop command to the press.

The Shadow light curtain is required for point-of-operation guarding if WPC 2000 is used with a Foot Switch or in One-hand operating mode. Multiple light curtains can be wired to a WPC 2000. WPC 2000 tests up to two pairs of Shadow inputs every time that the press is started and stopped. See Installing a Light Curtain, page 2-18 for more information.

WPC 2000 is designed to be used with a Shadow light curtain. If you order WPC 2000 without a light curtain, the control enclosure does not have a Mode Select switch, and the unit operates only in Two-hand mode.

The light curtain is placed between the Operator Station and the die space. Shadow’s mounting-bracket design allows plenty of room for adjustment.

WPC 2000 Display

The WPC 2000 display provides the following features (see Figure 1-1):

• Digital LED Display–A highly visible, six-digit readout which shows press speed (SPM),

crankshaft angle, stopping time, and other press parameters. The information displayed depends on the current Stroke Select setting (see Control Enclosure, page 1-1) and the indicator segment selected (see next item). The LED readout also displays WPC 2000 fault codes and abbreviated text messages.

• Indicator Segments–Ten LED indicators which, when illuminated (i.e., selected), display

press information in the digital LED readout. To select a segment in the upper group of six segments, press the Reset/Select button until that segment is illuminated. The segments in the lower group of four segments can only be selected when WPC 2000 is in Inch mode. When illuminated, indicator segments display press speed, crankshaft angle, 90° stop-time test result, stopping time, stopping angle, stroke counter, counter preset, top-stop angle, auto carry-up angle, stop-time limit, micro-inch ti me, and c am On/Of f a ngles. See Viewing and Setting Press Parameters, page 3-1.

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WPC 2000 User Manual 1128500

• Crank-angle clock–A circular series of LEDs that displays dynamically the approximate

angular position of the crankshaft whether the press is running or idle. Each LED in the clock represents approximately 11°.

• Reset/Select Button–Allows you to select indicator segments for display (see previous

item) and clear, or reset, fault conditions that appear on the digital LED display.

• WPC Settings Key Switch–When turned to “+” (i.e., counterclockwise), increments the

value displayed in the LED readout; when turned to “–” (i.e., clockwise), decrements the displayed value.

• Brake Warning LED–An amber LED that flashes when the stopping time of the press

increases to within 10 milliseconds of the preset Stop-time Limit, alerting the operator that it is time to schedule maintenance on the brake. The LED can be turned off only by powering down WPC 2000, then powering the unit back up.

• Interrupted Stroke LED–A red LED that flashes when an Interrupted Stroke (see

Standard Features, below) occurs.

• Mute Lamp–A lamp that illuminates when the light curtain is muted during the upstroke.

Requires installation of a light curtain and optional light curtain firmware.

Standard Features

WPC 2000 provides the following standard features:

• Interrupted Stroke–An Interrupted Stroke occurs when the press is Emergency-stopped

before the completion of a stroke by either the operator or an automatic device for personnel or equipment protection. When this happens, the Interrupted Stroke LED flashes, and WPC 2000 switches to “T wo-hand M aintained Single-stroke” mode. (If WPC 2000 was set to Inch mode, the press stays in Inch mode.) To clear the Interrupted Stroke, the operator pushes both Run/Inch buttons simultaneously and holds them until the press reaches the top of the stroke. At this point, the Interrupted Stroke LED turns off, and WPC 2000 automatically reverts to the original operating mode.

• Customized Status Codes–WPC 2000 provides nine user input s t hat allow you to moni tor

auxiliary press functions, such as lubrication systems. When one of these functions issues a Stop command, a unique status code is displayed on the digital LED readout to identify why the press stopped. Two of the inputs are cross-checked pairs, which you can use for safety interlocks. If you install the optional Option 1 board, you can connect up to 20 additional non-control-reliable inputs and up to 4 additional control-reliable, cross-checked input pairs (see Appendix C).

• Brake Monitor–WPC 2000’s Top-stop brake monitor checks the press’s braking

performance every time a Top-stop command is initiated or when the press completes a stroke at Top-stop. When the press’s stopping time is within ten milliseconds of the preset Stop-time Limit, the Brake Warning LED flashes. When the stopping time exceeds the Stop-time Limit, WPC 2000 issues a Stop command to the press and prevents the press from being restarted until the brake has been serviced.

• 90° Stop-Time Test–This standard feature is required in order to set the correct safety

distance for personnel-guarding devices including light curtains, two-hand controls, and type-B movable barriers. The test is performed at 90°, the press’s most critical stopping

Introduction 1-5

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1128500 WPC 2000 User Manual

point, with the press running in Continuous and the heaviest die installed. The results of the test provide the stopping time (Ts) value specified in both OSHA 1910.217 and ANSI B11.1-2009 (see Appendix A).

• Counter and Counter Preset–The counter maintains a cumulative total of the number of

strokes made by the press. When the count total reaches the value set on the Counter Preset indicator segment (see page 4-6), WPC 2000 stops the press. The counter is reset to “1” with the Reset/Select button. The counter preset feature is useful for batch sizing or periodic QC checks.

• Micro-inch–A feature that allows you to set the amount of time that the Dual Safety Valve

is open in Inch mode when you push the Run/Inch palm buttons. Normally, in Inch the DSV is open for only as long as the Run/Inch buttons are depressed. The Micro-inch setting specifies the length of time the DSV is open regardless of how long the Run/Inch buttons are held. Allowing finer adjustments than are possible in Inch, Micro-inch is designed to facilitate setup on high-speed or short-stroke presses. Requires installation of optional Micro-inch selector switch (see page 1-2).

• Error Codes–WPC 2000 displays a two-digit code preceded by the letter “E,” “F,” or “H

whenever the press is stopped because of a fault. The two-digit code identifies the specific problem that caused the fault. The initial letter indicates how the fault should be reset, and in the case of F and H errors, specifies the processor (A or B) that detected the problem. Underlying causes and remedies for each fault code are provided in Chapter 5.

• Lockout–Selected error codes that are associated with serious error conditions generate the

lockout message “Loc,” which displays in the digital LED readout when the error has been reset. The lockout function provides an added safety feature to WPC 2000, forcing the operator to perform two different Reset operations. The “Loc” message is cleared by turning the Stroke Select key switch to “OFF,” then to “INCH.”

Optional Features

WPC 2000 can be ordered with any of the following optional features:

• Counterbalance Air Pressure Switch–Operating identically to the clutch air pressure

switch, this switch is used with the counterbalance air supply on presses equipped with counterbalances, as required by OSHA regulations.

• Four-channel Programmable Cam Switch–Provides cam timings for feed, pilot release,

air blow-off, lubricator, or other non-safety press equipment.

• One-hand Control–A low-force switch that can be used with WPC 2000 running One-

hand/Two-hand/Foot firmware and equipped with a Shadow light curtain guarding the point of operation. The One-hand Control switch can be mounted on or near the press, allowing the operator to press the switch as part of his normal hand motion after loading a part.

• Foot Switch–A device that frees the operator’s hands for increased, fully-guarded

protection and productivity. One-hand/Two-hand/Foot firmware is required, and a Shadow light curtain must be installed.

• Bar Mode Control–Allows operators and setup personnel to bar the press by hand for die

setting and adjustment. Recommended for smaller-capacity presses of 65 tons or less.

1-6 Introduction

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WPC 2000 User Manual 1128500

DANGER

NOTICE

• Automatic Single-stroke (External Trip)–Allows feed equipment to signal WPC 2000 to

initiate a stroke upon completion of a feed. This option is useful in applications where the feed must be completed before the press can be stroked.

• Automatic Continuous On-demand–Allows an external device to signal WPC 2000 to

start the press in Continuous mode and maintain operation in Continuous.

• Auto Compensated Top Stop (ACTS)–A feature that automatically adjusts the Top-stop

“On” Angle to an earlier point in the stroke to compensate for increases in press speed. ACTS is designed specifically for variable-speed presses. See Switch 4 – Enabling Auto Compensated Top Stop (ACTS), page 3-28 for additional information about this feature.

• Multiple Operator Stations–Two Operator Stations can be connected directly to WPC

2000. If you wish to install more than two Op. Stations, contact Wintriss Tech. Support (see Installing Multiple Operator Stations, page 2-17).

HAZARDS EXPOSED BY NON-WORKING OPERATOR STATION

• Safeguard the point of operation exposed by the non-working Operator Station when using multiple Operator Stations. The exposed area near a disabled Operator Station must be properly guarded.

• Ensure that guarding is properly installed to prevent access to the machine over, under or around any guarding device.

Failure to comply with these instructions will result in death or serious injury.

Use light curtains in addition to multiple operator stations for best personnel safeguarding.

• Display Configuration Options–WPC 2000 is available without an enclosure.

Installation instructions for panel mount and display board kit options are provided beginning on page 2-51.

• Auxiliary E-Stop Output Relay Board–Allows up to three auxiliary devices such as a

feed or transfer to be stopped or prevented from starting when an E-stop button is pressed, a light curtain is interrupted, or a cross-checked input is open.

If your WPC 2000 has Shadow light curtain muting firmware, you can prevent the auxiliary E-stop relays from issuing a Stop command if the light curtain is interrupted during the muted portion of the stroke by setting option switch 2 on switch block S102 on the WPC 2000 Main Processor board (see page 3-32). The auxiliary E-stop muting function is necessary in applications where parts must be ejected through a light curtain. Auxiliary relay muting does not prevent the auxiliary relays from issuing a Stop command when an E-stop button is pressed or a cross-checked input is open.

Layout of the Auxiliary E-Stop Output Relay board is shown in Figure 2-12, page 2-23 or Figure 2-13, page 2-24. Wiring connections are shown in Table 2-19, page 2-63.

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1128500 WPC 2000 User Manual

Specifications

WPC 2000 specifications are shown in Table 1-1.

Table 1-1. WPC 2000 Specifications

Control Enclosure: 14.00 x 19.62 x 7.00 in. (355.6 x 498.3 x 177.8 mm), NEMA 12,

shock-mounted. Panel Mount: 7.50 x 10.00 in. (190.5 x 254.0 mm) Standard items include 6-digit LED display, display indicators, crank-angle

clock, Interrupted Stroke and Brake Warning LEDs, Reset/Select button, Mute lamp, and Settings key switch. Enclosure also provides Stroke Select key switch and holes for two optional key switches.

Equipment Available from Wintriss Controls

Wintriss AC Power Supply (Included)

Power Requirements if not Using Wintriss AC Power Supply

Operating Temperature

Inputs Resolver

Resolver

0.75 in. (19 mm) keyed shaft. Rated shaft loading: 200 lb axial, 200 lb radial.

Operator Station

NEMA 12. Includes two palm buttons, T op-stop, Emergency-stop, and Prior Act buttons, and palm time and mute lamps. Pre-wired; unwired version also available.

Dual Safety Valve (DSV)

Available in 0.75 in. (19 mm) or 1 in. (25 mm) Ross DM2 models.

Air Pressure Switch

12-150 PSI. Monitors clutch air supply pressure. Input: 100-240 ± 10% Vac (universal switching), 75 VA, 50/60 Hz.

Output: 24 ± 1% Vdc, 200 mA maximum for customer use including auxiliary outputs.

24 ± 5% Vdc, 2 A. Must be certified to CSA C22.2 No. 234 Standard.

32° to 122° F (0° to 50° C).

Overrun limit switch Two operator stations DSV monitor Air pressure switch

1-8 Introduction

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WPC 2000 User Manual 1128500

Table 1-1. WPC 2000 Specifications (Cont)

Additional Inputs Motor

Forward and reverse contacts

Shadow Light Curtains (2)

Checks proper functioning at every stroke initiation and stop.

Customized Status Codes

Four for E-stop Three for Top-stop One cross-checked pair for E-stop One cross-checked pair for E-stop/Lockout

Outputs DSV

Two monitored relays, rated 4 A @ 120 Vac, for E-stopping and To p-sto ppi ng pres s.

Lockout

One monitored relay, rated 4 A @ 120 Vac, for de-energizing motor and other devices under critical conditions.

Auxiliary Stop Output

Provides a signal to stop auxiliary equipment during an interrupted stroke.

Optional Auxiliary E-Stop Output Relays

Two monitored relays, rated 4 A @ 120 Vac, for up to three auxiliary devices (e.g., feed, transfer , etc.), which can be stopped or prevented from starti ng if any E- stop bu tton is d epres sed, an y ligh t curt ain is interr upte d, or

any cross-checked inputs are open. Speed 7-500 SPM; 500-2000 SPM optional. Displays Six-digit LED. Displays press speed, crankshaft angle, presettable counter,

° stop-time test result, stopping time, stopping angle, top-stop angle,

auto carry-up angle, stop time limit, and micro-inch as well as cam on/off

angles and status/error codes. Also displays press control timings, which

are secured with keylock and/or internal press option switch. Crank-angle

clock.

LED indicators for Interrupted Stroke and Brake Warning.

Diagnostic LEDs on Main Processor board for power and for all inputs,

including buttons and switches.

Presettable Counter

Counts number of strokes; can be used to stop the press for batch sizing or

QC checks. Includes 6-digit counter on front panel of WPC 2000.

Introduction 1-9

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1128500 WPC 2000 User Manual

Table 1-1. WPC 2000 Specifications (Cont)

Options Shadow V, Shadow VI, Shadow VII, or Shadow 8 Light Curtain

Heights from 6 to 60 in., scanning ranges from 23’ to 65’. Refer to Shadow literature for more information.

Firmware

Muting for Shadow light curtain on the upstroke. Two-hand only. Onehand*, two-hand or foot operation*. Automatic Single-stroke (External Trip). Continuous On-demand. Auto compensated top-stop (ACTS). High Speed (>500 SPM).

Selector Switches

Mode (One-hand*, two-hand, or foot operation*). Micro-inch on/off. Automatic (single-str oke or continuous on-demand) on/off to slave the press to an external device. Operator station select for either of two operator stations or both operator stations.

4-Channel Programmable Cam

Enclosure: 5.41 x 7.38 x 3.48 in. (137. 4 x 187. 5 x 88.4 m m), sho ck-mounted Relay: SPDT 0-3A resistive at 240V (standard) DC Solid State: SPST 2A at 5-60 Vdc optional AC Solid State: SPST 1A at 70-250 Vac (optional)

Foot Switch

Safety switch for foot actuation* (1-hand/2-hand/foot firmware required).

One-hand Control

Control for one-hand actuation* (1-hand/2-hand/foot firmware required).

Counterbalance Air Pressure Switch

12-150 PSI. Monitors counterbalance air supply (uses one custom input).

Bar Mode Control

Allows manual turning of crankshaft.

Motor Control and Custom Packages

Refer to Press Control/Motor Starter literature, and/or contact your Wintriss representative or factory for more details.

Option 1 User Inputs

Provides 20 additional non-control-reliable inputs and 4 additional controlreliable, cross-checked input pairs for customized status codes.

Eight inputs are E-stop Ten inputs are Top-stop Two inputs are E-stop/Lockout Two cross-checked pairs are E-stop Two cross-checked pairs are E-stop/Lockout

* Shadow light curtain required

1-10 Introduction

Page 28

Chapter 2. Inst allation

DANGER

IMPROPER INSTALLATION, USE OR MAINTENANCE

• Follow all procedures in this manual. Perform only the tests and repairs listed in this manual. Use only factory-supplied replacement parts.

• Ensure that WPC 2000 clutch/brake control is installed, tested and repaired by qualified personnel.

• Wire, install and maintain WPC 2000 clutch/brake control in accordance with the applicable safety standards. Carry out all inspection procedures in OSHA 1910.217.

• Wire and install all equipment in accordance with the requirements of OSHA 1910.147 Control of Hazardous Energy (Lockout/Tagout).

• Install and maintain your machine guarding system according to OSHA standard 1910.217, ANSI B11.1, ANSI B11.19 and any other regulations and standards that apply. Ensure that guarding is properly installed to prevent access to the machine over, under or around any guarding device.

• Perform the checkout sequence after installation and after any modification or repair of the WPC 2000 clutch/brake control.

• Lockout/Tagout the press during all installation, modification, repair or maintenance procedures.

• Ensure that supervisors, die-setters, maintenance persons, machine operators, foremen, and any others responsible for operation of the machinery have read and understood all instructions for use of the WPC 2000 clutch/brake control.

• Disconnect the “Continuous” mode position of your stroke selector switch and cover the “CONT” label on your control if the press is not properly guarded for use in Continuous mode.

Failure to comply with these instructions will result in death or serious injury.

FAULTY INSTALLATION

• Ensure that wiring is correct.

• Use only safety-certified components for safety functions, including interlock switches used in safety applications.

• Install guarding to prevent access to hazardous areas. Prevent access to hazardous areas over, under, or around any guarding devices.

• Ensure that there is one active Operator Station for each operator if you are using Two-hand mode.

Failure to comply with these instructions will result in death or serious injury.

Installation 2-1

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1128500 WPC 2000 User Manual

DANGER

NOTICE

ELECTRIC SHOCK OR HAZARDOUS ENERGY

• Disconnect main power before installation.

• Remove all power to the press, press control, and other equipment used with the press.

• Remove all fuses and “tag out” per OSHA 1910.147 Control of Hazardous Energy (Lockout/ Tagout).

• Ensure that installation is performed by qualified personnel.

• Complete all installation procedures before connecting to the AC power source.

Failure to comply with these instructions will result in death or serious injury.

When you have completed installation procedures, perform the tests in the Installation Verification section, page 2-58 to ensure that WPC 2000 is installed correctly and working properly before proceeding to Chapter 3.

ALL SIGNAL GROUNDS MUST BE CONNECTED THROUGH MAIN PROCESSOR BOARD

Connect all signal grounds through pins on the WPC 2000 Main Processor board.

READ INSTALLATION INSTRUCTIONS BEFORE STARTING INSTALLATION

If you install WPC 2000 yourself, read this installation chapter carefully and plan how you are going to proceed before you start drilling holes, running conduit, or cutting wires. Make sure you are familiar with the WPC 2000 display (see page 1-2). If you encounter problems during installation, contact Wintriss Tech. Support.

PRESS MUST BE AT TDC

Before starting installation, make sure that the die has been removed from the press and the press ram has been moved to top dead center (TDC). The press must be at TDC when you make final adjustments for the resolver. The TDC setting should be 0° ±2°. Use a dial indicator on the face of the ram, if necessary, to ensure that the ram is positioned correctly.

2-2 Installation

Page 30

WPC 2000 User Manual 1128500

Installation Guidelines

Observe the following guidelines when installing WPC 2000, referring to Figure 2-1, page 2-4 when necessary.

• For AC wiring, use 16 AWG wire (14 AWG if required by local codes) with a minimum

75° C temperature rating. For other wiring, use 18 AWG with 600 V insulation.

• All signal grounds must run through the WPC 2000 Main Processor board. Use chassis

ground only for terminating cable shields.

• Run flexible, liquid-tight conduit for high voltage lines (120V power, relay circuits) to the

upper left knockout on the WPC 2000 enclosure.

• Never run wires for 120V and for lower voltages (such as 24V or 60V) inside the same

conduit. For example, the Operator Station cables should not share the same conduit with 120 Vac wiring. However, power and logic wiring for the light curtain or Dual Safety Valve (DSV) can be run in the same conduit.

• Provide a dedicated 120V power circuit from the press control transformer to the WPC

2000 input power connection. Do not power any relays or solenoids from this circuit or the auxiliary power terminals on WPC 2000. Doing so may cause erratic press shutdowns due to electrical noise.

• Run one or two low-voltage conduits for the resolver wires to the knockouts on the bottom

of the WPC 2000 enclosure.

• Because WPC 2000 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.

• Make sure the WPC 2000 is properly grounded.

• All relays and solenoids controlled by WPC 2000 must be suppressed. Suppressors should

be installed across the load and as close to the load as possible. Never install a suppressor across the relay contacts. The suppressors tend to fail shorted. In some cases, suppressors are required in the Top-stop and Emergency-stop circuits. Additional suppressors (part number 2238801) can be obtained from Wintriss.

Installation 2-3

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1128500 WPC 2000 User Manual

Overrun limit switch

Timing chain

Resolver

Air pressure switch

Dual Safety Valve

(DSV)

DSV wiring

Resolver, overrun limit switch and air pressure switch wiring

Operator Station wiring

120 Vac high voltage wiring (from Customer Control Transformer)

Wintriss

Clutch/brake

Control

Operator Station

Motor

Control

Crankshaft

Figure 2-1. WPC 2000 Wiring Overview

2-4 Installation

Page 32

WPC 2000 User Manual 1128500

Insert wire here

Tighten screw to clamp wire in terminal

NOTICE

Connecting Wires to Terminal Block Connectors

When connecting wires to terminal block connectors, follow these steps:

1. Find the correct terminal and loosen the screw over it by turning the screw

counterclockwise (see Figure 2-2).

2. Strip the correct wire for this terminal 1/4 in. (6.4 mm) from the end.

3. Insert bare wire into the terminal 90% of the way.

4. Tighten the screw. The metal tooth inside the terminal will clamp down on the bare wire

for a tight connection. Make sure that the metal tooth is clamped down on the bare part of the wire, not on the insulation.

Figure 2-2. Correct Way to Attach Wires to Terminal Block Connectors

Terminating Cable Shields

TERMINATE BOTH ENDS OF SHIELD

Be sure to terminate the cable shield at both ends where possible.

Perform the following steps to terminate shielded cables to the ground studs located inside the WPC 2000 enclosure near the cable’s point of entry, referring to Figure 2-3, page 2-6.

1. Strip the cable jacket as far as the end of the conduit fitting.

2. Cut the drain wire to a length that can wrap at least once around the nearest ground stud.

Loosen the nut, wrap the drain wire clockwise around the stud, and tighten the nut.

3. Connect the rest of the wires in the cable to the terminal block as appropriate.

Installation 2-5

Page 33

1128500 WPC 2000 User Manual

Secure drain wire under nut on ground stud

Drain wire

Strip cable jacket as far as end of conduit fitting

Figure 2-3. Cable Shield Termination

Mounting the Control Enclosure

Mount the control enclosure (see Figure 2-4, page 2-7 for mounting dimensions) so that it is convenient to the operator. An optimal location is one that allows the operator to read the digital display and reach the key switches while standing at the front of the press. The best location will vary depending on the type of enclosure you have ordered–center mount, left mount, or right mount.

The enclosure does not have to be mounted to the press but can be installed on a free-standing pedestal, pendant, or column.

For easy access to the interior of the enclosure, make sure that there is enough room to open the control enclosure door at least 120°.

Plastic cable ties and self-sticking cable clamps are provided in the accessory parts bag. Use them to organize the cables and wiring inside the control enclosure.

Wiring the Control Enclosure

WPC 2000 requires the following electrical components:

• Motor forward auxiliary contact (24V)

• Slide adjust monitor circuit (24V)

• Motor stop circuit (110V), if applicable

• Motor reverse auxiliary contact (24V), if applicable

Power to WPC 2000 should be provided by a step-down control transformer capable of handling 75 VA at 115 Vac ± 10%.

Most of the original controls on the press will be replaced during rewiring except the disconnect, motor starter, and control transformer. Make sure to rewire so that the motor starter operates properly.

2-6 Installation

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WPC 2000 User Manual 1128500

NOTICE

12.00

(304.8)

14.68

(372.8)

17.62

(447.6)

16.88

(428.8)

Note: Allow sufficient clearance for opening door

7.27

(184.5)

14.28

(362.7)

Dimensions: inches (mm)

NON-ENCLOSURE INSTALLATION

See Installing WPC 2000 without Enclosure, page 2-51 for installation instructions if you are installing WPC 2000 in your own enclosure or console.

Figure 2-4. WPC 2000 Enclosure: Mounting Dimensions

Slide Adjust Considerat i ons

If your press has a motorized slide adjustment for the ram, you must prevent slide adjustment while the press is running. Connect spare contacts on the slide adjustment swit ches (i.e., Slide Adjustment “On” or Slide Adjustment “Up”/“Down” switch) to the WPC 2000 Emergencystop circuit or a user interlock to stop the press as soon as the ram adjust switches on. For help in determining how to connect this wiring, call Wintriss Tech. Support.

Installation 2-7

Page 35

1128500 WPC 2000 User Manual

DANGER

LINE

NEUT

Connect ground wire to set screw ground terminal

Neutral

Line

Top left corner inside enclosure

Input Power Terminal block

Connecting AC Wiring

ELECTRIC SHOCK OR HAZARDOUS ENERGY

• Disconnect main power before installation.

• Remove all power to the press, press control, and other equipment used with the press.

• Remove all fuses and “tag out” per OSHA 1910.147 Control of Hazardous Energy (Lockout/ Tagout).

• Ensure that installation is performed by qualified personnel.

• Complete all installation procedures before connecting to the AC power source.

Failure to comply with these instructions will result in death or serious injury.

All wires can be run through flexible, liquid-tight conduit to the control as long as all circuits are 115V. If your Top-stop circuits and Emergency-stop circuits are low voltage (for example, 24V), run two conduits–one for 115V wires and one for 24V wires. Be sure to number all wires so they are consistent with the electrical prints for your press.

Bring the wiring connections for AC power to a convenient point so that you can connect them to the power terminal block at the top left of the enclosure (see Figure 2-5). No. 16 wire (No. 14, if local codes require it) is recommended for these circuits with a minimum 75° C temperature rating.

Figure 2-5. AC Input Wiring Connections

2-8 Installation

Page 36

WPC 2000 User Manual 1128500

NOTICE

DANGER

WPC 2000 AUTOMATICALLY ADJUSTS TO 115 OR 230 VOLT INPUT POWER

You do not need to use a switch or other device to set the level of input power.

To make AC power wiring connections, perform the following steps:

1. Locate the power supply input terminal block on the back wall at the top left of the

enclosure, as shown in Figure 2-5.

2. Determine how you will bring wiring from your 115 or 230 Vac power source to the

enclosure. For 115 Vac, you need three wires—high (black), neutral (white) and ground (green). For 230 Vac, wires are black and red, with green or green-yellow for ground.

3. Run the power wires to the enclosure through flexible, liquid-tight conduit. Because WPC

2000 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.

4. Connect the ground wire to the set screw terminal on the roof of the enclosure, referring to

Figure 2-5 and to Figure 13 (Ross Serpar DSV), Figure 14 (Herion DSV), or Figure 17 (Ross DM2 DSV) at the back of the manual.

5. Connect the power wires.

For 115 Vac power, connect the black wire to the LINE terminal and the white wire to NEUT.

For 230 Vac, connect the black wire to the LINE terminal and the red wire to NEUT. Strip the wire 1/4 in. from the end. Loosen the screw in the input power terminal block,

insert the stripped portion of the wire, and tighten the screw.

6. Double-check connections.

7. Make all necessary conduit connections to ensure NEMA 12 protection.

Inst alling a Dual Safety Valve

USER-SUPPLIED DUAL SAFETY VALVE NOT SUITABLE FOR SAFETY USE

Ensure that your dual safety valve meets the applicable safety standards. Contact the valve manufacturer for information.

Failure to comply with these instructions will result in death or serious injury.

INSTALL DSV CLOSE TO CLUTCH/BRAKE ASSEMBLY TO REDUCE STOPPING TIME

Install the dual safety valve as close as possible to the clutch/brake assembly. Any excess piping between the valve and the clutch/brake assembly increases the Stopping Time of the press.

Failure to comply with these instructions will result in death or serious injury.

Installation 2-9

Page 37

1128500 WPC 2000 User Manual

WARNING

NOTICE

DSV MUFFLER CLOGGING OR LOOSENING

• Clean the DSV muffler periodically. A clogged muffler can degrade Stopping Time.

• Tighten the muffler securely to the valve body. Periodically check to make sure the muffler is securely installed. Vibration may cause it to loosen and fall. To tighten the muffler, secure the valve body, hold the muffler with both hands and turn clockwise as tightly as possible without stripping the threads.

Failure to comply with these instructions could result in death or serious injury.

ALL SIGNAL GROUNDS MUST BE CONNECTED THROUGH MAIN PROCESSOR BOARD

Connect all signal grounds through pins on the WPC 2000 Main Processor board.

If you have ordered a Ross or Herion DSV with your WPC 2000, refer to the appropriate wiring diagram at the end of this manual and to the documentation that came with your valve to install the DSV. Note the following requirements:

• Ross DM2

To wire the Ross DM2 DSV, refer to figures 6 and 17 at the back of the manual. The Reset circuit requires that a diode be installed across the coil in the solenoid to provide

noise suppression (see Figure 17). This wiring has already been done for you in the Hirschmann connector for the 24 Vdc Reset solenoid, which is provided along with two Hirschmann connectors for the 120 Vac valve solenoids in the Ross DM2 kit.

MAKE SURE TO INSTALL NOISE SUPPRESSION DEVICES

Noise suppression devices (Pactrons) are provided in the WPC Installation Kit. Be sure to install them across the two Hirschmann connectors for the 120 Vac valve solenoids as shown in Figure 17.

The Reset solenoid connector comes in two styles. One has a black shell with an electrical circuit including a diode symbol ( ) printed on it, the other a transparent shell with a red LED indicator visible inside. You install this connector on the Reset solenoid at one end of the DSV. The Reset solenoid connector is the only connector at this end of the DSV. The other two connectors are installed on the two valve solenoids at the other end of the DSV, which has three connectors altogether, including one for the DSV monitor that is already installed. You wire the Reset solenoid and valve solenoid connectors to WPC 2000 as shown in Figure 17.

2-10 Installation

Page 38

WPC 2000 User Manual 1128500

CAUTION

NOTICE

DO NOT WIRE RESET CIRCUIT TO 110 VAC

The Reset circuit works only on 24 Vdc. Do not wire the Reset circuit to 110 Vac.

Failure to comply with these instructions could result in property damage.

Note that the DM2 Reset circuit is wired to the OFF position on the WPC 2000 Stroke Select switch (see Figure 6). To reset the Ross DM2 DSV after an F47 error (see page 5-12), press Reset/Select, and turn the Stroke Select switch to OFF, then back to one of the other operating modes (i.e., Inch, Single-stroke, or Continuous).

Make sure to install air supply lines that match the inlet port size of the DM2 DSV to provide sufficient air to reset the unit in case of a fault (see page 5-20).

• Ross Serpar with EP Monitor

This Ross DSV requires a separate user-supplied reset switch. See Figure 14 at the end of this manual. Also, all jumpers except those shown in the wiring diagram must be removed; otherwise, the WPC 2000 Main Processor board may be damaged.

• Herion XSZ

Make sure that you wire the Herion DSV monitor between pin #20 and a +24 Vdc output. See Figure 13 at the end of the manual.

Installing Air Pressure Switches

Your WPC 2000 requires switches to monitor clutch air pressure and counterbalance air pressure if there is a counterbalance.

Both the clutch air and counterbalance air pressure switches are held closed when pressure is applied above the setpoint limit.

Installi ng a Clutch Air Pressure Switch

Install and wire the clutch air pressure switch as follows:

1. Install a filter regulator and lubricator in-line before the clutch air pressure switch if they

are not already present.

2. Connect shop air to the clutch air pressure switch input port.

3. Run the cable through flexible, liquid-tight conduit, observing NEMA 12 requirements.

4. Wire the normally open terminals of the switch between pin #8 and ground (e.g., pin #54)

on the WPC 2000 Main Processor board, referring to Figure 2 at the end of the manual.

5. Set the clutch air pressure switch to 35 PSI, or the pressure recommended by the press

manufacturer.

Installation 2-11

Page 39

1128500 WPC 2000 User Manual

NOTICE

Installing a Counterbalance Air Pressure Switch

Install and wire a counterbalance air pressure switch as follows if there is a counterbalance:

1. Install a filter regulator and lubricator in-line before the counterbalance air pressure switch

if they are not already present.

2. Connect shop air to the counterbalance air pressure switch input port.

3. Run the cable through flexible, liquid-tight conduit, observing NEMA 12 requirements.

4. Wire the normally open terminals of the switch to pin # 83 (User Input 4) and ground (e.g.,

pin # 31), referring to Figure 2 at the end of the manual.

If pin #83 has already been assigned to other user-selected auxiliary equipment, then wire the counterbalance switch contacts across a terminal on the WPC 2000 Main Processor board that generates an E-stop when the connection to ground is broken. See Wiring WPC 2000 User Inputs, page 2-28 for more information.

5. Set the counterbalance air pressure switch to the pressure recommended by the press

manufacturer, typically the pressure required for the smallest upper die you plan to use in this press.

USING RAMPAC (SMARTPAC 1 OR 2) TO CONTROL C OUNT ERB ALANCE PRESSURE

If you use RamPAC to control the counterbalance pressure, set the WPC 2000 counterbalance pressure switch to the pressure required to balance the empty ram.

Installing Operator Station(s)

The Operator Station should be installed in a location from which the operator can conveniently run the press. On most gap-frame (OBI or OBG) presses, this will be on the front of the bolster. For straight-side presses, the Operator Station may be installed on the press or on a pedestal.

The Operator Station should not be permanently mounted until you have calculated the correct safety distance (see Calculating the Safety Distance, page 3-19) and performed the applicable verification (see page 2-58) and checkout (see page 3-35) tests. When you have finished wiring, you can place the Operator Station temporarily on the floor or on a cart.

If you are not installing a light curtain, and if you are planning to use the Operator Station as a two-hand safety device, the Operator Station must be mounted at the correct safety distance from the nearest pinch point on the press. This distance must be calculated based on the Stopping Time of your press. See Calculating the Safety Distance, page 3-19 for details. Mounting the Operator Station at the correct safety distance prevents an operator from leaving the station and reaching the pinch point before the press stops.

2-12 Installation

Page 40

WPC 2000 User Manual 1128500

MUTE

PALM TIME

PRIOR

ACT

INTRISS

TOP STOP

R U N

I N C H

R U N

I N C H

MUTE

PALM TIME

PRIOR

ACT

INTRISS

TOP

STOP

Mute Lamp

Pre-wired Operator Stations top view

Side-button Operator Station Cover, opened, showing underside of cover. (Top-button station is similar.)

Mute Lamp Connections

for WPC 2000

If you are installing a light curtain, the Operator Station must be placed outside the area guarded by the light curtain. You do not need to calculate a specific safety distance for your Operator Station since the light curtain now prevents access to the pinch point. You must not, however, mount the Operator Station between the light curtain and the pinch point.

Wiring a Pre-wired Operator Station

Checking Pre-wired Operator Station Wiring

Before connecting your pre-wired Operator Station to WPC 2000, check the wiring to the mute lamp inside the Operator Station and modify, if necessary, according to the instructions below. Operator stations shipped as part of WPC 2000 systems should not need modification.

1. Find the mute lamp on the Operator Station, as shown in Figure 2-6.

2. Open the Operator Station, and locate the mute lamp connections on the underside of the

Figure 2-6. Pre-wired Operator Stations Showing Mute Lamp Connections

cover.

Installation 2-13

Page 41

1128500 WPC 2000 User Manual

Free the black wire.

Disconnect the pair of white-and-red wires.

Connect the black wire where you just disconnected the pair of white-and-red wires.

Bend the white-and-red wires back on themselves. Ty-wrap them in place. Insulate connector lug with electrical tape.

Black wire with connector lug, not connected to anything

Pair of white-and-red wires connected to one terminal of the mute lamp

Examine the mute lamp wiring as it came from the factory.

NOTE: Orientation of connections may be different.

3. Determine whether you need to modify the mute lamp wiring:

• If your mute lamp wiring looks like panel “E” in Figure 2-7 (i.e., the black wire is

connected, the red-and-white wire not connected), the wiring is correct.

• If your mute lamp wiring looks like panel “A”, follow steps A through E in Figure 2-7

to disconnect the white-and-red wires and connect the black wire.

4. When the mute lamp wiring is correct, connect the Operator Station to WPC 2000.

2-14 Installation

Figure 2-7. Wiring S teps to Modify Operator Station for WPC 2000

Page 42

WPC 2000 User Manual 1128500

MUTE

PALM TIME

PRIOR

ACT

INTRISS

TOP

STOP

5.8

(148)

REF

4.69

(119.1)

16.75

(425.5)

R U N

I N C H

R U N

I N C H

5.50

(139.7)

21.25

(539.8)

Dimensions:

inches

(mm)

6.06

(154.0)

MUTE

PALM

TIME

PRIOR

ACT

INTRISS

TOP

STOP

16.75

(425.5)

28.75

(730.3)

5.50

(139.7)

4.69

(119.1)

Dimensions:

inches

(mm)

Making Wiring Connections

To wire a pre-wired Operator Station, perform the following steps:

1. Punch a hole in the Operator Station enclosure for conduit or sealtight.

2. Connect the conduit or sealtight to the hole; then open the Operator Station box.

Figure 2-8. Pre-wired Operator Station with Side Run Buttons: Mounting Dimensions

Figure 2-9. Pre-wired Operator S tation with Top Run Buttons: Mounting Dimensions

Installation 2-15

Page 43

1128500 WPC 2000 User Manual

DANGER

Dimensions:

inches

(mm)

PRIOR

ACT

INTRISS

TOP

STOP

5.8

(148)

REF

4.69

(119.1)

16.75

(425.5)

R U N

I N C H

R U N

I N C H

5.50

(139.7)

21.25

(539.8)

3. Run the Operator Station cable in the sealtight.

4. Plug the connector end of the cable into the Operator Station.

5. At the other end of the cable, connect the wires to the Main Processor board connector

terminals, as shown in Table 2-17, page 2-62 and Figure 1 at the end of the manual.

6. Mount the Operator Station in a permanent location after performing the applicable

verification and checkout tests and calculating the correct safety distance. Refer to Figure 2-8 and Figure 2-9 (previous page) for mounting dimensions.

Wiring an Unwired Operator Station

OPERATOR STATION MAY NOT MEET SAFETY REQUIREMENTS

• Ensure that th e Operator Station is wired correctly.

• Run all necessary tests to verify that each Operator Station is wired correctly and provides proper anti-tie-down and anti-repeat protection. Test procedures are provided at the end of this chapter and at the end of Chapter 3.

Failure to comply with these instructions will result in death or serious injury.

To wire the unwired Wintriss Operator Station, follow the wiring diagram in Figure 7 at the end of this manual. Before using your press, be sure to check the wiring carefully, run all the applicable verification and checkout tests, and calculate the safety distance. You can then mount the Operator Station in a permanent location, referring to Figure 2-10 for mounting dimensions.

Figure 2-10. Unwired Operator Station: Mounting Dimensions

2-16 Installation

Page 44

WPC 2000 User Manual 1128500

DANGER

NOTICE

Wiring a User-built Operator Station

NON-WINTRISS OPERATOR STATION MAY NOT MEET SAFETY REQUIREMENTS

• Ensure that th e Operator Station is wired correctly.

• Ensure that on any non-Wintriss Operator Station the Run buttons are placed so that two hands are required to push them at the same time and that buttons cannot be pushed simultaneously with one hand or with one hand and one elbow.

• Ensure that on any non-Wintriss Operator Station the Run buttons comply with the requirements specified in Table B-2, page B-2.

• Ensure that on any non-Wintriss Operator Station the Run buttons have ring guards or other means in place to prevent unintentional operation.

Failure to comply with these instructions will result in death or serious injury.

If you build your own Operator Station, refer to Appendix B for applicable safety requirements. To wire your user-built Operator Station, refer to Figure 7 at the end of the manual. Before using your press, be sure to check the wiring carefully and run all the applicable verification and checkout tests. After calculating the correct safety distance, you can mount the user-built Operator Station in a permanent location.

Installing Multiple Operator Stations

HAZARDS EXPOSED BY NON-WORKING OPERATOR STATION

• Safeguard the point of operation exposed by the non-working Operator Station when using multiple Operator Stations. The exposed area near a disabled Operator Station must be properly guarded.

• Ensure that guarding is properly installed to prevent access to the machine over, under or around any guarding device.

Failure to comply with these instructions will result in death or serious injury.

Use light curtains in addition to multiple Operator Stations for best personnel safeguarding.

You can wire up to two Operator Stations to the WPC 2000 (see Figure 4 at the back of the manual for dual Op. Station wiring). Make sure that switch 6 on S102 on the WPC 2000 Main Processor board is set to OFF if you connect dual Operator Stations (see page 3-33).

If you wish to install more than two Operator Stations, contact Wintriss Tech. Support. Do not order standard Wintriss “Multiple Operator Stations” when installing more than two Op. Stations. All Operator Stations in a multi-Op.-Station configuration except the Op. Station

Installation 2-17

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1128500 WPC 2000 User Manual

DANGER

NOTICE

connected to the “A” inputs must contain a Two-hand Control module. When you install more than two Operator Stations, set switch 6 on S102 to ON.

When wiring dual operator stations, make sure to label each Operator Station correctly. Install the label “A” prominently on the Operator Station wired into inputs for Operator Station “A” or “1.” Install the label “B” prominently on the Operator Station wired into inputs for Operator Station “B” or “2.” Test each Operator Station individually. Confirm that selector switch position “A” controls Operator Station “A” and selector switch position “B” controls Operator Station “B.” Also test switch position “Both” to confirm that it controls both Operator Station “A” and Operator Station “B.”

Installin g a Lig ht Curtain

PREVENT OPERATOR FROM STANDING BETWEEN LIGHT CURTAIN AND HAZARDOUS AREA

Ensure that the operator cannot position himself between the light curtain and the hazardous area. Use another pair of light curtains or a mechanical barrier at knee to waist height to prevent the operator or a passerby from being “trapped” between the light curtain and the hazard.

Failure to comply with these instructions will result in death or serious injury.

INCORRECT LIGHT CURTAIN INSTALLATION

• Mount the light curtains at the correct safety distance as instructed in Calculating the Safety Distance, page 3-19. The light curtain will only provide full protection for operators when

mounted at the correct safety distance .

• Install and wire your light curtains correctly, following the instructions in your Shadow manual and referring to Figures 3, 10, 11, 15, 16, 18, and 19 at the end of this manual.

Failure to comply with these instructions will result in death or serious injury.

The light curtain is normally mounted in front of the die space and must be located at least the safety distance from the pinch point. This location ensures that the light curtain can send a Stop command to the press in time for the press to stop before anyone can reach the pinch point. Any opening or access to the die space that is not guarded by the light curtain must be guarded by mechanical barriers.

To determine the Stopping Time of the press, refer to page 3-14. To calculate the correct safety distance, see page 3-19.

You cannot permanently mount the light curtain until the WPC 2000 is working properly and you have measured the Stopping Time, set the brake monitor, and calculated the correct safety distance. However, you will be able to wire the light curtain.

2-18 Installation

Page 46

WPC 2000 User Manual 1128500

WARNING

WPC 2000 provides wiring connections for up to two pairs of light curtains (see Table 2-17, page 2-62). If you wire two sets of light curtains, you must enable them on S101 option switch 6 (see Table 3-9, page 3-29).

Installing Shadow Light Curtains

Wiring connections for Shadow light curtains are provided in the following wiring diagrams at the back of the manual:

• Shadow V–Figure 3

• Shadow VI–Figure 10

• Shadow VI Integrated–Figure 11

• Shadow VII–Figures 15 and 16

• Shadow 8–Figures 18 and 19

For Shadow I or Shadow II wiring, contact Wintriss Tech. Support. For complete Shadow light curtain mounting instructions, see your Shadow user manual.

Setting Jumpers for Shadow VII and Shadow 8 Light Curtains

When you install Shadow VII or Shadow 8 light curtains on your press, you must set jumpers JP121-JP124 on the WPC 2000 Main Processor board (see Figure 2-12, page 2-23 or Figure 2-13, page 2-24) to the positions shown in Table 2-1. Wiring diagrams are provided in figures 15 (Shadow VII control box), 16 (Shadow VII DIN controller), 18 (Shadow 8 optional control), and 19 (Shadow 8 wired directly to WPC 2000) at the back of the manual.

Table 2-1. Shadow VII and Shadow 8 Light Curtain Jumper Settings

Jumper on Main

Processor Board Settings

Light Curtain #1

Light Curtain #2

JP123 PNP JP124 INT JP121 PNP JP122 INT

Installing Non-Shadow Light Curtains

It is your responsibility to ensure that your light curtains are control reliable and intended for use on a mechanical power press as a primary point-of-operation guard. The manufacturer of your light curtain should be able to provide the necessary information.

Failure to comply with these instructions could result in death or serious injury.

Installation 2-19

Page 47

1128500 WPC 2000 User Manual

DANGER

CAUTION

If you plan to interface a light curtain system other than Shadow with your WPC 2000, please call Wintriss Tech. Support for instructions. Be ready to provide the following information:

• Light curtain manufacturer

• Light curtain model number

• WPC model (i.e., WPC 2000)

• WPC 2000 firmware version number (located on A or B microprocessor chip label)

• Wiring diagram from the light curtain manufacturer’s manual

If your WPC 2000 does not have the firmware that allows Foot or One-Hand control and/or muting of a light curtain on the upstroke, you can connect the light curtain’s dry contact outputs directly in series with WPC 2000’s E-stop string.

Installing the Resolver

RESOLVER OUT OF SYNCH WITH CRANKSHAFT

Retain the sprockets on the crankshaft and resolver shaft mechanically so they cannot shift or move out of radial alignment. Be sure that the key on the resolver shaft retains the resolver sprocket. Use a pin or other method to fix the position of the sprocket on the crankshaft.

Failure to comply with these instructions will result in death or serious injury.

Because the resolver must provide WPC 2000 with the exact position of the crankshaft at every degree of the stroke (see Resolver, page 1-1), the device must be driven smoothly at a 1:1 ratio with the crankshaft of the press. Design a method of driving the resolver directly from the crankshaft, using a chain or timing belt (not a V belt) and sprockets. Use either an idler sprocket or a spring-loaded resolver base to compensate for slack or stretch.

DAMAGE TO RESOLVER

Be sure that the sprocket or gear driving the resolver chain or timing belt is mounted so it is centered on the crankshaft. If the gear or sprocket is mounted off-center, the resulting loads on the resolver shaft may cause the unit to fail.

Failure to comply with these instructions could result in property damage.

The drive method you choose must also allow for adjustment of the resolver to its zero position at top dead center. All sprockets must be keyed or pinned. The resolver shaft has a standard key. Wintriss Controls Group stocks a spring-loaded base with a hole pattern to match the resolver.

When designing the drive for the resolver, observe the following precautions:

• Do not use a chain more than three feet in length

• Do not use gears, right-angle joints, or shafts with universal joints, which will develop

either too much backlash or too much play

2-20 Installation

Page 48

WPC 2000 User Manual 1128500

2.75

(69.9)

1.06

(26.9)

1.75

(44.5)

2.00

(50.8)

3/4 dia. shaft (19.05) standard key

Electrical connector

for cable

3.62

(91.9)

0.34 (8.6) dia holes 2 places

9.16

(232.7)

RESOLVER IS AT ZERO WHEN KEYWAY IS ALIGNED WITH ARROW

3.00

(76.2)

3.75

(95.3)

1.50

(38.1)

Resolver shown in zero-degrees position, with key perpendicular to base

Dimensions: inches

(mm)

• Do not try to couple the resolver directly to the crankshaft. Such a placement requires

extreme precision. If the resolver is only slightly off-center , its bearing will be subjected to side loads well in excess of its rated capacity and will ultimately fail.

• Do not use flexible couplings, which can be inaccurate, or V belts, which can also be

inaccurate and will slip

• Do not use a flexible shaft like a speedometer cable. The resolver will lag the crankshaft

because of the twisting of the shaft on start-up. When the crankshaft stops, the resolver will turn past the true stopping point and snap backward.

Mounting the Resolver

To mount the resolver, perform the following steps:

Figure 2-11. Resolver: Mounting Dimensions

Installation 2-21

Page 49

1128500 WPC 2000 User Manual

NOTICE

It does not matter which direction the resolver turns when the press runs. You adjust for the direction of rotation when you wire the unit (see Wiring the Resolver, next section).

1. Mount the resolver by bolting it to the press or other platform at the desired location.

2. Make sure the press is at TDC.

3. Rotate the resolver shaft so that the keyway is aligned with the arrow on the housing (see

Figure 2-11).

4. Keeping the keyway aligned with the arrow, attach the chain or drive mechanism.

Wiring the Resolver

To wire the resolver, perform the following steps:

1. If the resolver cable is not already connected to the resolver, locate the cable, plug the

molded connector into the resolver (it only goes one way), and twist the locknut so the connection is tight.

2. Run the resolver cable through conduit from the resolver to one of the knockouts in the

bottom of the WPC 2000 enclosure.

You can run the resolver and overrun limit switch cables through the same conduit (see Figure 2-1, page 2-4 for an example). If you do so, make sure not to cut the cable and wires until both the resolver and the overrun limit switch are installed.

3. Find the resolver terminal block, TB 106, on the WPC 2000 Main Processor board (see

Figure 2-12, page 2-23 or Figure 2-13, page 2-24), and remove the L-shaped connector.

4. Viewing the resolver from the shaft end, determine whether the shaft will turn clockwise

or counterclockwise when the press runs.

5. Measure and cut the resolver wires so they reach TB 106, then wire them to the L-shaped

connector, referring to T able 2-21, page 2-63, and Figure 2 at the end of the manual. Make sure you connect the black and yellow wires correctly, based on the direction in which your resolver will rotate–clockwise or counterclockwise. Refer to Connecting Wires to Terminal Block Connectors, page 2-5 if you need help wiring the TB 106 connector.

CONNECTOR WIRING

Before wiring, place the connector over its base the way it will plug in (it can plug in only one way) and double-check pin assignments to make sure you wire correctly.

6. Double-check connections when you are finished wiring.

7. Plug the L-shaped connector firmly into its base. It can plug in only one way.

2-22 Installation

Page 50

WPC 2000 User Manual 1128500

TB 106

Resolver

TB 108

Display cable

TB 109

Cam outputs

TB 107

Serial port

TB 303

DS 302

DS 301

DS 303

TB 302 TB 301

TB 403

TB 402 TB 401

TB 105

Power

F 303

F 302

DSV/Lockout relay board

Aux. E-stop relay board (Optional)

DS 401

DS 402

TB101

TB104

TB103

LEDs

Hi/Lo speed

jumper JP126

(underneath

DSV/Lockout

relay board)

Light

curtain A

output type

jumper JP123

Hi/Lo speed

jumper

JP125

Transmit

DS1381

Receive DS1371

Transmit

DS1421

Receive DS1431

Serial

port LEDs

Display

cable LEDs

Light curtain B

test mode

jumper

JP122

+ 24V I/O

LED

DS150

+5V A processor

LED

DS149

Light curtain B

output type

jumper

JP121

Light curtain A

test mode

jumper

JP124

+5V B processor

LED

DS151

Option

switches

S101

Option

switches

S102

Green

OrangeGreen

Green

Green Orange

TB102

Green Orange

INT

EXT

PNP

NPN

RAM

chip

U102

pro-

cessor

chip

U111

87654321

pro-

cessor

chip

U134

INT

EXT

PNP

NPN

LED #

8990919293949596979899100101102103

105104 107106 109108 110 112111 114113 115 117116 119118 120 122121 124123 125 127126 129128 130

DSV ADSV B

Group 4Group 3

Group 1 Group 2

Group 5 Group 6

Group 7

Installation 2-23

Figure 2-12. WPC 2000 Main Processor Board (Right or Center Configuration):

Location of Important Component s

Page 51

1128500 WPC 2000 User Manual

TB 106

Resolver

TB 108

Display cable

TB 109

Cam outputs

TB 107

Serial port

TB 303

DS 302

DS 301

DS 303

TB 302TB 301

TB 403

TB 402TB 401

TB 105

Power

F 303

F 302

DSV/Lockout relay board

Aux. E-stop relay board (Optional)

DS 401

DS 402

TB101

TB104

TB103

LEDs

Hi/Lo speed

jumper

JP126

(underneath

DSV/Lockout

relay board)

Light

curtain A

output type

jumper JP123

Hi/Lo speed

jumper

JP125

Transmit

DS1381

Receive DS1371

Transmit

DS1421

Receive DS1431

Serial

port LEDs

Display cable LEDs

Light curtain B test mode jumper JP122

+ 24V I/O

LED

DS150

+5V A processor LED DS149

Light curtain B output type jumper JP121

Light curtain A

test mode

jumper

JP124

+5V B processor

LED

DS151

Option

switches

S101

Option

switches

S102

Green

Orange Green

Green

GreenOrange

TB102

GreenOrange

INT

EXT

PNP

NPN

RAM

chip

U102

pro-

cessor

chip

U111

87654321

pro-

cessor

chip

U134

INT

EXT

PNP

NPN

LED #

89 90 91 92 93 94 95 96 97 98 99 100101 102 103

105104107106109 108110112 111114 11311511 711 611 911 8120122121124123125127126129128130

DSV A DSV B

Group 4 Group 3

Group 1Group 2

Group 5Group 6

Group 7

2-24 Installation

Figure 2-13. WPC 2000 Main Processor Board (Left Configuration):

Location of Important Component s

Page 52

WPC 2000 User Manual 1128500

DANGER

Checking the Resolver’s Direction of Rotation

To determine whether you have wired the resolver so that it rotates in the correct direction, do the following:

1. Run the press in Inch mode, and observe whether the crankshaft angle shown in the digital

LED display increases or decreases.

• If the angle increases (i.e., moves from 0° to 1°, 2°, 3°, etc.), the resolver wiring is

correct. Go to the next section.

• If the angle decreases (moves from 0° to 359°, 358°, 357° etc.), the yellow and black

resolver wires are reversed. Go to step 2.

2. Rewire the yellow and black resolver wires correctly, referring to Table 2-21, page 2-63

and Figure 2 at the end of the manual.

3. Inch the press again, and observe the movement of the crankshaft angle in the LED

display. The angle should now increase.

4. If the direction of rotation is still incorrect, contact Wintriss Tech Support.

Replacing the Resolver

If you need to replace your resolver, do the following:

1. Perform the Mounting the Resolver and Wiring the Resolver procedures, above.

2. Rezero the resolver, following the instructions in Re-zeroing the Resolver, page 3-4.

Installing the Overrun Limit Switch

MOUNT OVERRUN LIMIT SWITCH SO IT PROVIDES CORRECT TIMING

• Install the overrun limit sensor magnet on a component, such as the crankshaft, that moves independent of the resolver and whose motion is not affected by the condition of the resolver or the resolver’s drive mechanism. Safe operation of the press depends on the overrun limit sensor working correctly when the resolver or its drive mechanism fails.

• Install the overrun limit sensor magnet in the correct angular location according to the instructions starting on page 3-6.

Failure to comply with these instructions will result in death or serious injury.

The overrun limit sensor, also called the “overrun sensor,” enables WPC 2000 to monitor operation of the resolver and to stop the press whenever the resolver fails to work properly, as can happen when the resolver drive chain breaks or slips or when the resolver is broken. The overrun sensor provides a signal to WPC 2000 at the same resolver angle on every stroke. Whenever this angle changes, WPC 2000 detects that the resolver is no longer rotating at a 1:1 ratio with the crankshaft and sends an Emergency-stop command to the press, simultaneously displaying an error code.

Installation 2-25

Page 53

1128500 WPC 2000 User Manual

10

Actuating

Magnet

5 (127 mm) diameter

23 of dwell

10 (254 mm) diameter

11 of dwell

Crankshaft

5

Optimum dwell: 15 to 25

NOTICE

Planning Your Overrun Sensor Installation

The overrun sensor consists of a magnetic switch and a magnet. Select a mounting location for both components that ensures that the magnet moves past the switch once on every stroke and within 1/8 in. to 3/16 in. (3 mm to 5 mm) of the switch, close enough for the switch to sense the magnet’s presence. The magnet is mounted to the crankshaft or another component that rotates identically on every stroke. The switch is hard-mounted to the press or other surface and remains stationary.

There must be no connection between the overrun limit sensor and the resolver to ensure that the overrun sensor continues to operate if the resolver or its drive mechanism fails.

To obtain an adequate overrun signal at high speeds, the magnet should be mounted so that it can be sensed by the switch for 15° to 25° of the stroke. The interval during which the magnet is sensed, called the “dwell,” decreases as the diameter of the rotating shaft increases (see Figure 2-14). Select a shaft whose diameter will allow the sensor to detect the ma gnet fo r the required dwell.

Figure 2-14. Overrun Sensor Magnet Placement: Dwell as a Function of Shaft Diameter

Mounting the Overrun Sensor Switch

INSTALL MAGNET AFTER MOUNTING SWITCH

Install the overrun magnetic switch as instructed in this section. Refer to page 3-6 for instructions on installing the overrun magnet.

The overrun sensor magnetic switch comes already installed in a bracket. Mount the bracket and switch at a location past which the magnet will pass on every stroke and within 1/8 in. to 3/16 in. (3 mm to 5 mm) of the magnet, referring to Figure 2-15, page 2-27.

2-26 Installation

Page 54

WPC 2000 User Manual 1128500

Crankshaft

Gap between magnet and magnetic switch

1/8 to 3/16

Crankshaft

Press

Magnetic switch

Magnet

Mount temporarily

with tape.

Hard mount later.

Diameter

4-6

NOTICE

Figure 2-15. Overrun Sensor Magnetic Switch: Installation Example

Place the magnet temporarily on the crankshaft or other mounting surface while you set the gap between the switch face and the magnet. After tightening down the bracket’s mounting screws, remove the magnet and put it in a safe place until you mount it permanently.

Wiring the Overrun Sensor Switch

You can run both the resolver wires and the overrun limit sensor cable through the same conduit. If you do so, wait to cut the cable and wires until both the resolver and the overrun limit sensor are installed.

Run the cable for the magnetic switch through conduit to the WPC 2000. Connect the wires to terminal blocks on the WPC 2000 Main Processor board, as shown in Table 2-2 and Figure 2 at the end of the manual.

Table 2-2. Overrun Sensor Switch Wiring Connections

Pin # Signal Wire Color

23 +24 Vdc Red 24 Overrun input to WPC 2000 White 25 Ground Black

Installation 2-27

Page 55

1128500 WPC 2000 User Manual

DANGER

Wiring WPC 2000 User Inputs

USER INPUTS 1 THROUGH 7 NOT SUITABLE FOR SAFETY USE

DO NOT use inputs 1 through 7 as part of any personnel-protection system. These inputs are not control reliable.

Failure to comply with these instructions will result in death or serious injury.

USER INPUTS ADD DELAY TO STOPPING TIME

DO NOT connect light curtains or other presence-sensing devices to any user inputs. The crosschecked input pairs (8/9 and 10/11), though control reliable, are suitable only for applications such as connecting to safety switches used with interlocking barrier guards.

Failure to comply with these instructions will result in death or serious injury.

MAKE SURE TO WIRE CROSS-CHECKED INPUT PAIR CORRECTLY

Input pairs 8/9 and 10/11 are control reliable only if wired correctly in a pair according to the instructions in this section.

Failure to comply with these instructions will result in death or serious injury.

CHECK PRESS TO MAKE SURE IT STOPS WHEN USER INPUT ACTUATES

• WPC 2000 comes from the factory with the inputs bypassed by jumpers. Make sure to remove the appropriate jumper from the Main Processor board connector when you wire a user input. Otherwise, WPC 2000 will not receive the signal from the input. Leave all unused inputs jumpered/bypassed.

• Perform checkout procedures to ensure that the user inputs are wired correctly and that WPC 2000 responds correctly when the user input faults (see page 3-58).

Failure to comply with these instructions will result in death or serious injury.

WPC 2000 user inputs allow you to connect signals from other equipment in order to monitor auxiliary press functions such as lubrication systems. WPC 2000 provides connections for two pairs of control-reliable, cross-checked inputs and seven independent inputs that are not control reliable.

When one of these inputs issues a Stop command by opening a normally closed (N/C) relay, a fault code for the input(s) appears on the LED display. User inputs 1, 2 and 4 and crosschecked input pair 8/9 issue an Emergency-stop command. User inputs 3, 5, and 6 generate a Top-stop command. User input 7 and cross-checked input pair 10/11 generate an Emergency Stop, simultaneously opening the Lockout relay and displaying the “Loc” message on the digital LED readout. The stop type, fault code, and wiring connections for each input are shown in Table 2-3, page 2-29.

2-28 Installation

Page 56

WPC 2000 User Manual 1128500

NOTICE

Table 2-3. WPC 2000 User Inputs: Stop Types, Fault Codes, and Wiring Connecti ons

Jumper User Input (Interlock) Stop Type

User 1 ESTOP 21 +24 Vdc 51 User 2 ESTOP 82 +24 Vdc 52 User 3 TOP STOP 71 +24 Vdc 53 User 4 ESTOP 83 Ground 54 User 5 TOP STOP 72 Ground 55 User 6 TOP STOP 84 Ground 56 User 7 ESTOP/

LOCKOUT

User 8 paired with 9

User 9 paired with 8

User 10 paired with 11

User 11 paired with 10

ESTOP

ESTOP/ LOCKOUT

73 Ground 57

85 Ground

74 Ground

86 Ground

18 Ground

Connection

(Bypass)

Fault Code

58, 17

50, 18

Name of Auxiliary Equipment

The cross-checked input pairs generate a fault either when one or both inputs in the pair are open or when the inputs “disagree” (i.e., one input is open, the other closed) for longer than

100 mS. Cross-checked input pair 10/11 can be used to detect critical safety problems such as the removal of die receptacle blocks.

Since faults for input 7 and cross-checked input pair 10/11 open the Lockout relay, you can wire this relay to your motor starter so that ungrounding of input 7 or of either input in the input pair will shut off the motor.

To clear the “Loc” message on the LED display, turn the Stroke Select switch to OFF and then back to INCH (see Wiring the Lockout Relay, next section, and Lockout Message, page 5-3).

ALL SIGNAL GROUNDS MUST BE CONNECTED THROUGH THE MAIN PROCESSOR BO ARD

Connect all signal grounds through pins on the WPC 2000 Main Processor board.

To wire the user inputs, run conductors from the appropriate terminal number on the Main Processor board to your equipment and then back to either +24 Vdc or ground, as shown in Table 2-3 and Figure 2 at the end of the manual. (There are several available “Ground” and “+24 Vdc” terminals on the Main Processor board from which to choose.) After you have wired the inputs you will use, be sure to bypass all the unused inputs by connecting them to +24 Vdc or Ground.

Installation 2-29

Page 57

1128500 WPC 2000 User Manual

NOTICE

DANGER

If you do not bypass the unused inputs, WPC 2000 will not work properly.

You can add up to 20 more non-control-reliable user inputs and up to 4 more control-reliable, cross-checked user inputs to your WPC 2000 by purchasing the Option 1 “daughter” board, which you install on the WPC 2000 Main Processor board. If you are interested in this product, contact your local Wintriss representative or call Wintriss Tech. Support. To install, wire, and troubleshoot the Option 1 board, refer to Appendix C.

Wiring the Lockout Relay

The Lockout relay, which is designed to be wired to critical press functions such as the motor starter, provides an added safety feature to WPC 2000. Whenever a serious error condition

occurs, the “Loc” message will appear in the digital LED display. To clear the “Loc” message, turn the Stroke Select switch to OFF, then back to INCH or one of the other operating modes.

Wire the function you want to be controlled by the Lockout relay to TB 301 on the DSV/ Lockout relay board, which is located in the upper left corner (see Figure 2-12, page 2-23) or lower right corner (see Figure 2-13, page 2-24) of the WPC 2000 Main Processor board. Wiring connections are shown in Table 2-4 and in Figures 13 (Herion DSV), 14 (Ross Serpar DSV), and 17 (Ross DM2 DSV) at the end of the manual.

Table 2-4. Lockout Relay Wiring Connections (DSV/Lockout Relay Board)

TB301

Pin # Signal

97 Lockout relay input 98 Lockout relay output 99 Lockout relay output

Wiring Auxiliary Outputs

NON-SAFETY OUTPUT USED FOR SAFETY FUNCTIONS

Use Auxiliary outputs 1, 2, and 3 for non-safety functions only , such as convenience in automation. They cannot protect personnel from a moving hazard.

Failure to comply with these instructions will result in death or serious injury.

WPC 2000 provides three optional Auxiliary outputs that you can use to automate equipment connected to your clutch/brake control. A summary of wiring connections and change conditions for these three outputs is provided in Table 2-5, page 2-31. Details about each output are given following the table. Additional wiring details are provided in Table 2-17, page 2-62 and in Figure 2 at the back of the manual.

2-30 Installation

Page 58

WPC 2000 User Manual 1128500

Table 2-5. Auxiliary Output Wiring Connecti ons and Ch ange Con ditions

Pin #

(WPC 2000

Output

Aux. 1 28 On (N/C) Off (or Open) • WPC 2000 fault

Aux. 2 36 Off (N/O) On (or Closed) • WPC 2000 fault

Aux. 3 29 Off (N/O) On (or Closed) • DSV energized

Cntrl Bd.)

Normal

State

Change

State Change Conditions

• E-stop string open

• Light curtain interruption

• Interrupted Stroke (controlled by option switch 8–see Table 2-6)

• Interrupted stroke

• Key switch in Inch and DSV energized

Auxiliary Output 1

Auxiliary 1 is normally closed (N/C), or On. The output opens, or turns Off, when a fault condition occurs, an E-stop string opens, or a light curtain is interrupted while the press is running. The output can also be programmed to turn Off during an Interrupted Stroke (see page 4-3 for an explanation of Interrupted Stroke).

Aux. Output 1 response to an Interrupted Stroke is controlled by option switch 8 on the WPC 2000 Main Processor board. Switch settings are shown in Table 2-6.

Table 2-6. Option Switch 8 Settings for Auxiliary Output 1 State Change

Option Switch 8 Auxiliary Output 1 State Change during Interrupted Stroke

OFF Output turns OFF when an Interrupted Stroke occurs

ON Output remains ON during an Interrupted Stroke unless the Interrupted Stroke

is preceded by a WPC 2000 fault or an Emergency Stop, in which case the output turns OFF

When switch 8 is set to OFF, Auxiliary Output 1 opens, or turns Off, at the occurrence of an Interrupted Stroke. When switch 8 is set to ON, the output turns Off during an Interrupted Stroke only when there is also a fault or Emergency-stop condition; otherwise, the output remains On during an Interrupted Stroke. See Auxiliary Output 1 Response to Interrupted Stroke, page 3-31 for additional details.

The switch 8 ON setting allows the press to be “inched” during an Interrupted Stroke, when the WPC 2000 is in Two-hand Maintained Single-stroke mode. Normally, in Two-hand Maintained Single-stroke, the operator must hold down the Run/Inch palm buttons until the press reaches its Top-stop position in order to avoid another Interrupted Stroke. With switch 8 set to ON, the operator may release the Run/Inch buttons while inching the press to Top-stop without initiating an Interrupted Stroke.

Auxiliary Output 1 can be wired to a customer-supplied control relay and used to stop auxiliary equipment such as scrap choppers, conveyors, etc. when one of the conditions described above causes the press to stop. When a warning beacon is connected to the control relay, the beacon illuminates when a fault occurs and Aux. Output 1 opens.

Installation 2-31

Page 59

1128500 WPC 2000 User Manual

NOTICE

Auxiliary Output 2

Auxiliary Output 2 is normally open (N/O), or Off. The output closes to ground, or turns on, whenever there is an interrupted stroke or fault condition or the press is placed in Inch mode.

Auxiliary Output 2 can be connected to the Setup Mode inputs of DiPro 1500 and AutoSet 1500/1504 Plus. The output is used to disable green sensors in DiPro 1500 or repeatability setpoints in AutoSet 1500/1504 Plus whenever the press is switched to Inch mode or an interrupted stroke or fault condition occurs. A customer-supplied output relay can be wired into this circuit. Refer to the applicable manuals for wiring details.

Auxiliary Output 3

Auxiliary Output 3 is normally open (N/O), or Off. The output closes, or turns On, when the DSV is energized. When Bar Control is in use (see Operating the Press in Bar Mode, page 4-19), Aux. Output 3 remains open, or Off, when the DSV is energized.

Auxiliary Output 3 can be wired to the input check circuit of DiPro 1500 or ProCam 1500 and is used to prevent Loss of Rotation faults on these units when Bar Control is activated.

When WPC 2000 is in Bar Control mode, the DSV is energized to enable the crankshaft to be turned by hand. Under normal conditions, whenever the DSV is energized, Aux. Output 3 turns On, sending a low voltage (i.e., 24 Vdc) input check signal to the DiPro 1500 or ProCam

1500. DiPro/ProCam 1500 uses the input check signal to initiate monitoring of the programmed start

time limit, the interval within which the crankshaft must begin rotating in order to avoid a Loss of Rotation fault. In Bar Control mode, Aux. Output 3 disables the input check signal, preventing the 1500 unit from monitoring the start time limit.

Wire Auxiliary Output 3 to the “A” connection of the input check circuit of DiPro 1500 or ProCam 1500. Wire one of the +24 Vdc outputs on the WPC 2000 Main Processor board (pins #37 through #42) to the “B” connection of DiPro 1500 or ProCam 1500. If your DiPro 1500 or ProCam 1500 is equipped with a voltage selector switch for the input check circuit, set it to the 12-60 volt position. Refer to the DiPro 1500 or ProCam 1500 manual for details.

Connecting Multiple Controls to the Resolver

MAKE WPC 2000 THE “MASTER” WHEN CONNECTING MULTIPLE CONTROLS

When connecting multiple controls to the resolver, make sure that the connection between the resolver and WPC 2000 is direct, thereby making WPC 2000 the “master” control. Wire the other Wintriss controls in parallel to the resolver as “slaves.”

You can connect the resolver to as many as three additional Wintriss controls (e.g., WPC 2000, DiPro 1500). To do so, perform the following steps:

2-32 Installation

Page 60

WPC 2000 User Manual 1128500

1. Check the resolver connector TB106 on the WPC 2000 Main Processor board (see

Figure 2-12, page 2-23 or Figure 2-13, page 2-24) to make sure that the resolver is wired to the WPC 2000 as instructed on page 2-22.

2. Locate the 7-conductor shielded resolver cable. Run the cable through 1/2 in. conduit

from the WPC 2000 to the other control. If there is a connector on one end of the cable, cut it off.

3. Pull the TB106 resolver connector out of its socket.

4. Attach the wires to TB106 as shown in Table 2-21, page 2-63 and in Figure 2 at the end of

the manual. You will be wiring in parallel (#104 brown to brown, #105 orange to orange, etc.), so that when you are finished, you should have two wires of the same color connected to each terminal on that connector.

5. Connect the cable from TB106 to the resolver connector in the first “slave” unit.

Remember to wire in parallel.

6. Locate the master/slave jumper on the Main Processor board of the “slave” unit(s). Move

each of these jumpers to the pins designating “slave.” Refer to the applicab le user manual.

7. Repeat steps 5 and 6 to connect additional “slave” units.

Connecting Other Wintriss Products to WPC 2000

You can connect other Wintriss products to WPC 2000, such as DiPro 1500 and ProCam

1500. Before you wire, complete all WPC 2000 installation, initialization and checkout procedures. Then run the press in all modes of operation–Inch, Single-stroke, and Continuous (if applicable). Also make sure that the press has working Top-stop and Emergency-stop circuits. Since WPC 2000 is connected to the press stop circuits, it is extremely important to verify that the press operates and stops properly before connecting WPC 2000 to other units. Do not forget to mark on your electrical prints where you wire in WPC 2000.

When the Stopping Time is critical to your operation, as it is with die protection, be sure to wire as follows. Whenever you have Emergency-stop circuits, wire them between terminals #67 and #68 or terminals #68 and #69 on the Main Processor board. For Top-stop circuits, wire them between terminals #79 and #80 or terminals #80 and #81. Refer to Figure 1 at the end of the manual for specific wiring schematics.

Use customized status code wiring (see Wiring WPC 2000 User Inputs, page 2-28) when the auxiliary equipment that you are connecting does not have its own self-explanatory displays, as are available in DiPro 1500 or AutoSet load analyzers.

Wiring Micro-inch

Micro-inch is a feature that enables you to control the amount of time (and, therefore, the distance) that the ram moves when the Run/Inch palm buttons are depressed in Inch mode. Allowing finer adjustments than are possi ble in Inch, Micro-inch is designe d to facilitate setup on high-speed or short-stroke presses.

Installation 2-33

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1128500 WPC 2000 User Manual

Stroke select TB 701

Micro-inch/Set auxiliary cams TB 705

Set cams switch S701

Operator station select TB 704

Automatic single-stroke or Continuous on-demand TB 703

Mode select TB 702

Display cable

TB 706

Reset/Select

button/WPC Settings

key switch J 707

LEDs

DS750

DS755

DS749

DS762

DS748

DS760 DS761 DS747

DS759

DS754

DS753

DS752

SET CAMS

NORMAL

Jumper JP 720

(Must be on Run setting)

Monitor

Run

149148147146 151150 154153152

157156155

162161160159158

145144143142141

WPC Settings key

switch up (+) DS751

Reset/Select button on DS757

Spare DS756

WPC Settings key

switch down (-) DS758

LEDs

Transmit DS764

Receive DS763

Display cable LEDs

Micro-inch can be wired to be permanently enabled or to be switched on and off. To wire Micro-inch so that it is permanently enabled, install a jumper between pins #157 and

#155 (Ground) on TB705 on the WPC 2000 Display board (see Figure 2-16 and Table 2-23, page 2-63).

To wire Micro-inch so that it can be turned on and off, wire a switch to pins #157 and #155 on TB705 as shown in Table 2-7, below, and Figure 5 at the end of the manual. An optional Micro-inch On/Off switch is available from Wintriss (see page 1-2).

To set the Micro-inch time, refer to Setting Micro-Inch, page 3-25.

Figure 2-16. WPC 2000 Display Board: Location of Important Components

2-34 Installation

Table 2-7. Micro-inch Wiring Connections

Display Board TB705

Pin # Signal

157 Micro-inch input 155 Ground

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WPC 2000 User Manual 1128500

DANGER

Disabling Top-stop in Inch

By default, Inch mode is set so that the ram top-stops whenever the Run/Inch palm buttons on the Operator Station are pressed and held continuously (see Top-stop in Inch, page 4-9). You can disable this default setting, allowing the ram to continue cycling in Inch mode as long as the Run/Inch buttons are depressed. To do so, connect pin #13 on the Main Processor board to +24 Vdc. You can connect to any convenient terminal that supplies +24 Vdc, such as pin #9. See Table 2-17, page 2-62. When pin #13 is connected to +24 Vdc, the “Top stop inch disable” LED on the WPC 2000 Main Processor board is illuminated (see Figure 3-14, page 3-37 or Figure 3-15, page 3-38).

Wiring a Remote Reset Switch

If you would like to be able to reset the WPC 2000 from a location remote from the enclosure, the WPC 2000 Main Processor board provides a terminal (i.e., pin #70) for wiring a remote Reset switch (see Table 2-8 and Figure 2 at the end of the manual). The remote Reset terminal can be wired to other equipment (e.g., the remote Reset circuit on a SmartPAC 2), or you can use a simple switch to activate the Reset function.

To wire the remote Reset circuit, connect a wire from pin #70 to a normally open switch. Connect another wire from the switch to a ground terminal (e.g., pin #54). WPC 2000 is reset with a momentary connection to ground.

Table 2-8. Remote Reset Switch Wiring Connections

Main Processor Board

Pin # Signal

70 Remote Reset input 54 Ground

Installing 4-channel Programmable Cam

NON-SAFETY OUTPUTS USED FOR SAFETY FUNCTIONS

Use cams for non-safety functions only, such as convenience in automation. They cannot protect personnel from a moving hazard.

Failure to comply with these instructions will result in death or serious injury.

You connect the cam channels from TB 109 on the WPC 2000 Main Processor board (see Figure 2-12, page 2-23 or Figure 2-13, page 2-24) to the cam output assembly, which contains the output relay modules that control the timing signals for your connected equi pment. These relays open and close circuits to your equipment at the crankshaft angles you program (see Setting Programmable Cams, page 3-33).

Installation 2-35

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1128500 WPC 2000 User Manual

CAUTION

Mounting and Wiring the Cam Output Assembly

The cam output assembly can be ordered in an enclosure or as a PC board. To mount and wire either option, do the following:

BOARD DAMAGE OR SHORT CIRCUIT WHEN MOUNTED WITHOUT ENCLOSURE

• Mount the cam output assembly in a clean area where it will be safe from damage.

• Provide at least 0.5 in. (12.7 mm) clearance between the back of the board and any metal surface.

Failure to comply with these instructions could result in property damage.

1. Select a convenient location for mounting the cam output assembly, choosing one that

allows you to easily run conduit from WPC 2000 to the cam outputs. You do not need to access the cam outputs once they are installed and wired.

2. Mount the cam output assembly, referring to Figure 2-17 or Figure 2-18, page 2-37 for

mounting dimensions. Use the holes on the flanges to mount the cam output enclosure or the corner holes to mount the cam output board.

3. The relays that will control your equipment should already be plugged into the cam output

board. If you need to replace a relay, simply pull the device out of its socket. Before installing a relay , make sure that all the pins match the socket holes so you do not bend the pins; then, press the relay in firmly.

4. Locate the twelve-conductor shielded cable that connects the WPC 2000 Main Processor

board to the cam outputs, and terminate the shield at each end near the entry point to the enclosure or console (see Terminating Cable Shields, page 2-5).

5. Remove the TB109 connector from the WPC 2000 Main Processor board, and attach the

wires at one end of the cable to the terminals shown in Table 2-9, page 2-38 and Figure 6 at the end of the manual. Plug each connector back into its socket when you are finished.

2-36 Installation

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WPC 2000 User Manual 1128500

4.00

(101.6)

5.41

(137.4)

6.62

(168.1)

7.38

(187.5)

Dimensions: inches

(mm)

3.48

(88.4)

DS1 DS2 DS3 DS4

N/O

N/C

N/O

N/C

N/O

N/C

N/O

N/C

CHAN 1 CHAN 2

TB3TB2

CHAN 3 CHAN 4

TB4 TB5

CHASSIS

+24V

GND

CH 3

CH 2

CH 1

CH 4

5A 125 VAC

SLO-BLO

5A 125 VAC

SLO-BLO

5A 125 VAC

SLO-BLO

5A 125 VAC

SLO-BLO

4.35

(110.5)

4.75

(120.7)

5.50

(139.7)

5.10

(129.5)

0.20 (5.1) TYP

0.20

(5.1)

TYP

clearance hole for #6 screw 4 PLACES

Dimensions: inches

(mm)

Figure 2-17. Cam Output Enclosure: Mounting Dimensions

Figure 2-18. Cam Output Board: Mounting Dimensions

Installation 2-37

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1128500 WPC 2000 User Manual

NOTICE

DANGER

Table 2-9. WPC 2000 Main Processor Board (TB109) to Cam Output Assembly (TB1):

Wiring Connections

WPC 2000 Main Proc. Board

Wire Color

Brown 130 Cam 1 7 Channel 1 Violet 129 Cam 2 6 Channel 2 Orange 128 Cam 3 5 Channel 3 Yellow 127 Cam 4 4 Channel 4

Black 122 Ground 3 Ground Red 121 +24 Vdc 2 +24 Vdc Shield Terminate drain wire to ground stud 1 Chassis

Pin # Signal

126 Counter 125 Zero Cam 124 Spec 1 123 Spec 2

4-channel Cam I/O Assembly (TB1) Pin # Signal

6. Run the twelve-conductor cable through flexible, liquid-tight conduit to the terminal

points at the cam output assembly. You can use the knockouts directly below the connectors if you have the cam output enclosure.

7. Remove the TB1 connector from the Cam Output board, and attach the wires at the other

end of the cable to the terminals shown in Table 2-9 and Figure 6. If you ordered the enclosure, a wire from the CHAS terminal (pin #1) to a lug on the enclosure should already be connected. Plug the connector back into its socket when you are finished.

TRIM UNUSED WIRES

If your installation does not require all the wires in the cable to be used, trim the unused wires, cutting them flush with the ends of the cable jacket.

Making Wiring Connections to Cam Relays

NON-SAFETY OUTPUTS USED FOR SAFETY FUNCTIONS

Use cams for non-safety functions only, such as convenience in automation. They cannot protect personnel from a moving hazard.

Failure to comply with these instructions will result in death or serious injury.

To connect the cam relays on the Cam Output board to your equipment, do the following:

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WPC 2000 User Manual 1128500

NOTICE

N/O

N/C

N/O

N/C

N/O

N/C

N/O

N/C

CHAN 1 CHAN 2

TB3TB2

CHAN 3 CHAN 4

TB4 TB5

WARNING

1. Remove the TB2 through TB5 connectors (for cam channel 1 through cam channel 4)

from the cam output board and wire them as follows, referring to Figure 2-19:

• Connect one wire to the terminal labelled “C”

• Connect the other wire to the terminal labelled “N/O” if you want your equipment to be

“on” during the cam angle interval set in WPC 2000 or Connect the other wire to the terminal labelled “N/C” if you want your equipment to be

“on” except during the cam angle interval set in WPC 2000

Generally, you use the N/O terminal so that equipment is “off” except when you use WPC 2000 to turn it “on.” Use the N/C terminal only if it is more practical to do the reverse.

Figure 2-19. Connectors TB2 through TB5 on Cam Output Board

2. Plug TB2 through TB5 back into the Cam Output board.

SUPPRESSORS INSTALLED ACROSS RELAY CONTACTS

DO NOT install suppressors across the relay contacts in the cam output assembly. If a suppressor is installed across the relay contacts and the relay fails shorted, the equipment controlled by that relay will remain energized.

Failure to comply with these instructions could result in death or serious injury.

3. To reduce electrical noise and extend the life of the relays, do the following:

a. Install arc suppressors across each inductive AC load (motors, coils, etc.) that is

connected to a cam relay. Suppressors are supplied with your WPC 2000 cam outputs. Install the suppressors across the load or as close to the load as possible. Attach suppressors by connecting leads across existing terminals or junction points. Figure 2-20, page 2-40 shows the correct way to install suppressors.

b. Install a diode across each DC load, such as relays, solenoids and PLC inputs, as

shown in Figure 2-21, page 2-40.

Installation 2-39

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1128500 WPC 2000 User Manual

RIGHT

WRONG

ACCEPTABLE

not recommended

c n/o

Power

Power Return

Suppressor

Relay

c n/o

Power

Suppressor

Power

Return Power Return

Relay

c n/o

Power

Suppressor

Power Return

Relay

+ DC IN



DC RETURN

Relay

C N/O

IN4001 or equivalent

Enabling Cam Adjustments

You can enable adjustments to cam angles in three ways:

• Moving switch S701 on the WPC 2000 Display Board to its Up position

• Moving switch 1 on switch block S102 on the WPC 2000 Main Processor board to ON

• Wiring a key switch

Figure 2-20. Installing a Suppressor across an AC Load

Figure 2-21. Installing a Diode across a DC Load

2-40 Installation

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WPC 2000 User Manual 1128500

NOTICE

S701

DOWN position: Normal operation

UP position: Enable cam adjustments

ENABLING CAM ADJUSTMENTS

You should enable cam adjustments only when you are actually ready to set the cams. Otherwise, you will not be able to adjust Top-stop Angle, Auto Carry-up Angle, etc.

Setting Switch S701 on the Displ ay B oar d

You enable the Set Cams function on switch S701 (see Figure 2-16, page 2-34 for switch location) by moving the switch to its Up position, as shown in Figure 2-22.

Figure 2-22. “Set Cams” Switch (S701) Positions

Setting Switch 1 on S102 on the Main Processor Board

You can also enable the Set Cams function by setting switch 1 on switch block S102 on the Main Processor board (see Figure 2-12, page 2-23 or Figure 2-13, page 2-24 for location) to its ON (or Up) position. (See Making Settings on Switch Block S102, page 3-31 for further details.) Using this switch may be preferable if the Display board is difficult to access.

Wiring a Remote Switch

You can also enable the Set Cams function by wiring your own two-position switch and turning the function On and Off remotely. Wire the remote switch to pins #155 (Ground) and #156 (Prog. Cams) on the WPC 2000 Display board, referring to Figure 2-16, page 2-34 and Figure 5 at the end of the manual. If you opt to use a remote switch to enable cam settings, make sure that switch S701 is in the Down position.

Installation 2-41

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1128500 WPC 2000 User Manual

DANGER

Wiring Zero Cam Output to AutoSet

WPC 2000 provides a zero cam output that automatically turns on at 270° and turns off at 30 ° on every stroke. You can wire this output to AutoSet 1500 and 1504 load analyzers, as shown in Table 2-10, below, and Figure 6 at the end of the manual.

Table 2-10. Zero Cam Output Wiring Connections

WPC 2000 Main Processor Board

(TB 109)

Pin # Signal

pin # 125 Zero Cam Output pin # 2 Zero Cam

AutoSet 1500 (TB101B)

or 1504 (TB101A)

Pin# Signal

Wiring a Foot Switch

UNGUARDED HAZARDS

When using a foot switch, ensure that light curtains and other safeguards are properly installed and operating to protect operators.

Failure to comply with these instructions will result in death or serious injury.

IMPROPER FOOT SWITCH

Ensure that any foot control switch complies with OSHA 1910.217 (b) (7) (x), including protection from accidental actuation by falling or moving objects or unintentional stepping on the control.

Failure to comply with these instructions will result in death or serious injury.

Foot Switch, an option available from Wintriss, enables the operator to use both hands during operation of the press as, for example, when manually feeding parts. If you choose to order a foot switch, you must obtain optional One-hand/Two-hand/Foot firmware from Wintriss and install a Shadow safety light curtain.

Wire the Foot Switch’s normally closed contact to pin #4 on the WPC 2000 Main Processor board and the normally open contact to pin #14, then wire both contacts to +24 Vdc, as shown in Table 2-11, below, and Figure 2 at the end of the manual.

Table 2-11. Foot Switch Wiring Connections

WPC 2000 Main Processor Board

Pin #

4 N/C input

14 N/O input

+24 Vdc (e.g., #37) Common

Foot Switch

Contacts

Refer to page 3-27 for Foot Switch settings.

2-42 Installation

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WPC 2000 User Manual 1128500

DANGER

Instal lin g a One-hand Control

INSTALL SAFEGUARDS TO PREVENT ACCESS TO HAZARDOUS AREA

• Follow all applicable OSHA and ANSI regulations for safeguarding your press system. Point-ofoperation safeguarding is the single most important factor in the prevention of injuries.

• Follow all applicable OSHA and ANSI regulations when installing a one-hand control.

• Ensure that proper safeguarding devices are installed and working properly. Wintriss takes no responsibility if safeguarding devices are not installed or working correctly.

• DO NOT use WPC 2000 or a one-hand control as a safeguarding device.

• Install and operate WPC 2000 and a one-hand control in accordance with OSHA and ANSI regulations.

Failure to comply with these instructions will result in death or serious injury.

PREVENT OPERATOR FROM STANDING BETWEEN LIGHT CURTAIN AND HAZARD

Failure to comply with these instructions will result in death or serious injury.

One-hand Control is a switch available from Wintriss that allows operators to use their free hand to feed a part while their other hand operates the switch. This option can only be used with WPC 2000 systems equipped with One-hand and Single-stroke modes, employing a Shadow light curtain to guard the point of operation, and running One-hand/Two-hand/Foot firmware.

The One-hand Control is mounted on or near the press and allows the operator to cycle the press without using the Operator Station. To stroke the press, the operator simply pushes the button as part of his normal hand motion after loading a part.

The One-hand Control can be used in two different modes. In Normal mode, the press cycles in Single-stroke whenever you push the One-hand Control button. In “Light Curtain Break” mode, the press cycles only when you push the One-hand Control button within eight seconds after removing your hand(s) from the light curtain. If the button is pushed after this interval expires, the press does not cycle.

Light Curtain Break mode prevents inadvertent operation of the press when an operator is loading or unloading parts.

The mode used for One-hand Control is determined by the setting on option switch 3 (see Enabling Light Curtain Br eak Mode in a One-hand Control, page 3-27). When switch 3 is set to OFF, One-hand Control operates in Normal mode. When switch 3 is set to ON, One-hand Control operates in Light Curtain Break mode.

Installation 2-43

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1128500 WPC 2000 User Manual

DANGER

Mounting a One-hand Control

DO NOT MOUNT OPERATOR CONTROL TOO CLOSE TO HAZARD

Mount the One-hand Control outside the area protected by the light curtain. DO NOT mount the One-hand Control between the light curtain and the point of operation.

Failure to comply with these instructions will result in death or serious injury.

To mount the One-hand Control, perform the following steps, referring to Figure 2-23, below, and Figure 2-24, page 2-45 for mounting dimensions:

Figure 2-23. One-hand Control Switch: Mounting Dimensions

2-44 Installation

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WPC 2000 User Manual 1128500

DANGER

Figure 2-24. One-hand Control Switch Base: Mounting Dimens ions

1. Shut off power to the press and to WPC 2000.

2. Choose a mounting location on or near the press convenient to the operator. The

One-hand Control should be mounted so the operator can reach it as part of normal hand movement after loading a part. An adjustable bracket may be necessary.

3. Mount the One-hand Control, using the tapped holes on the bottom of its metal enclosure.

Wiring a One-hand Control to WPC 2000

ELECTRIC SHOCK OR HAZARDOUS ENERGY

• Disc onn ec t main powe r before install atio n.

• Remove all power to the press, press control, and other equipment used with the press.

• Remove all fuses and “tag out” per OSHA 1910.147 Control of Hazardous Energy (Lockout/ Tagout).

• Ensure that installation is performed by qualified personnel.

• Complete all installation procedures before connecting to the AC power source.

Failure to comply with these instructions will result in death or serious injury.

To wire One-hand Control, you need to make connections to both the Operator Station and to the WPC 2000 Main Processor board. To do so, perform the following steps:

1. Turn off power to the press and to the WPC 2000.

Installation 2-45

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1128500 WPC 2000 User Manual

2. Loosen the clips at the bottom of the front panel of the Operator Station. Swing the front

panel up and support it so you can work inside the box. (The cover will stay up if you slide it slightly to the left or right.)

3. Knock out a hole in the bottom of the Operator Station near the existing conduit from the

WPC 2000 control enclosure.

4. Using the conduit hole provided in the base of the One-hand Control, run conduit and

wiring to the Operator Station, referring to Figure 2-25 for terminal locations on the bottom of the One-hand Control.

Figure 2-25. Wiring Connections in One-hand Control Switch (Switch Cover, Bottom View)

5. Measure wires to fit before cutting, then make the appropriate wiring connections,

referring to Table 2-12, below, and Figure 8 at the end of the manual.

Table 2-12. One-hand Control Wiring Connections

WPC 2000 Main Processor Board and

One-hand Control

Terminal # *

11 1 Palm switch A N/C input + 12 Blue wire in Operator Station cable 13 3 One-hand A input + 14 Blue wire in Operator Station cable

* Refer to Figure 2-25, above

6. Fasten the switch cover onto the base with the screws provided.

7. Tighten all conduit connections that may have been loosened during installation.

8. Close and latch the cover of the Operator Station and WPC 2000.

9. Make sure that you have run all your ground wires. Do not use conduit as ground.

Operation St ation Connections

Pin# Signal

2-46 Installation

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WPC 2000 User Manual 1128500

BAR CONTROL

OPERATESELECT

OFF ON

DATA INSTRUMENTS

Wintriss Controls Group

6.23

(158.2)

7.49

(190.2)

3.13

(79.5)

3.24

(82.3)

4.60

(116.8)

5.02 (127.5)

6.70

(170.2)

0.312 (7.9)

4 places

2.00 (50.8)

4.40 (111.8)

Dimensions: inches

(mm)

Mounting and Wiring the Bar Control Enclosure

Mount the Bar Control enclosure in a location that is convenient to the operator while he is releasing the machine’s brake and barring the press. Make sure that the operator will not block a light curtain while pressing the Bar control Operate button. Refer to Figure 2-26 for mounting dimensions.

To wire the Bar Control, connect the Bar selector switch input to pin #6 on the WPC 2000 Main Processor board and the Bar actuator input to pin #16, as shown in Table 2-13 and Figure 2 at the end of the manual.

Figure 2-26. Bar Control Enclosure: Mounti ng Dimensi ons

Table 2-13. Bar Control Wiring Connections

WPC 2000 Main Processor Board

Bar Control Contacts

Pin #

16 Bar actuator input

6 Bar selector switch input

+24 Vdc (e.g., #37) Common

Installation 2-47

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1128500 WPC 2000 User Manual

DANGER

Wiring Automatic Single-stroke

PRESS STARTING UNEXPECTEDLY

• Ensure that light curtains and other safeguards are properly installed and operating to protect operators when using Automatic Single-stroke. Since the external trigger starts the stroke, a stroke can occur unexpectedly.

• Ensure that guarding is properly installed to prevent access to the machine over, under, or around any guarding device.

Failure to comply with these instructions will result in death or serious injury.

Automatic Single-stroke is an operating mode that enables the operator to automate a manual press using a feeding device or robot. To wire the switch that turns on this feature, refer to Figure 5 at the back of the manual. To wire the Automatic Single-stroke actuating mechanism, refer to Table 2-14 and Figure 2 at the back of the manual.

Table 2-14. Automatic Single-stroke Wiring Connections

WPC 2000 Main Processor Board

Pin #

15 N/C input

5N/O input

+24 Vdc (e.g., #37) Common

Foot Switch

Contacts

Though an SPDT contact is shown in Figure 2, you can also use solid state switches (proximity switches, for example) or outputs from a programmable logic controller (PLC). To make sure that the contacts are clear and reliable, the switch or relay should be new and unused.

You set the wait time for Automatic Single-stroke with option switch 5 (see page 3-29). To operate the press in this operating mode, refer to page 4-16.

Wiring Automatic Continuous On-demand

PRESS STARTING UNEXPECTEDLY

• Ensure that light curtains and other safeguards are properly installed and operating to protect operators when using Automatic Continuous On-demand mode, in which a stroke can occur unexpectedly.

• Ensure that guarding is properly installed to prevent access to the machine over, under, or around any guarding device.

Failure to comply with these instructions will result in death or serious injury.

Contact Wintriss Tech. Support for information on using this operating mode.

2-48 Installation

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WPC 2000 User Manual 1128500

DANGER

CAUTION

Installing Revised Firmware in WPC 2000

MACHINE MALFUNCTION AFTER INSTALLING REVISED SOFTWARE

Perform the installation verification (see page 2-58) and final checkout (see page 3-35) tests after performing the firmware installation.

Failure to comply with these instructions could result in death or serious injury.

ELECTRIC SHOCK OR HAZARDOUS ENERGY

• Disc onn ec t main powe r before install atio n.

• Remove all power to the press, press control, and other equipment used with the press.

• Remove all fuses and “tag out” per OSHA 1910.147 Control of Hazardous Energy (Lockout/ Tagout).

• Ensure that installation is performed by qualified personnel.

• Complete all installation procedures before connecting to the AC power source.

Failure to comply with these instructions will result in death or serious injury.

To install revised firmware in WPC 2000, follow these steps:

1. Record the following WPC 2000 settings, referring to Viewing and Setting Press

Parameters, page 3-1 for help in displaying them in the digital LED readout:

• Stop-time Limit

• Auto Carry-up Angle

• Top-stop Angle

• Micro-inch time

• Cam On/Off settings

• Counter Preset

• Counter (if necessary)

2. Turn off power to WPC 2000. The LED display and crank-angle clock should go blank.

STATIC DISCHARGE DAMAGE TO CHIP

Ground yourself before touching circuit boards or chips by touching a large metal object such as the press. Static electricity can destroy electronic components.

Failure to comply with these instructions could result in property damage.

3. Making sure that you are grounded, open the WPC 2000 enclosure and locate firmware

chips A (labelled “U111”) and B (labelled “U134”) on the Main Processor board (see Figure 2-12, page 2-23 or Figure 2-13, page 2-24). Note that each chip has a white label and a semi-circular notch at one end. The notch on the chip faces in the same direction as the notch on its socket.

Installation 2-49

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1128500 WPC 2000 User Manual

NOTICE

CAUTION

NOTICE

Each new WPC 2000 firmware chip must be installed with the notch facing in the same direction as the chip it is replacing.

If you use a screwdriver, be careful not to insert the screwdriver under the socket or you may damage the board.

Failure to comply with these instructions could result in property damage.

4. Use a chip puller to remove the old chips, or insert a small screwdriver between the

bottom of the chips and their sockets and carefully pry the chips from the board. Put the chips aside.

5. Making sure you are grounded, open the package containing the new firmware chips, and,

one at a time, remove the chips from their holders.

CHIP INSTALLED INCORRECTLY

• Install each chip with the notch facing in the same direction as the notch on the old firmware chip; otherwise, when you power up the control, the chips will be destroyed.

• Align pins correctly with the socket before plugging chips in.

Failure to comply with these instructions could result in property damage.

6. Plug each chip into its socket, inserting the left row of pins first, then aligning the right

row of pins over the socket and pushing them in. Make sure that the notch in the chip faces in the same direction as the notch in the old chip and that all of the pins are in the socket.

If the two rows of pins are spread too far apart to plug easily into the socket, hold the chip on its side on a flat surface with the pins pointing toward you. Being careful not to overbend the pins, gently draw the top of the chip toward you until the pins bend a little. Turn the chip over so that the other row of pins is now flat and pointing toward you. Draw the top of the chip toward you again until the pins bend. When the rows of pins look parallel, plug the chip into its socket again. If the chip still doesn't fit, repeat this procedure.

7. To verify that both chips are installed correctly, power up the WPC 2000.

• If the unit powers up normally (i.e., with “Loc” displayed in the LED readout), go to

step 8.

• If the unit powers up with “rolling” LEDs, or otherwise malfunctions, one or more pins

may be bent or not plugged in properly . Turn the power off, and repeat the procedure in the Notice for step 6 for each chip. Power the unit up again. If WPC 2000 continues to malfunction, call Wintriss Tech. Support.

2-50 Installation

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WPC 2000 User Manual 1128500

DANGER

8. Re-initialize the system, following the instructions starting on page page 3-3.

MAKE SURE THAT STOP TIME LIMIT IS CORRECT AFTER INITIALIZATION

Whenever you initialize WPC 2000, the Stop-time Limit is reset to its factory value of 500 mS. Make sure to set the Stop-time Limit to a value based on the actual stopping time of your press. Use the stopping time measured in the 90º stop-time test to calculate the safety distance.

Failure to comply with these instructions will result in death or serious injury.

9. Re-enter the settings you recorded in step 1.

10. Perform installation verification (see page 2-58) and final checkout (see page 3-35) tests.

Installing WPC 2000 without Enclosure

When you order WPC 2000 without enclosure, you receive a Main Processor board, power supply, and input power terminal block mounted on an aluminum plate and either a panel mount display or display board kit. First, install the mounting plate as instructed in the next section, then mount the display according to instructions in Installing the Panel-mount Display, page 2-52 or Installing Display Board Kit with Selector Switches, page 2-55.

Installing the WPC 2000 Mounting Plate

The mounting plate has a hole in each corner to facilitate mounting of the WPC 2000 Main Processor board and related components in your enclosure or console. When installing the mounting plate, refer to Figure 2-27, page 2-52 for mounting dimensions. Be sure to allow at least 1 in. clearance on top, bottom, and both sides of the plate and above the power supply and Main Processor board. Allow at least 2 1/2 in. clearance on the right side of the plate for making wiring connections to terminal blocks TB101-TB104.

The power supply on the mounting plate is pre-wired to the power terminal, TB105, on the Main Processor board and to the input power terminal block on the plate. To connect AC wiring to the input power terminal block, follow the instructions in Connecting AC Wiring, page 2-8.

Installation 2-51

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1128500 WPC 2000 User Manual

TB105

TB104TB103TB102TB101

TB 109

.312

(7.92)

4 places

x .125

(3.18)

4 places

TB 106

Dimensions: inches (mm)

Allow 1 clearance on top, bottom, and left side of mounting plate and above board/power supply. Allow 2 1/2 clearance on right side (i.e., side to which TB101-TB104 are connected).

.090 (2.3)

TB 107 TB 108

Input power terminal block

.25

(6.4)

10.65

(270.5)

10.00

(254.0)

2.25

(57.1)

7.00

(177.8)

13.00

(330.2)

12.25

(311.2)

2.67

(67.8)

NOTICE

Figure 2-27. WPC 2000 Mounting Plate: Mounting Dimensions

Installing the Panel-mount Display

Mounting the Display

Install the panel mount display at a height convenient for all users. Experiment to determine a good height for every user before mounting the display.

To install the panel-mount display in your enclosure or console, do the following, referring to Figure 2-28, page 2-53 for mounting and cutout dimensions:

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WPC 2000 User Manual 1128500

YOUR

PANEL

tapped or

clearance

holes for

No. 10 hardware 12 places

allow

9 in. (230 mm)

service

loop

allow at least

4 in. (100 mm)

clearance

behind panel

Dimensions: inches (mm)

0.5 (12.7) 2 places

6.50 (165.1)

10.00

(254.0)

9.00

(228.6)

7.50

(190.5)

6.00

(152.4)

0.25 (6.4) 2 places

4.00

(101.6)

4 places

8.00

(203.2)

0.25 (6.4) 2 places

3.00

(76.2)

4 places

WPC SETTINGSRESET/SELECT MUTE

1. Determine a convenient location to mount the display panel and selector switches in your

enclosure or console. Mount the display so that operators and setup personnel can easily see the readouts and reach the switches. Make sure that all switches are no more than one ft. (300 mm) from the display.

2. Cut out a hole in your enclosure or console, and drill and tap twelve holes for #10-32

screws, referring to Figure 2-28.

Figure 2-28. WPC 2000 Panel Mount Display: Mounting and Cutout Dimensions

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1128500 WPC 2000 User Manual

NOTICE

DANGER

NOTICE

3. Prop the display panel near the location where you plan to mount it. You can do this by

connecting ty wraps from two of the left holes on the panel to the corresponding holes on the enclosure or console, creating hinges. Allow 9 in. of service loop when performing the wiring connections, and make sure all cables will reach the connectors.

Connecting the Panel-mount Display to the WPC 2000 Main Processor Board

Connect the display cable from TB706 on the Display board to TB108 on the Main Processor board, referring to Table 2-15 and Figure 5 at the end of the manual for wiring connections.

CONNECT DISPLAY CABLE CORRECTLY

Make sure that the display cable is connected correctly at both ends. Connect the display cable to TB706 on the Display board with the black wire closest to the small numeral 1 toward the bottom of the board. The black wire indicates pin #1.

Table 2-15. Display Cable Wiring Connections, Display Board to Main Processor Board

Display Board

TB706 Pin # Wire Color Signal

158 Red V+ 116 159 White CAN+ 1 17 160 SHIELD 118 161 Green CAN- 119 162 Black COM 120

Main Processor Board

TB108 Pin #

Installing Selector Switches and Final Assembly

DO NOT USE CONTINUOUS MODE ON PRESS WITHOUT PROPER GUARDING

Disconnect the “Continuous” position on the stroke selector switch and cover the “CONT” label on your control if your press is not guarded properly for use in Continuous mode or you do not run your press in Continuous mode.

Failure to comply with these instructions will result in death or serious injury.

Mount selector switches within 1 ft. (300 mm) of the Display board.

1. Select a mounting location for the selector switches. Switches must be mounted within 1

ft. (300 mm) of the display.

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WPC 2000 User Manual 1128500

0.172 (4.37)

0.672 (17.1)

1.218 dia. (30.9)

Dimensions: inches (mm)

NOTICE

2. Cut holes in your enclosure or console for the selector switches, referring to Figure 2-29

for cutout dimensions. Dimensions are the same for all switches.

Figure 2-29. Selector Switch: Cutout Dimensions

3. Install the selector switches.

4. Wire each selector switch to the appropriate terminal block on the WPC 2000 Display

board, referring to Table 2-16 and Figure 5 at the back of the manual for wiring connections

Table 2-16. Selector Switch Wiring Connections

Terminal Block on

Selector Switch

Stroke Select TB701 Mode Select TB702 Automatic Single-stroke (External Trip) TB703 Operator Station Select TB704 Micro Inch TB705

WPC 2000 Display Board

Installi ng Display Board Kit wi th Selector Switches

Install the panel mount display at a height convenient for all users. Experiment to determine a good height for every user before mounting the display.

1. Make sure that your display board kit contains the following components:

• Label

• PC board

• Push button

• Mute lamp

• Key switch with wiring harness assembly

• Four standoffs

• Four lock nuts.

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1128500 WPC 2000 User Manual

NOTICE

Dimensions: inches (mm)

2.500

(63.5)

5.000

(127.0)

0.500 (12.7) DIA. 2 places

0.64 (16.3)

4.12

(104.6)

4.500

(114.3)

5.235

(133.0)

3.400 (86.4)

0.76 (19.3)

1.700

(43.2)

6-32 x 0.625 studs (on far side) 4 places

2.500

(63.5)

DIA.

Install selector switches within 1 ft. (300 mm) of the Display board.

2. Determine a convenient location to mount the display and selector switches in your

enclosure or console. Mount the display so that operators and setup personnel can easily see the readouts and reach the switches. Make sure that all switches are no more than 1 ft. (300 mm) from the display.

3. Cut or punch holes in your enclosure or console for the display, selector switches, and four

#6-32 x 5/8 studs. Refer to Figure 2-30, below, for cutout dimensions for the display, to Figure 2-29, page 2-55 for cutout dimensions for the selector switches.

Figure 2-30. WPC 2000 Display Board Kit: Mounting and Cutout Dimensions

4. Install the four #6-32 x 5/8 studs from inside the enclosure or console.

5. Mount the Display board on the four studs with the standoffs and lock nuts, making sure

that the LED display is at the top facing outward.

6. Orient the label correctly from outside the enclosure or console to match the cutouts, then

remove the protective paper from the label and carefully affix it.

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NOTICE

No connection

Yellow wire

2 Black wires

Switch body (Reset/Select button)

Enclosure or console

7. Connect the display cable from TB706 on the Display board to TB108 on the Main

Processor board, referring to Table 2-15, page 2-54 for wiring connections.

CONNECT DISPLAY CABLE CORRECTLY

8. Install the Reset/Select button in the left cutout below the display. Wiring for the Reset/

Select button is provided on the Settings key switch wiring harness (see step 10).

9. Install the Mute lamp in the center cutout. The Mute lamp includes wiring that you

connect to terminals on the WPC 2000 Main Processor board.

10. Install the Settings key switch in the right cutout. The Settings key switch includes a

wiring harness with connectors for attachment to the Reset/Select button and the WPC 2000 Display board.

11. Slide the connector at the end of the yellow wire on one arm of the Settings key switch

wiring harness over the topmost terminal on the switch body of the Reset/Select button, as shown in Figure 2-31.

Slide the connector at the end of the two black wires on the same arm of the wiring harness over the lower terminal on the Reset/Select button switch body, as shown in Figure 2-31.

Figure 2-31. Reset/Select Button Wiri ng Connections

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1128500 WPC 2000 User Manual

NOTICE

DANGER

NOTICE

12. Plug the connector on the other arm of the Settings key switch wiring harness into J707

on the WPC 2000 Display board.

13. Connect the wiring from the mute lamp to pins #76 (+24 Vdc) and #54 (Ground) on the

WPC 2000 Main Processor board (see Figure 1 at the end of the manual).

SPLICE ADDITIONAL WIRING ONTO MUTE LAMP WIRING

The mute lamp comes with a 3 in. wire pigtail. You will need to butt splice an additional length of wire to the pigtail to make connections at the Main Processor board. Use 18 or 20 AWG wire and a Wintriss-supplied butt splice (part. no. Amp # 8-34070-4) or equivalent.

14. Install the selector switches.

15. Wire each selector switch to the appropriate terminal block on the WPC 2000 Display

board, referring to T able 2-16, page 2-55 and Figure 5 at the back of the manual for wiring connections.

JUMPER JP720 ON DISPLAY BOARD MUST BE SET TO R (RUN) POSITION

DO NOT change the position of jumper JP720 on the WPC 2000 Display board. This jumper comes from the factory in the R (or Run) position (see Figure 2-16, page 2-34 and Figure 1 at the end of the manual). If you set JP720 to the M (or Monitor) position, the clock display will not turn on.

Installation Verification

PERFORM INSTALLATION VERIFICATION BEFORE OPERATING PRESS

Complete Installation Verification procedures before operating the press.

Failure to comply with these instructions will result in death or serious injury.

ALL SIGNAL GROUNDS MUST BE CONNECTED THROUGH THE MAIN PROCESSOR BO ARD

Connect all signal grounds through pins on the WPC 2000 Main Processor board.

When you have completed all the installation procedures in this chapter, perform the following Installation Verification steps before setting up and initializing WPC 2000 as instructed in Chapter 3. When you have completed initialization and set-up procedures, be sure to perform the Final Checkout tests at the end of Chapter 3.

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DANGER

Checking Safeguarding Devices

DO NOT USE NON-SAFETY INTERLOCK SWITCHES IN SAFETY APPLICATIONS

• Ensure that all interlock switches used on safeguards are designed and rated for safety applications. Check with the manufacturer to verify the rating of each interlock switch.

• Ensure that safe ty int erl ock switch es a re co nne cted t o co ntro l-r eli abl e inpu t s if t hey are u sed for safeguarding applications.

Failure to comply with these instructions will result in death or serious injury.

PREVENT INJURY DURING TESTING

• Keep all personnel away from the press during testing.

• Be sure there is no die or other tooling in the press during testing.

• Use extreme caution when testing moveable guards. Keep hands and other body parts outside the guarded area.

Failure to comply with these instructions will result in death or serious injury.

Before turning on the press, check to verify the following conditions:

• All fixed safeguards prevent entry of a hand or other body part into the hazardous area.

• All moveable safeguards are correctly installed and wired to prevent operation of the press

when they are open and prevent entry of a hand or other body part into the hazardous area.

• All interlock switches used with safeguards are designed and rated for use in safety

applications. Check with the switch manufacturer to confirm their suitability for safety use.

• Interlock switches used for safeguarding are connected to control-reliable inputs.

• Any light curtains are installed and working properly.

• Any Two-hand controls used as safeguarding devices are mounted at least the safety

distance from the hazardous area.

• Safeguards are in place to prevent entry to the hazardous area under, over or around light

curtains or other safeguarding devices.

Test safeguarding devices as follows:

1. Run the press in Inch mode. Block the light curtain, if one is installed, with an opaque

object. The press should stop immediately.

• If the press stops, go to the next step.

• If the press does not stop, check the wiring of the light curtain and correct any problems.

Repeat the test. If the press still doesn’t stop, call Wintriss Tech. Support.

Installation 2-59

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1128500 WPC 2000 User Manual

WARNING

2. Run the press in Inch mode. Keeping hands outside the guarded area, open one of the

moveable guards just enough to open the interlock switch. The press should stop immediately.

• If the press stops immediately when you open the guard, go to the next step.

• If the press does not stop, check the wiring of the moveable guard and correct any

problems. Repeat the test. If the press still doesn’t stop, call Wintriss Tech. Support.

3. Close the guard you just tested, reset the press control, and repeat step 2 for each

moveable guard. When you have tested all moveable guards, go to the next section.

Checking Dual Safety Valve (DSV) Wiring

PREVENT ELECTRIC SHOCK WHEN WORKING INSIDE THE ENCLOSURE

Turn off and disconnect power from the WPC 2000, the press and any other machinery it is connected to before working inside the enclosure. This includes power to the press motor.

Failure to comply with these instructions could result in death or serious injury.

Follow the checkout procedure below to ensure that the dual safety valve is wired correctly. Proper installation and operation of the DSV is crucial to personnel safety.

1. Power down the press and press control.

2. On the DSV/Lockout Relay board (see Figure 2-12, page 2-23 or Figure 2-13, page 2-24

for location), remove fuse F302 or F303. F302 and F303 are the DSV fuses.

3. Power up the press and press control, select INCH with the Stroke Select switch, and push

both Run/Inch buttons. Observe what happens.

• If the ram does not move and the display shows F79 or one of the DSV faults (see

page 5-16), the DSV is operating properly. Go to the next step.

• If the ram moves and/or the display shows a fault other than F79 or one of the DSV

faults, check the wiring of the DSV and correct any problems, then repeat step 3. If the ram still moves and/or the display still shows a fault other than F79 or one of the DSV faults, power down the press immediately, and call Wintriss Tech. Support.

4. Power down the press and press control.

5. On the DSV/Lockout Relay board, replace the DSV fuse (i.e., F302 or F303) you removed

in step 2, and remove the other DSV fuse.

6. Power up the press and press control, make sure the press is in Inch mode, and push both

Run/Inch buttons. Observe what happens.

• If the ram does not move and the display shows F79 or one of the DSV faults, the DSV

is operating properly. Go to the next step.

• If the ram moves and/or the display shows a fault other than F79 or one of the DSV

faults, check the wiring of the DSV and correct any problems, then repeat step 6. If the

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WPC 2000 User Manual 1128500

ram still moves and/or the display still shows a fault other than F79 or one of the DSV faults, power down the press immediately and call Wintriss Tech. Support.

7. Power down the press and press control, and replace the fuse you removed in step 5.

8. Power up the press and press control, make sure the press is still in Inch mode, and push

both Run/Inch buttons briefly. The ram should move.

• If the ram moves, go to the next section.

• If the ram does not move, check the wiring of the DSV and correct any problems.

Power up the press and press control. Push the Run/Inch buttons again. If the ram still does not move, call Wintriss Tech. Support.

Checking for Faults

To check for faults, do the following:

1. Run the press in Inch for a few strokes.

• If the press runs normally, go to the next section.

• If a fault appears on the display, look up the fault code in Chapter 5, and follow the

remedy provided. Once the problem is corrected, press the Reset/Select button, and run the press again in Inch for a few strokes, checking for error codes. If you need assistance, call Wintriss Tech. Support.

Checking the Emergency-stop Circuit

To check the Emergency-stop circuit, do the following:

1. Run the press in Inch mode. While the ram is moving, have someone push the Emergency

Stop button on the Operator Station. The press should Emergency-stop immediately.

• If the press Emergency-stops, go to the next section.

• If the press does not Emergency-stop, there is a problem in your E-stop circuit.

Recheck wiring and correct any problems, then repeat this test. If the press still does not Emergency-stop, call Wintriss Tech. Support. Do not continue with this checkout procedure until the press E-stops correctly.

Installation Verification Complete

The WPC 2000 Installation Verification procedure is complete. Clear any error message by pressing the Reset/Select button.

Wiring Tables

Tables showing WPC 2000 wiring connections are provided on the following pages.

Installation 2-61

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1128500 WPC 2000 User Manual

Table 2-17. WPC 2000 Main Processor Board, TB101-TB104: Wiring Connections

Pin Signal Pin Signal

TB104 Top TB104 Bottom

44 Analog ground 88 Light curtain B2 input ** 43 Counterbalance air (Analog 2) input 87 Light curtain A2 input ** 42 +24 Vdc output 86 User input 10 – (paired w/ User Input 1 1*) 41 +24 Vdc output 85 User input 8 – (paired w/ User Input 9*) 40 +24 Vdc output 84 User input 6 – 39 +24 Vdc output 83 User input 4 – 38 +24 Vdc output 82 User input 2 + 37 +24 Vdc output 81 36 Aux. 2 output 80 Top-stop string center loop connection 35 Light curtain 2 enable 79 Top-stop string drive output

Top-stop string input (connects internally to 49)

TB103 Top TB103 Bottom

34 Analog ground 78 Light curtain B1 input ** 33 Main system air (Analog 1) input 77 Light curtain A1 input ** 32 +24 Vdc output 76 Mute lamp 2 output + 31 Ground 75 Unused input – 30 Ground 74 User input 9 – (paired w/ User Input 8*) 29 Aux. 3 output 73 User input 7 – 28 Aux. 1 output 72 User input 5 – 27 Light curtain 1 enable 71 User input 3 + 26 Unused input + 70 Remote reset input – 25 Ground 69 24 Overrun limit switch input - 68 E-stop string center loop connection 23 +24 Vdc output 67 E-stop string drive output

E-stop string input (connects internally to 45)

TB102 Top TB102 Bottom

22 Top stop limit switch input – 66 Mute lamp 1 output + 21 User input 1 + 65 Palm time lamp output – 20 DSV monitor input + 64 Prior act lamp output – 19 Unused input – 63 Prior act B input + 18 User input 11 – (paired w/ User Input 10*) 62 Prior act B output 17 Motor reverse input + 61 Prior act A input (connects internally to 62) 16 Bar actuator input + 60 Top-stop B2 input + pulse 15

Auto. Single-stroke (Ext. Trip) actuator N/C + 14 Foot switch N/O input + 58 13

Top Stop in Inch Disable input + 12 Palm switch B N/O input + 56 E-stop B2 output

11 Palm switch A N/O input + 55 E-stop A2 input (connects internally to 56)

59 Top-stop B2 output

Top-stop A2 input (connects internally to 59)

57 E-stop B2 input + pulse

TB101 Top TB101 Bottom

10 Ground 54 Ground

9 +24 Vdc output 53 +24 Vdc output 8 Clutch air pressure switch input – 52 Top-stop B1 input + pulse 7 Motor forward input + 51 Top-stop B1 output 6 Bar selector switch input + 50 5

Auto. Single-stroke (Ext. Trip) actuator N/O +

4 Foot switch N/C input + 48 E-stop B1 input + pulse 3 One hand A input + 47 E-stop B1 output 2 Palm switch B N/C input + 46 E-stop A1 input (connects internally to 47) 1 Palm switch A N/C input + 45 E-stop A output

*See Wiring WPC 2000 User Inputs, page 2-28. ** Input polarity depends on setting (NPN or PNP) of Light Curtain Output Type jumpers (JP121 and JP123) on

WPC 2000 Main Processor board (see Fig ure 2-12, page 2-23 or Figure 2-13, page 2-24).

Top-stop A1 input (connects internally to 51)

49 Top-stop A output

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Table 2-18. Power Supply (TB105) Wiring

Pin #

90 +24 Vdc input 89 COM

Signal

Table 2-19. Aux. E-stop Relay Board Wiring

Pin #

96 Circuit 3 output 95 Circuit 3 input 94 Circuit 2 output 93 Circuit 2 input 92 Circuit 1 output 91 Circuit 1 input

Signal

Table 2-20. DSV/Lockout Relay Board Wiring

Pin #

103 DSV B relay output

102 DSV B relay input

101 DSV A relay output

100 DSV A relay input

99 Lockout relay output 98 Lockout relay output 97 Lockout relay input

Signal

Table 2-21. Resolver (TB 106) Wiring

CW (clockwise) rotation shown, viewing shaft end.

For CCW, reverse black and yellow wires.

Pin #

104 S4 Return Brown 105 R2 Ground Orange 106 S3 Return Yellow 107 R1 Drive Red 108 S2 Cosine Green 109 S1 Sine Black 110 Shield

Signal Wire Color

Table 2-22. Cam Outputs (TB 109) Wiring

Pin #

130 Cam 1 129 Cam 2 128 Cam 3 127 Cam 4 126 Counter 125 Zero cam 124 Spec 1 123 Spec 2 122 Ground 121 +24 Vdc

Signal

Table 2-23. Display Board Wiring

Pin #

157 Micro-inch selector input – 156 Cams selector input – 155 Ground 154 Operator station 1 selector input – 153 Operator station 2 selector input – 152 Ground 151 150 Ground 149 One hand selector input – 148 Foot selector input – 147 Spare selector input – 146 Ground 145 Off selector input – 144 Inch selector input – 143 Single-stroke selector input – 142 Continuous selector input – 141 Ground

Signal

External/Two break selector input –

Table 2-24. AC Power Wiring

Pin #

Signal

L1 (Hi) L2 (Neutral) Ground

Installation 2-63

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2-64 Installation

Page 92

Chapter 3. Initialization, Setup, and

DANGER

Checkout

OPERATOR STATION WIRED INCORRECTLY

Run all necessary tests to verify that each Operator Station is wired correctly and provides proper anti-tie-down and anti-repeat protection.

Failure to comply with these instructions will result in death or serious injury.

MORE OPERATORS THAN OPERATOR STATIONS

• Ensure that there are the same number of active operator stations as there are operators if the press is not equipped with properly installed and operating light curtains.

• During setup, lockout/tagout the press if there are more operators than operator stations.

• Verify at every shift change that there are the same number of active operator stations as there are operators if the press is not equipped with properly installed and operating light curtains.

Failure to comply with these instructions will result in death or serious injury.

TWO-HAND CONTROL TOO CLOSE TO HAZARDOUS AREA

Verify at each shift change that any moveable Two-hand controls are located at least the safety distance from the pinch point or hazardous area.

Failure to comply with these instructions will result in death or serious injury.

This chapter shows you how to initialize and set up your WPC 2000 and perform final checkout tests.

Viewing and Setting Press Parameters

The WPC 2000 allows you to view and, in some cases, to set the following press parameters:

• Crankshaft angle or strokes per minute (SPM)

• 90° stop time test result

• Counter

• Stopping time

• Counter preset

• Stopping angle

• Top-stop angle

• Stop-time limit

• Auto carry-up angle

• Micro-inch time setting

Initialization, Setup, and Checkout 3-1

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1128500 WPC 2000 User Manual

Digital Display

Crank Angle

Press Speed

Counter

Error Codes

Settings

Crank-angle Clock

LEDs

Display Indicator Segments

Interrupted Stroke

LED

Brake Warning

LED

BRAKE WARNING

INTERRUPTED STROKE

TOP STOP ANGLE

AUTO CARRYUP

STOP TIME LIMIT MICRO-INCH

STOPPING TIME STOPPING ANGLE

° STOP TEST

COUNTER

COUNTER PRESET

ANGLE / SPM

cam on angle

cam off angle

To select a parameter so you can view or adjust its setting, press the Reset/Select button on the WPC 2000 display until the indicator segment for that parameter is illuminated. The value of the parameter appears in the digital LED readout. Locations of the indicator segments on the WPC 2000 display are shown in Figure 3-1.

Each time you press the Reset/Select button, the next indicator segment in the sequence is illuminated. To illuminate the group of four indicator segments in the lower half of the display, you must switch the press to Inch mode.

“Angle/SPM” is the default indicator segment when the press is in Inch mode, the crankshaft angle being displayed in the digital LED readout. Whenever you change operating mode to Single-stroke or Continuous, “Counter” becomes the active (i.e., illuminated) segment, and the current parts count is displayed in the digital readout. These defaults are summarized in Table 3-1. When the press is stopped and “Angle/SPM” is selected, the crankshaft angle is displayed for all Stroke Select settings.

When the default indicator segment is selected, the crank-angle clock shows the crankshaft angle of the press in all Stroke Select settings. Each LED on the clock represents approximately 11°. The crank-angle clock shows the press Stopping Angle, Top-stop Angle, and Auto Carry-up Angle when those indicator segments are illuminated.

3-2 Initialization, Setup, and Checkout

Figure 3-1. WPC 2000 Display Showing Indicator Segments

Table 3-1. WPC 2000 Display: Default Parameters (Press Running)

Stroke Select Setting Parameter Shown in Digital LED Display

Inch * Crankshaft angle (in degrees) Single-stroke Parts count Continuous Parts count

* The Counter does not operate in Inch mode.

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WPC 2000 User Manual 1128500

DANGER

NOTICE

BRAKE WARNING

INTERRUPTED STROKE

TOP STOP ANGLE

AUTO CARRYUP

STOP TIME LIMIT MICRO-INCH

STOPPING TIME STOPPING ANGLE

° STOP TEST

COUNTER

COUNTER PRESET

ANGLE / SPM

Sytem Initialized message

cam on angle cam off angle

Initializing the System

INCORRECT STOP-TIME LIMIT AFTER INITIALIZATION

Determine the Stopping Time and set the Stop-time Limit to a value that reflects the actual Stopping Time of your press whenever you initialize WPC 2000. Use the stop time measured in the 90° stop time test to calculate the safety distance. When you initialize WPC 2000, the Stop-time Limit is returned to its factory setting of 500 mS.

Failure to comply with these instructions will result in death or serious injury.

To initialize only the Start-time Limit, see page 3-5.

After you have completed installation of WPC 2000 and run the Installation Verification tests, you should first initialize the WPC 2000 system. To do so, perform the following steps:

1. Verify that your press is at top dead center (TDC), using a dial indicator or other means.

TDC is considered to be any position between 358° and 2°. Inch the press to TDC if necessary.

2. Turn off power to the WPC 2000.

3. Turn the WPC Settings key switch to its “+” setting (i.e., counterclockwise) and turn

power to the WPC 2000 back on. When the message “Int” appears in the LED display (see Figure 3-2), release the key.

Figure 3-2. WPC 2000 Display Showing “System Initialized” (“Int”) Message

Initialization, Setup, and Checkout 3-3

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1128500 WPC 2000 User Manual

BRAKE WARNING

INTERRUPTED STROKE

TOP STOP ANGLE

AUTO CARRYUP

STOP TIME LIMIT MICRO-INCH

STOPPING TIME STOPPING ANGLE

° STOP TEST

COUNTER

COUNTER PRESET

ANGLE / SPM

Resolver Zeroed message

cam on angle cam off angle

This procedure returns the following WPC 2000 parameters to their factory settings:

• Stop-time Limit–Set to 500 milliseconds. When you begin operating your press, you must

adjust this setting (see Setting the Stop-time Limit, page 3-16).

• Start-time Limit–Set to two times the S tart T ime measured by WP C 2000 on the first stroke

after the system has been initialized. The Start Time is the interval between the closing (turning on) of the output relays on the DSV/Lockout Relay board, which provides the signal for the Dual Safety Valve (DSV) to energize, and the resolver signal, which indicates that the crankshaft has begun to turn. The greater part of this interval is the time it takes for the clutch mechanism to activate and engage.

The Start-time Limit allows WPC 2000 to detect resolver drive failure. When the measured Start Time exceeds the Start-time Limit, WPC 2000 sends a Stop signal to the press and displays fault code F79 (see Loss of Rotation, page 5-17).

There are times when you may need to initialize only the Start-time Limit, such as during troubleshooting (see page 3-5 for instructions).

• Resolver Zero Setting–Set to zero.

Re-zeroing the Resolver

If you need to zero the resolver without re-initializing the Start-time and Stop-time limits, follow these steps:

1. Verify that your press is at top dead center (TDC), using a dial indicator or other means.

TDC is considered to be any position between 358° and 2°. Inch the press to TDC if necessary.

2. Turn off power to the WPC 2000.

3. Press and hold the Reset/Select button and turn power to the WPC 2000 back on. When

the message “rES” appears in the LED display (see Figure 3-3), release the key.

3-4 Initialization, Setup, and Checkout

Figure 3-3. WPC 2000 Display Showing “Resolver Zeroed” (“rES”) Message

When you use this procedure to zero the resolver, WPC 2000 electronically adds or subtracts any offset between the resolver and the crankshaft, so the resolver always knows

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WPC 2000 User Manual 1128500

NOTICE

BRAKE WARNING

INTERRUPTED STROKE

TOP STOP ANGLE

AUTO CARRYUP

STOP TIME LIMIT MICRO-INCH

STOPPING TIME STOPPING ANGLE

° STOP TEST

COUNTER

COUNTER PRESET

ANGLE / SPM

Initializaing Start-time Limit

message

cam on angle cam off angle

the true zero position of the ram. After zeroing, if the press is at TDC, the crank angle value in the LED display should read 0°. If it does not, repeat the zeroing process.

Initializing Only the Start-time Limit

The Start-time Limit value cannot be changed manually.

If you want to re-initialize only the Start-time Limit without re-initializing the Stop-time Limit and Resolver Zero settings (see Initializing the System, page 3-3), do the following:

1. Power down WPC 2000.

2. While powering WPC 2000 back up, turn the WPC Settings key switch to “–” (i.e.,

clockwise) and hold it there. When “Str” appears in the LED display (see Figure 3-4), release the key.

Figure 3-4. WPC 2000 Display Showing “Initializing Start-time Limit” (“Str”) Message

The next time you start the press, WPC 2000 will set the St art-time Limit t o twice the Start Time measured on the first stroke. This value cannot be changed manually.

Viewing the Start-time Limit

To view the Start-time Limit, do the following:

1. Press the Reset/Select button repeatedly, until the “Stopping Angle” indicator segment

illuminates.

2. Turn the WPC Settings key switch to “–” (i.e., clockwise). The Start-time Limit in

milliseconds is shown in the LED display.

Viewing the Last Start Time

To view the Start Time measured the last time you started your press, do the following:

Initialization, Setup, and Checkout 3-5

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NOTICE

1. Press the Reset/Select button repeatedly until the “Stopping Angle” indicator segment

illuminates.

2. Turn the WPC Settings key switch to “+” (i.e., counterclockwise). The Start Time in

milliseconds that was measured the last time you started the press is shown in the LED display.

Installing the Overrun Sensor Magnet

INCORRECT INSTALLATION OF OVERRUN LIMIT SWITCH

Ensure that the overrun sensor magnet is installed at a proper location if you have Two-hand Control without light curtains, or light curtains with muting. Proper installation of the magnet ensures that if the Top-stop output relay fails, a hazardous situation will not occur on the downstroke. The magnet must be mounted as close as possible to the Top-stop “On” Angle (see Table 3-2, page 3-8).

Failure to comply with these instructions could result in death or serious injury.

This section shows you how to install the magnet that, with the overrun sensor, makes up the overrun limit switch. You should already have installed the overrun sensor (see page 2-25). The overrun limit switch enables WPC 2000 to monitor operation of the resolver and to stop the press whenever the resolver fails to work properly.

The press cannot be run in Continuous or Single-stroke unless the overrun sensor and magnet are installed and working correctly. Without the overrun limit switch, you can only operate the press in Inch.

The angle at which you mount the magnet depends on the Top-stop “On” Angle. You must first determine and set the Top-stop “On” Angle before installing the magnet.

Setting the Top-stop “On” Angle

For a variable-speed press, you need to determine the latest Top-stop “On” Angle, which is the angle at which the press top-stops at its slowest speed and with the shortest stopping angle/time.

BEFORE YOU SET THE TOP-STOP “ON” ANGLE, MAKE SURE THAT

• The press ram has been mechanically set to top dead center (TDC) (see NOTICE on page 2-2)

• The resolver has been aligned as close as possible to TDC (i.e., 0° ±2°) (see Mounting the Resolver, page 2-21)

• The resolver has been zeroed (see page 3-4)

To determine the angle at which the Top-stop command is given on your press and change the Top-stop “On” Angle setting on the WPC 2000 display, do the following:

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NOTICE

1. Make sure the following WPC 2000 features are set correctly:

• Option switches 1 and 2 on switch block S101 on the WPC 2000 Main Processor board

should be set to OFF so that any Top-stop “On” Angle between 211° and 355° can be set on the WPC 2000 display. See Figure 2-12, page 2-23 or Figure 2-13, page 2-24 for location of the switch block and Switches 1 and 2 – Top-stop “On” Angle Range, page 3-26 for instructions on how to set the switches.

• Pin #13 on the WPC 2000 Main Processor board should not be wired in order to disable

Top-stop in Inch (see Top-stop Bypass (Top-stop in Inch Disabled), page 4-9).

• Micro-inch (if you have wired this feature) should be disabled (see Wiring Micro-inch,

page 2-33).

• Option switch 4 on switch block S101 should be set to OFF to disable the Auto

Compensated Top Stop (ACTS) feature (see page 3-28). ACTS compensates for increases in press speed by adjusting the Top-stop “On” Angle backward (i.e., decreasing the “on” angle).

2. Power down, then power up the WPC 2000 to enable the new settings.

3. Clear the “Loc” message on the WPC 2000 display by turning the Stroke Select switch to

OFF, then to INCH.

If you have a variable-speed press, set the press to the slowest production speed, but not slower than 6 SPM.

4. With the press in Inch mode, press the Reset/Select button until the “Top Stop Angle”

indicator is lit.

The Top-stop “On” Angle is set at the factory to 211°. If you haven’t changed the default setting, you can skip step 5.

5. Temporarily set the Top-stop “On” Angle to 211°, using the WPC Settings key switch.

Turning the key to “+” (counterclockwise) increases the angle; turning the key to “–” (clockwise) decreases the angle.

6. Press the Reset/Select button repeatedly until the “Angle/SPM” indicator is lit. This

action saves your Top-stop “On” Angle setting.

7. With the press still in Inch mode and the main motor on, press and hold both Run/Inch

palm buttons until the press top-stops.

8. Note the crankshaft angle shown in the LED display. Subtract the displayed value from

360°, then add the result to the default 211° Top-stop “On” Angle setting. This is your calculated Top-stop “On” Angle.

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NOTICE

EXAMPLE

If the displayed Top-stop “On” Angle is 287°, you would calculate as follows: 360° - 287° = 73°

211° + 73° = 284° You would set your Top-stop “On” Angle to 284°.

WHEN DETERMINING TOP-STOP “ON” ANGLE

Remember that the Top-stop angle has an internal dwell of 20°. The internal Top-stop timing turns off 20° after the Top-stop angle that you set. This internal Top-stop timing must turn off before the overrun limit switch turns on. If the Top-stop timing and the overrun limit switch are “on” simultaneously, an “80 series” error code will display (see Top-stop and Overrun Setting Faults, page 5-18).

9. Select the “Top Stop Angle” indicator, and set the Top-stop “On” Angle to the value you

calculated in step 8.

10. Save the new Top-stop “On” Angle setting by pressing the Reset/Select button until the

“Angle/SPM” indicator is lit.

11. Determine the angle at which to install the overrun sensor magnet, referring to Table 3-2.

First, locate the cell in the “Top-stop Angle” row displaying the range of angles within which your calculated Top-stop “On” Angle falls; then, move down one row in that column to find the mounting angle for the overrun sensor magnet. If you wish, you can use the “Your Settings” column in the second row to record the correct mounting angle.

Table 3-2. Overrun Sensor Magnet Location and Option Switch Settings

Top-stop Angle Magnet Mounting Angle Switch 1 Setting Switch 2 Setting

Example

You calculated in step 8 that your Top-stop “On” Angle is 284°, which falls in the 271° to 300° column in Table 3-2. The correct mounting angle for the overrun sensor magnet would

be 330°. See Figure 3-5.

< 240° 241° to 270° 271° to 300° > 301° Your Settings

270° 300° 330° 359°

ON ON OFF OFF ON OFF ON OFF

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Figure 3-5. Setting Overrun Timing: Example

12. Determine the option switch 1 and 2 settings required for your calculated Top-stop “On”

Angle, referring to Table 3-2. WPC 2000 uses these settings to determine at what angle to begin the overrun sensor closure test, which is used to make sure that the overrun limit switch closes at the same angle on every stroke.

Move down from the cell in which the correct magnet mounting angle falls (see step 1 1) to find the correct switch settings in last two rows of the table. If you wish, you can use the “Your Settings” column in those rows to record those settings.

Example

You calculated in step 8 that your Top-stop “On” Angle is 284°, which falls in the 271° to 300° column in Table 3-2. The correct switch settings would be OFF for switch 1 and ON for switch 2. See Figure 3-5.

13. Set option switches 1 and 2 on S101 on the WPC 2000 Main Processor board to the

positions you determined in step 12, referring to page 3-26 for instructions.

14. If you are using the Auto Compensated Top Stop feature, return switch 4 on S101 to its

ON setting to enable it (see step 1).

15. Power down, then power back up the WPC 2000 to enable the new option switch settings.

Mounting the Overrun Sensor Magnet

To mount the overrun sensor magnet, perform the following steps:

Initialization, Setup, and Checkout 3-9