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AutoSet PAC Wintriss Load Analyzer A SmartPAC Module1101600Rev. N December 2018Tech Support Hotline800-586-83248-5 EST Wintriss Controls Group, LLC100 Discovery WayUnit 110Acton MA 01720 USAPhone (800) 586-8324Fax (978) 263-2048PRINTED IN USADA46021www.wintriss.com
Changes for Revision N of theAutoSetPAC User Manual (1101600)This revision of the AutoSetPAC user manual covers AutoSetPAC software version 2.28 and higher.The changes include: Addition of SmartPAC PRO installation, usage information, and wiring diagrams 8 – 12. AutoSetPAC 1500 and 1504 references changed to 2-channel and 4-channel, respectively.
Thank you for purchasing a Wintriss Product. We appreciate your business and want to do whateverwe can to ensure your satisfaction. Wintriss products are built to stay on the job day after day, and arebacked by an ironclad guarantee, international standards approvals, and unbeatable support.Whenever you need assistance or service, we back all our products with excellent spare partsinventories, training programs, and prompt repair service. We would like to share with you a list ofservice options–probably the largest number of service options offered in the industry. Technical AssistanceWe offer a toll-free line for technical assistance. Call our Wintriss Technical Support Hotline at1-800-586-TECH (8324) should you have any questions about your equipment. Our technical staff isready to assist you Monday through Friday, 8 a.m. to 5 p.m. EST. In many cases our experiencedtechnical staff can resolve your inquiry right over the phone. Return AuthorizationPlease call our “800” number for a return authorization (RMA) number to return a product for repair.Returned goods must arrive freight prepaid. In order to process your return quickly, we ask that youprovide us with the following pertinent information when you call: purchase order number, shippingaddress, contact name and telephone number, and product type. The assigned RMA number shouldappear on all packages returned to Wintriss Controls Group to ensure prompt service.At the time of requesting an RMA, you will be quoted a flat-rate repair price for the product you arereturning. We ask that you either fax us a PO for that amount or enclose the PO with the returneditem. This will enable us to ship the item back to you as soon as the repair has been completed. If theitem cannot be repaired or there are additional charges, you will be contacted for approval.Please be sure to carefully pack all returned items and ship to our Acton, MA location. Expedited Repair ProgramRush service providing 48 hour turnaround is available for most products upon request. An ExpediteFee will be applied to our standard repair rate. Board Exchange ProgramIf your needs are urgent, you can take advantage of our Board Exchange (EX) program. Call our“800” number between 8 a.m. and 5 p.m. EST and we will send a replacement to you overnight. A feedoes apply to this service. Contact Wintriss Technical Support at 800-586-8324 for details. Service CenterOur Service Center for product service is located at our headquarters in Acton MA. If your equipmentrequires 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 800-5868324. Product TrainingWe also offer both product training and maintenance/troubleshooting courses at our Acton, MA andChicago-area facilities. On-site training is available from the factory or through your local Wintrissrepresentative. Restocking ChargeReturned goods are subject to a 20% restocking charge if returned for credit. The minimum charge is 50, not to exceed 250 per item.Whatever the product, we are committed to satisfying you with innovative engineering, qualityconstruction, reliable performance, and ongoing, helpful support. Call us whenever you needassistance.
Table of ContentsChapter 1 Introduction. 19AutoSetPAC Benefits . 20SmartPAC PRO, SmartPAC 2, and Original SmartPAC . 20Original SmartPAC and SmartPAC 2 Front Panels . 22SmartPAC PRO Front Panel . 23Strain Links . 25Calibration . 25AutoSetPAC Operation . 26AutoSetPAC Faults . 26AutoSetPAC Specifications . 27Chapter 2 Installation. 29Mounting AutoSetPAC . 29Mounting the AutoSetPAC Enclosure without Display . 30Mounting the AutoSetPAC Enclosure with AutoSet 2-Channel/4-Channel Display . 31Installing the AutoSetPAC Panel Mount. 32Installing the AutoSetPAC Processor Board, 85 to 264 Vac Version (No Enclosure). 34Installing the AutoSetPAC Processor Board (24 Vdc Version) . 35Connecting AC and Stop Circuit Wiring. 36Installing Strain Links . 41Mounting Strain Links . 42Wiring Strain Links . 46Connecting the Zero Cam Signal to SmartPAC 2 or SmartPAC PRO . 48Connecting Communications Wiring to SmartPAC 2 or SmartPAC PRO. 50Wiring an Oscilloscope (Optional) . 51Connecting AC Wires to Power Source . 53Connecting a New AutoSetPAC to Original SmartPAC . 53Connecting an AutoSet to SmartPAC . 54Connecting AutoSet to SmartPAC Pro or SmartPAC 2 . 54Connecting an AutoSet to Original SmartPAC . 56Powering Up AutoSetPAC . 57Installing New AutoSetPAC Firmware . 58Chapter 3 Initialization and Calibration. 61Making Settings on Switch Block S101 . 61Accessing the SmartPAC Main Initialization Menu . 63Making Tonnage/Waveform Initialization Settings . 65Initializing Parameters . 65Setting Input Names . 66Disabling/Enabling AutoSetPAC Parameters . 68Setting Reverse Setpoint % of Press Capacity . 68Locking Run Mode Actions . 69Viewing Communications . 71Calibrating AutoSetPAC . 72Zeroing Strain Links . 73Recording Tonnage on an AutoSet Calibration Kit. 77Setting Full-scale Tonnage on Your AutoSetPAC . 85Adjusting AutoSetPAC To Read the Correct Tonnage . 87Checking Linearity . 91Final Checkout . 92AutoSetPAC User ManualTable of Contents11016007
Chapter 4 Using AutoSetPAC in Program Mode . 93AutoSetPAC’s Setpoint Calculation Process. 93Startup Counter. 95Accessing the Tonnage Monitor Programming Menu . 96Making Tonnage Monitor Settings . 98Loading Tonnage Monitor Settings . 99Copying Tonnage Monitor Settings .100Changing Tonnage Monitor Settings .101Viewing and Adjusting Setpoints .101High Setpoint Limits .102Low Setpoint Limits .103Repeatability Setpoint Limits .103Recalculating Setpoints .104Chapter 5 Using AutoSetPAC in Run Mode . 107Accessing the Tonnage Monitor Run Menu .107Displaying Tonnage in Plan View .109Displaying Tonnage in Bargraph View .110Viewing and Adjusting Setpoints .111High Setpoint Limits .112Low Setpoint Limits .112Repeatability Setpoint Limits .113Setpoint Calculation Period .114Recalculating Setpoints .114Viewing Tonnage History .115Viewing Tonnage History for a Selected Strain Link Input .115Viewing History for the Total Strain Link Tonnage .118Clearing Tonnage History .119Recalculating Setpoints .119Viewing Reverse Tonnage .120Loading a New Tool .121Chapter 6 Troubleshooting . 123Responding to AutoSetPAC Faults .123Setpoint Faults .125Offset Errors .126Troubleshooting Common AutoSetPAC Problems .127Glossary. 129Index. 131Wiring Diagrams at End of ManualFigure 1. 120 VAC AutoSetPAC 2 Channel with SmartPAC 2Figure 2. 120 VAC AutoSetPAC 4 Channel with SmartPAC 2Figure 3. SmartPAC 2 Loopback Wiring ConnectionsFigure 4. 120 VAC AutoSetPAC 2 Channel with SmartPAC 1Figure 5. 120 VAC AutoSetPAC 4 Channel with SmartPAC 1Figure 6. 24 VDC AutoSetPAC 4 Channel with SmartPAC 2Figure 7. 24 VDC AutoSetPAC 2 Channel with SmartPAC 2Figure 8. 120 VAC AutoSetPAC 2 Channel with SmartPAC PROFigure 9. 120 VAC AutoSetPAC 4 Channel with SmartPAC PROFigure 10. SmartPAC PRO Loopback Test WiringFigure 11. 24 VDC AutoSetPAC 4 Channel with SmartPAC PROFigure 12. 24 VDC AutoSetPAC 2 Channel with SmartPAC PRO8Table of Contents
AutoSetPAC User Manual1101600List of FiguresFigure 1-1. SmartPAC 2 and Original SmartPAC . 21Figure 1-2. SmartPAC PRO . 23Figure 2-1. AutoSetPAC Enclosure: Mounting Dimensions. 30Figure 2-2. AutoSetPAC Enclosure with AutoSet 4-Channel Display: Mounting Dimensions . 31Figure 2-3. AutoSetPAC Panel Mount: Mounting and Cutout Dimensions . 33Figure 2-4. AutoSetPAC 4-Channel Processor Board (85 to 264 Vac Version): MountingDimensions . 34Figure 2-5. AutoSetPAC Processor Board (24 Vdc Version): Mounting Dimensions . 35Figure 2-6. AutoSetPAC 2-Channel Processor Board: Location of Important Components . 37Figure 2-7 AutoSetPAC 4-Channel Processor Board: Location of Important Components. . 38Figure 2-8. AC Power Connections. 39Figure 2-9. Strain Link: Mounting Dimensions . 42Figure 2-10. Strain Link Mounting Options on Gap-frame Presses . 43Figure 2-11. Strain Link Mounting Options on Straight-side Presses . 44Figure 2-12. Strain Link Drill Jig: Mounting Dimensions . 45Figure 2-13. Shield Drain Wire Connected to Ground Stud on Enclosure . 47Figure 3-1. Switch Block S101 (Default Settings Shown) . 62Figure 3-2. SmartPAC 2 Main Initialization Menu . 64Figure 3-3. SmartPAC PRO Initialization Menu. 64Figure 3-4. Tonnage/Waveform Initialization Menu . 65Figure 3-5. Initialize Parameters Warning Message . 66Figure 3-6. Load Monitor Input Name Menu with “INPUT 1” Highlighted . 67Figure 3-7. Load Monitor Input Name Menu with Alphabetic Entry Window Displayed . 67Figure 3-8. Numeric Entry Window Superimposed on Tonnage Monitor Initialization Menu . 69Figure 3-9. Security Access Menu with Load Monitor Setting Highlighted . 70Figure 3-10. COMMUNICATIONS Item on Diagnostic Menu in Initialization Mode. 71Figure 3-11. Communication Data Viewer Screen . 71Figure 3-12. Communications Transmit/Receive Screen . 72Figure 3-13. Calibration Screen: Current Zero Offsets Display . 73Figure 3-14. Potentiometer Adjustment Screw on Strain Links without Access Hole in Cover . 74Figure 3-15. AutoSet 2-Channel Calibration Kit Processor Board: Old Style . 79Figure 3-16. AutoSet 2-Channel Calibration Kit Processor Board: New Style. 80Figure 3-17. AutoSet 2-Channel Calibration Kit Processor Board: AutoSet V2.0 Board. 81Figure 3-18. Tonnage Dial Indicators: Old-style Board (Left), New-style Board (Right) . 82Figure 3-19. Mode Switch #3 Set to “Decimal Point Off” Position (Old-style Processor Board) . 82Figure 3-20. Load Cell Gain Adjustment Potentiometer with Adjustment Screw . 84Figure 3-21. Tonnage/Waveform Initialization Menu with Numeric Entry Window Displayed . 86Figure 3-22. Calibration Screen . 87Figure 3-23. AutoSetPAC 4-Channel Processor Board: High/Low Gain Jumper and GainAdjustment Potentiometer for Left Rear Strain Link . 89Figure 3-24. Calibration Screen: Calfactors Display. 91Figure 4-1. Tonnages Produced on Left Strain Link during Sample Period: Example . 95Figure 4-2. Main Program Menu . 96Figure 4-3. Tool Manager Screen . 97Figure 4-4. Tool Programming Menu . 97Figure 4-5. Tonnage Monitor Programming Menu . 98Figure 4-6. Load Tool Warning Message. 100Figure 4-7. Tool Loading Message . 100Table of Contents9
Figure 4-8. Tool Manager Screen with Copy Tool Message and Numeric Entry WindowDisplayed . 100Figure 4-9. Adjust Setpoints Screen: High Setpoint Limits Display . 102Figure 4-10. Adjust Setpoints Screen: Low Setpoint Limits Display . 103Figure 4-11. Adjust Setpoints Screen: Repeatability Setpoint Limits Display . 104Figure 4-12. Main Program Menu with “RECALCULATE SETPOINTS” Warning Displayed . 105Figure 5-1. SmartPAC Main Run Menu . 108Figure 5-2. Tonnage Monitor Run Menu . 109Figure 5-3. Tonnage “Plan” View Screen (4-channel AutoSetPAC Shown) . 109Figure 5-4. Tonnage Bargraph View Screen . 110Figure 5-5. Adjust Setpoints Screen: High Setpoint Limits Display . 111Figure 5-6. Adjust Setpoints Screen: Low Setpoint Limits Display . 113Figure 5-7. Adjust Setpoints Screen: Repeatability Setpoint Limits Display . 113Figure 5-8. Adjust Setpoints Screen: Sample Period Display. 114Figure 5-9. Adjust Setpoints Screen: Recalculate Setpoints Warning Message . 114Figure 5-10. Tonnage History Menu. 115Figure 5-11. Tonnage History Display for “Left Rear” Input (#1) . 116Figure 5-12. Tonnage History for “Total Tonnage” Display . 118Figure 5-13. “Clear Tonnage History” Warning Message . 119Figure 5-14. Tonnage Monitor Run Menu: Recalculate Setpoints Warning Message . 119Figure 5-15. Reverse Tonnage Plan View Screen . 120Figure 5-16. Tool Manager Screen . 121Figure 5-17. Load Tool Warning Message . 121Figure 5-18. Tool Loading Message . 122Figure 6-1. AutoSetPAC Tonnage Fault Message: High Setpoint Exceeded . 123List of TablesTable 1-1. Original SmartPAC and SmartPAC 2 Panel Features . 22Table 1-2. SmartPAC PRO Panel Features . 24Table 1-3. AutoSetPAC Specifications . 27Table 2-1. AutoSetPAC AC Power and Stop Circuit Wiring Connections, TB103 . 40Table 2-1. AutoSetPAC 24 VDC Power Wiring Connections, TB109 . 40Table 2-1. AutoSetPAC 24 VDC Stop Circuit Wiring Connections, TB103 . 40Table 2-2. Strain Link Part Numbers with Cable Length or Connector Type . 41Table 2-3. Strain Link Connections on AutoSetPAC Processor Board . 46Table 2-4. Strain Link Wiring Connections, TB105 - TB108: Tension . 47Table 2-5. Strain Link Wiring Connections, TB105 - TB108: Compression . 47Table 2-6. Zero Cam Wiring Connections to SmartPAC PRO . 48Table 2-7. Zero Cam Wiring Connections to SmartPAC 2 . 49Table 2-8. Communications Wiring Connections. 50Table 2-9. Oscilloscope Wiring Connections, 120 VAC AutoSetPAC . 52Table 2-10. Oscilloscope Wiring Connections, 24 VDC AutoSetPAC . 52Table 2-11. Communications Wiring Connections: AutoSet and SmartPAC 2 or SmartPAC PRO . 55Table 2-12. Communications Wiring Connections: AutoSet and Original SmartPAC . 57Table 3-1. Switch Block S101 Settings . 62Table 3-2. Strain Link Potentiometer: Direction of Screw* Adjustment. 75Table 3-3. AutoSet Load Cell Tonnage Display Formats . 83Table 3-4. AutoSetPAC 2-Channel and 4-Channel Tonnage Display Formats . 86Table 3-5. Gain Adjustment Potentiometer and High/Low Gain Jumper Identifiers . 88Table 3-6. AutoSetPAC Load Readings: Ratio of Calibration Unit Readings . 8910Table of Contents
AutoSetPAC User Manual1101600Table 4-1. Tonnage Monitor Programming Menu Settings . 99Table 5-1. Tonnage History Information for Each Strain Link Input. 117Table 5-2. Tonnage History Information for Total Tonnage. 118Table 6-1. Common Causes of Tonnage Faults . 124Table 6-2. Setpoint Faults: Possible Causes . 126Table of Contents11
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How to Use This ManualThis manual shows you how to install, calibrate, program, run, and troubleshoot AutoSetPAC 2Channel and 4-Channel load analyzers. In some places, this manual assumes that you are runningAutoSetPAC with a SmartPAC 2 control, but the instructions also apply to AutoSetPACs connectedto an original SmartPAC or SmartPAC PRO.Chapter 1 provides an overview of AutoSetPAC features and operation.Chapter 2 shows you how to mount and wire AutoSetPAC.Chapter 3 shows you how to enter AutoSetPAC settings in SmartPAC Initialization mode andcalibrate AutoSetPAC.Chapter 4 shows you how to establish AutoSetPAC setpoint percentages and a sample period foreach tool in SmartPAC Program mode.Chapter 5 shows you how to view and adjust programmed AutoSetPAC settings in SmartPACRun mode.Chapter 6 shows you how to respond to AutoSetPAC faults and troubleshoot commonAutoSetPAC problems.The Glossary provides definitions of some of the terms used in the manual that may be unfamiliarto you.Wiring diagrams at the end of the manual show connections between AutoSetPAC and all threeversions of SmartPAC (original SmartPAC, SmartPAC 2, SmartPAC PRO) and the connectionsnecessary to conduct a loopback test.NOTICEDOWNLOAD WINTRISS DOCUMENTSDownload any
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
