Download Print this page

Wintriss SmartPAC 2 User Manual

Wintriss SmartPAC 2 User Manual

Press automation control with wpc 2000 clutch/brake control

Hide thumbs Also See for SmartPAC 2:

Instruction sheet (28 pages)

Table Of Contents

Table of Contents

Advertisement

Quick Links

Download this manual

®

®

SmartPAC 2

Press Automation Control

with WPC 2000 Clutch/Brake Control

®

®

includes optional DiPro PAC and ProCam PAC

1128600

Rev. P

January 2018

Tech Support Hotline

800-586-8324

8-5 EST

®

Wintriss Controls Group, LLC

100 Discovery Way

Unit 110

Acton MA 01720 USA

Phone (800) 586-8324

Fax (978) 263-2048

www.wintriss.com

PRINTED IN USA

DA70482

Table of Contents

Advertisement

Table of Contents

Troubleshooting

Need help?

Need help?

Do you have a question about the SmartPAC 2 and is the answer not in the manual?

Questions and answers

Summary of Contents for Wintriss SmartPAC 2

Page 1 DiPro PAC and ProCam PAC 1128600 Rev. P January 2018 Tech Support Hotline 800-586-8324 8-5 EST ® Wintriss Controls Group, LLC 100 Discovery Way Unit 110 Acton MA 01720 USA Phone (800) 586-8324 Fax (978) 263-2048 www.wintriss.com PRINTED IN USA...
Page 3 Wintriss Product. We appreciate your business and want to do whatever we can to ensure your satisfaction. Wintriss products are built to stay on the job day after day, and are backed by an ironclad guarantee, international standards approvals, and unbeatable support.
Page 5 Changes for Revision P of the SmartPAC 2 with WPC 2000 User Manual (1128600) This revision of the SmartPAC 2 user manual covers SmartPAC 2 software version 13.81 and higher and WPC 2000 software version 6.00 and higher. The changes include: In How to Use This Manual, added link to downloadable product documentation.
Page 7: Table Of Contents
SmartPAC 2 with WPC 2000 ........
Page 8 Installing SmartPAC 2 as a Panel Mount ....... . 2-48...
Page 9 SmartPAC 2 Operating Modes ........3-15...
Page 10 UPDATE FIRMWARE ..........4-65 Using SmartPAC 2 with a Link-motion Press ......4-65 Setting Link Motion .
Page 11 Turning a Sensor Off or On ......... . 5-53 Chapter 6. SmartPAC 2 Run Mode ......6-1 Entering and Exiting Run Mode .
Page 12 MESSAGING ..........6-37 Sending E-mail to Wintriss Technical Support......6-38 TOGGLE HOT KEYS .
Page 13 Updating Firmware Using a USB Disk....... D-1 Installing Updated Firmware from USB Disk to SmartPAC 2 ....D-2 Downloading Updated Firmware from the Wintriss Server .
Page 14 Restoring Tools to SmartPAC 2 ........
Page 15 Reset Strokes Counters ..........I-6 Setting up SmartPAC 2 to Report Downtime ......I-6 Making Downtime Reporting Settings .
Page 16 ..........I-1 Wiring Diagrams Figure 1. WPC 2000 and SmartPAC 2 System Wiring Figure 2. WPC 2000 Operator Station Wiring Figure 3.
Page 17 Figure 2-26. Wiring AC to Terminal Block, Inside Enclosure, Top Right ........2-53 Figure 2-27. Input Check Switch (S101) ..................2-55 Figure 2-28. DiProPAC and ProCamPAC Boards Installed on SmartPAC 2 Board ......2-57 Figure 2-29. DiProPAC Boards (8-, 16-, and 32-Sensor): Location of Components ......2-58 Figure 2-30.
Page 18 Figure 3-20. SmartPAC 2 Display, Run Mode ................3-14 Figure 3-21. Main Run Menu with “CAM SWITCH” Highlighted ..........3-14 Figure 3-22. SmartPAC 2 Operating Modes, Showing Main Menus ..........3-15 Figure 3-23. Initialization Mode Main Menu ................. 3-17 Figure 3-24. Navigation Example: Initialization Mode ..............3-18 Figure 3-25.
Page 19 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Figure 4-39. Alphanumeric Entry Window with Default Mail Server Displayed ......4-59 Figure 4-40. Diagnostics Menu .......................4-61 Figure 4-41. Communications Data Viewer Screen ................4-62 Figure 4-42. Transmit and Receive Data Screen: Combined View (Left), Split View (Right) ..4-62 Figure 4-43.
Page 20 Figure 6-30. Messaging Screen: List of Recipients ................ 6-36 Figure 6-31. Messaging Screen: List of Messages ................6-37 Figure 6-32. Sample E-mail to Wintriss Tech. Support ..............6-37 Figure 6-33. Toggle Hot Keys 1 and 2 Menu Items ............... 6-38 Figure 6-34.
Page 21 WPC 2000 Display Showing Fault Code ..............7-5 Figure 7-4. Ross DM2 DSV Showing Reset Button ..............7-32 Figure C-1. “PM Monitor” Highlighted on SmartPAC 2 Initialization Menu ........ C-4 Figure C-2. PM Password Screen ....................C-5 Figure C-3. PM Password Screen Showing Password Retrieval Number ........C-6 Figure C-4.
Page 22 Table 1-1. SmartPAC 2 with WPC 2000 Specifications ....... 1-12 Table 2-1.
Page 23 Table 2-15. SmartPAC 2 Resolver (TB101) Wiring ........
Page 24 Table D-1. Record of Current Counts ..........D-2 Table E-1. SmartPAC 2 Board: PS 2 and Y-Cable Configuration ......E-4 Table F-1.
Page 25 SmartPAC 2/WPC 2000 operation for individual tools. Chapters 6 shows you how to use SmartPAC 2 in Run mode, which is the mode you select to run the press and make minor adjustments to programmed settings.
Page 26: Smartpac 2 With Wpc 2000 Integration User Manual
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Important Highlighted Information Important danger, warning, caution and notice information is highlighted throughout the manual as follows: DANGER A DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.
Page 27 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.
Page 28 1128600 SmartPAC 2 with WPC 2000 Integration User Manual xxii Table of Contents...
Page 29: Chapter 1. Introduction
SmartPAC 2 features a large, bright color display, a numeric keypad, and easy-to-use keys to program and run your press. SmartPAC 2 can be connected to a computer network, enabling press operation to be monitored remotely and e-mail messages to be sent from the SmartPAC 2 control.
Page 30: Smartpac 2 Standard Features
SmartPAC 2. SmartPAC 2 upgrades and enhancements can be installed quickly and easily. Upgrades can • be either downloaded directly to SmartPAC 2 via the local network or mailed to you on a USB disk. WPC 2000 Standard Features WPC 2000 provides the following capabilities as standard features: Interrupted Stroke provision.
Page 31: Smartpac 2 Options
SmartPAC 2 screen. This option allows you to store information needed throughout the plant on a central server, where it is available to operators via SmartPAC 2’s Ethernet connectivity. In order to make use of Info Center functionality, SmartView (see Appendix E) must be installed.
Page 32: Wpc 2000 Options
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 2-12 for further details. System Air Pressure Sensor or Switch. This sensor or switch monitors the system air •...
Page 33 Compensated Top Stop (ACTS), page 4-37 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 2-21). DANGER HAZARDS EXPOSED BY NON-WORKING OPERATOR STATION •...
Page 34: Resolver-Based Operation
Wiring connections are shown in Table 2-29, page 2-115. Resolver-based Operation SmartPAC 2 is connected to a resolver mounted on the press that turns one to one (1:1) with the crankshaft. Like an electrical generator, the resolver has internal windings and works on the principle of inductance.
Page 35: Figure 1-1. Smartpac 2 Front Panel
CLEAR Figure 1-1. SmartPAC 2 Front Panel ENTER key When you press this key, SmartPAC 2 accepts the menu item you have selected or the number you have keyed in. RESET key You press this key when you are done with a programming or other procedure.
Page 36: Wpc 2000 Operator Station
SmartPAC 2 with WPC 2000 Integration User Manual WPC 2000 Operator Station Figure 1-2 identifies the switches and indicator lamps on a Wintriss Operator Station. (The configuration with side-mounted Run/Inch palm switches is shown.) Functions of Operator Station components are provided following the figure.
Page 37: Smartpac 2 Settings
In addition, the Brake Warning LED on the SmartPAC 2 front panel (see Figure 1-1, page 1-7 for location) flashes when press stopping time approaches within 10 milliseconds of the stop time limit, allowing you to schedule brake maintenance before the press has to be disabled.
Page 38: Sensors Available For Dipropac
Any electromechanical sensor can be used with SmartPAC 2 as long as it can switch between an open state (i.e., sensor circuit to SmartPAC 2 open) and a closed state (i.e., sensor circuit closed to ground or “grounded”). All types of NPN electronic sensors (e.g., proximity, photoelectric, and fiberoptic sensors) can be used as can simple contact sensors and probes.
Page 39: Procampac Programmable Cams
The optional ProCamPAC module enables you to connect up to eight or sixteen cam channels to your equipment. ProCamPAC consists of a PC board that you install in your SmartPAC 2 and a separate assembly that contains the relays that open and close on signals from SmartPAC 2.
Page 40: Smartpac 2 With Wpc 2000 Specifications
1128600 SmartPAC 2 with WPC 2000 Integration User Manual SmartPAC 2 with WPC 2000 Specifications SmartPAC 2 with WPC 2000 specifications are shown in Table 1-1. Table 1-1. SmartPAC 2 with WPC 2000 Specifications Enclosures SmartPAC 2 Enclosure 12.76 x 11.53 x 5.28 in. (324 x 293 x 134 mm), NEMA 12, shock-mounted.
Page 41 1128600 Table 1-1. SmartPAC 2 with WPC 2000 Specifications (Cont.) Accuracy ± 2/3° (± 1.33° for high speed version–see SmartPAC 2 Options, below) Counters Good parts, strokes, 3 batch with presets (7 digits) Number-of-hits-on-tool counter: counts all hits on tool; resettable to 0 after...
Page 42 Preventive Maintenance (PM) Monitor Tracks selected press functions requiring scheduled maintenance and alerts the user when maintenance is due PLC Interface Enables SmartPAC 2 to transmit additional tool settings to a Programmable Logic Controller for press automation and auxiliary functions 1-14 Introduction...
Page 43 SFC or LETS data collection software for generation of OEE and other reports. Requires purchase of SFC or LETS software. 3rd Party Comms This option allows SmartPAC 2 to transmit real-time and status information to external software for reporting and other tasks WPC 2000...
Page 44 1128600 SmartPAC 2 with WPC 2000 Integration User Manual 1-16 Introduction...
Page 45: Chapter 2. Installation
Chapter 2. Installation 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.
Page 46 NOTICE OPTIONAL MODULES PROCAMPAC AND DIPROPAC INCLUDED IN MANUAL When you order your SmartPAC 2 with WPC 2000 system, you may include the DiProPAC die protection and/or ProCamPAC programmable cam switch option. This manual includes instructions for installing and using both modules. Remember that they are options and might not be included in your system.
Page 47: Installation Guidelines
LEARN TO USE SMARTPAC 2 BEFORE INSTALLING ON A PRESS If you have not used SmartPAC 2 before, learn how to initialize and program it before installing it on a press. On the bench, connect your unit to a resolver (see page 2-24) and to AC power (see page 2-9) so that you can access all the menus and make settings.
Page 48: Figure 2-1. Installation Overview
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Figure 2-1. Installation Overview Installation...
Page 49: Connecting Wires To Terminal Block Connectors
Properly ground SmartPAC 2 and WPC 2000 • The ground wire from SmartPAC 2 should be connected to the main ground point of the WPC 2000. This ground point may be in the area where the control transformer is grounded. Finding a good place for a ground is sometimes difficult, but the location should be close to where the press receives its ground.
Page 50: Terminating Cable Shields
NOTICE TERMINATE BOTH ENDS OF SHIELD Be sure to terminate cable shields at both ends (for example, at SmartPAC 2 and DSI 2). Your SmartPAC 2 and WPC 2000 have ground studs on the inside of the enclosure for terminating cable shields at their point of entry. For each shielded cable, perform the following steps, referring to Figure 2-3.
Page 51: Checking The Press
MOVE RAM TO TDC BEFORE INSTALLING WPC 2000 AND SMARTPAC 2 Move the ram to top dead center (TDC) before installing WPC 2000 and SmartPAC 2. Be accurate when setting the press to TDC. Set to 0° ±2°. Use a dial indicator on the face of the ram if necessary.
Page 52: Wiring The Control Enclosure
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Figure 2-4. WPC 2000 Enclosure: Mounting Dimensions 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 •...
Page 53: Connecting Ac Wiring
Adjustment “On” or Slide Adjustment “Up”/“Down” switch) to the WPC 2000 Emergency- stop 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. Connecting AC Wiring...
Page 54: Figure 2-5. Ac Input Wiring Connections
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Locate the power supply input terminal block on the back wall at the top left of the enclosure, as shown in Figure 2-5. Figure 2-5. AC Input Wiring Connections Determine how you will bring wiring from your 115 or 230 Vac power source to the enclosure.
Page 55: Installing Wpc 2000 Without Enclosure
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 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 (see Figure 2-6 for mounting dimensions).
Page 56: Installing A Dual Safety Valve
1128600 SmartPAC 2 with WPC 2000 Integration User Manual 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 2-9.
Page 57: Installing Air Pressure Sensors Or Switches
See Figure 16 at the end of the manual. Installing Air Pressure Sensors or Switches Your SmartPAC 2 with WPC 2000 requires either sensors or switches to monitor clutch air pressure and counterbalance air pressure if there is a counterbalance. Wintriss offers two pressure sensors with the unit, one for clutch air pressure, the other for counterbalance air pressure (see Figure 2-7).
Page 58: Table 2-1. Clutch Air Pressure Sensor Wiring Connections
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Installing a Clutch Air Pressure Sensor Install and wire a clutch air pressure sensor as follows: Install a filter regulator and lubricator in-line before the clutch air pressure sensor if they are not already present.
Page 59 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Set the counterbalance air pressure sensor to the pressure recommended by the press manufacturer, typically the pressure required for the smallest upper die you plan to use in this press NOTICE...
Page 60: Installing Operator Station(S)
• Ensure that the 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.
Page 61: Figure 2-8. Pre-Wired Operator Stations Showing Mute Lamp Connections
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 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.
Page 62: Figure 2-9. Wiring Steps To Modify Operator Station For Wpc 2000
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Figure 2-9. Wiring Steps to Modify Operator Station for WPC 2000 Making Wiring Connections To wire a pre-wired Operator Station, perform the following steps: Punch a hole in the Operator Station enclosure for conduit or sealtight.
Page 63: Figure 2-10. Pre-Wired Operator Station With Side Run Buttons: Mounting Dimensions
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 At the other end of the cable, connect the wires to the Main Processor board connector terminals, as shown in Table 2-27, page 2-114 and Figure 2 at the end of the manual.
Page 64: Figure 2-12. Unwired Operator Station: Mounting Dimensions
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.
Page 65: Wiring A User-Built Operator Station
• Ensure that the 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.
Page 66: Installing A Light Curtain
1128600 SmartPAC 2 with WPC 2000 Integration User Manual 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.
Page 67 Shadow 9–Figures 25, 26, and 27 • 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, Shadow 8, and Shadow 9 Light Curtains...
Page 68: Installing The Resolver
All sprockets must be keyed or pinned. The resolver shaft has a standard key. Wintriss 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 •...
Page 69 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 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.
Page 70: Figure 2-13. Resolver: Mounting Dimensions
1128600 SmartPAC 2 with WPC 2000 Integration User Manual 0.34 (8.6) dia holes 3.62 2 places (91.9) 1.50 (38.1) 3.75 (95.3) 3.00 (76.2) RESOLVER IS AT ZERO WHEN KEYWAY IS ALIGNED WITH ARROW 9.16 (232.7) 3/4” dia. shaft (19.05) Electrical connector...
Page 71: Table 2-4. Wpc 2000 Resolver (Tb 106) Wiring
Double-check connections when you are finished wiring. Plug the L-shaped connector firmly into its base. It can plug in only one way. To connect resolver wiring between WPC 2000 and SmartPAC 2, refer to page 2-50. Replacing the Resolver NOTICE If the resolver you are replacing is defective, you may not be able to move the ram to TDC.
Page 72: Figure 2-14. Wpc 2000 Main Processor Board: Location Of Important Components
1128600 SmartPAC 2 with WPC 2000 Integration User Manual LED # Figure 2-14. WPC 2000 Main Processor Board: Location of Important Components 2-28 Installation...
Page 73: Installing The Overrun Limit Switch
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Installing the Overrun Limit Switch DANGER 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.
Page 74: Figure 2-15. Overrun Sensor Magnet Placement: Dwell As A Function Of Shaft Diameter
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Actuating Magnet 5” (127 mm) diameter Crankshaft 10” (254 mm) diameter 23 of dwell 11 of dwell 5” 10” Optimum dwell: 15 to 25 Figure 2-15. Overrun Sensor Magnet Placement: Dwell as a Function of Shaft Diameter...
Page 75: Wiring Wpc 2000 User Inputs
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 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.
Page 76 When an input issues a Stop command by opening a normally closed (N/C) relay, a fault code for the input(s) appears on the SmartPAC 2 display. Stop types for all inputs except cross- checked user input pair 10/11 are set to E-Stop by default; input pair 10/11 is set to E-Stop/ Lockout.
Page 77: Table 2-6. Wpc 2000 User Inputs: Stop Types, Fault Codes, And Wiring Connections
* Stop types for all inputs except input pair 10/11 are set to E-Stop by default; input pair 10/11 is set to E-Stop/Lockout. All inputs except input pair 10/11 can be reconfigured by the user. If you have SmartPAC 2 firmware version 3.32 or higher and WPC 2000 firmware version 1.70 or higher, an additional stop type option, Top-stop/Lockout, is available...
Page 78: Connecting Other Wintriss Products To Wpc 2000
SmartPAC 2 with WPC 2000 Integration User Manual Connecting Other Wintriss Products to WPC 2000 You can connect the stop circuits of other Wintriss products to WPC 2000. 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).
Page 79: Wiring Auxiliary Outputs
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Wiring Auxiliary Outputs DANGER 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.
Page 80 1128600 SmartPAC 2 with WPC 2000 Integration User Manual 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;...
Page 81: Wiring Operator Mode Outputs
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 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.
Page 82: Wiring A Foot Switch
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.
Page 83: Installing A One-Hand Control
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...
Page 84: Figure 2-18. One-Hand Control Switch: Mounting Dimensions
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Mounting a One-hand Control DANGER 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.
Page 85: Figure 2-19. One-Hand Control Switch Base: Mounting Dimensions
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Figure 2-19. One-hand Control Switch Base: Mounting Dimensions Shut off power to the press and to WPC 2000. 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.
Page 86: Figure 2-20. Wiring Connections In One-Hand Control Switch (Switch Cover, Bottom View)
1128600 SmartPAC 2 with WPC 2000 Integration User Manual 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.)
Page 87: Wiring A Keylock Switch To Prevent Changes To Wpc 2000 Settings
1128600 Wiring a Keylock Switch to Prevent Changes to WPC 2000 Settings You can use a keylock switch (not supplied by Wintriss) to provide additional security that supersedes the Run mode lockout provided in SmartPAC 2. Refer to Additional Security, page 4-52 for more information.
Page 88: Mounting And Wiring The Bar Control Enclosure
1128600 SmartPAC 2 with WPC 2000 Integration User Manual NOTICE Be sure to position the red and blue magnets on the flywheel approximately 180° apart. Figure 2-21. Installing the LMCS and Magnets Run the cable from the LMCS sensor through flexible, liquid-tight conduit to the WPC 2000 enclosure.
Page 89: Figure 2-22. Bar Control Enclosure: Mounting Dimensions
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 BAR CONTROL SELECT OPERATE DATA INSTRUMENTS Wintriss Controls Group Figure 2-22. Bar Control Enclosure: Mounting Dimensions Table 2-13. Bar Control Wiring Connections WPC 2000 Main Processor Bd. Bar Control Contacts Pin #...
Page 90: Wiring Automatic Single-Stroke
• 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. 2-46 Installation...
Page 91: Installing Smartpac 2
1128600 Installing SmartPAC 2 Mounting the SmartPAC 2 Control Enclosure NOTICE If your SmartPAC 2 is a panel mount version, go to the next section, page 2-48, for mounting instructions. NOTICE PLACE SMARTPAC 2 AT A CONVENIENT HEIGHT SmartPAC 2 should be installed at a convenient height for all users. Ideally, the top edge of the unit should be approximately at chin level.
Page 92: Installing Smartpac 2 As A Panel Mount
Drill and tap (if necessary) mounting holes, using a No. 7 drill and 1/4–20 tap, then mount the enclosure, using the enclosed shock mounts. Shock mount studs are 1/4–20. Go to Wiring between WPC 2000 and SmartPAC 2, page 2-50 to start wiring your SmartPAC 2.
Page 93: Figure 2-24. Smartpac 2 Mounting And Cutout Dimensions: Panel Mount
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 POWER BRAKE WARNING SINGLE STROKE PROG INCH CONT ENTER HELP RESET CLEAR Figure 2-24. SmartPAC 2 Mounting and Cutout Dimensions: Panel Mount Installation 2-49...
Page 94: Wiring Between Wpc 2000 And Smartpac 2
1/2 in. flexible, liquid-tight conduit from the bottom right of the WPC 2000 enclosure to the bottom left of the SmartPAC 2 enclosure (see Figure 2-1, page 2-4). Both WPC 2000 and SmartPAC 2 are 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.
Page 95: Figure 2-25. Smartpac 2 Board: Location Of Components
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Double-check connections when you are finished wiring. Locate jumper JP101 on the SmartPAC 2 board (see Figure 2-25), and move it to the “Slave” position. Table 2-15. SmartPAC 2 Resolver (TB101) Wiring...
Page 96: Table 2-16. Communications Wiring: Smartpac 2 To Wpc 2000
• Do not connect the AC power source until you are done with all other installation procedures. • Turn off and disconnect power from the machinery SmartPAC 2 is connected to before making any wiring connections. This includes power to the machine control and motor.
Page 97: Figure 2-26. Wiring Ac To Terminal Block, Inside Enclosure, Top Right
1/4 in. (6.4 mm) from end, loosen the screw on the terminal, slide the wire in the hole, and tighten the screw to secure the wire in place. SmartPAC 2 Panel Mount: Connect the ground wire to the ground stud on the face •...
Page 98: Table 2-17. Stop And Input Check Circuit Wiring Connections
SmartPAC 2 with WPC 2000 Integration User Manual Connecting Stop Circuits and Input Check Circuit To connect stop circuit and input check circuit wiring between WPC 2000 and SmartPAC 2, perform the following steps: Supplying your own multi-conductor cable (six wires minimum–two for the...
Page 99: Connecting Smartpac 2 To A Network
This signals SmartPAC 2 to initiate a stroke at the press. If SmartPAC 2 gets no signal from the resolver within the specified start time limit (resolver not turning), SmartPAC 2 opens the Emergency-stop circuit and a “loss of rotation”...
Page 100: Installing Smartpac 2 Options
MAKE SURE TO CLEAR TABLES AFTER INSTALLING DIPROPAC 32 If you are installing a DiProPAC 32 board, you must clear some of the SmartPAC 2 memory tables; otherwise, your SmartPAC 2 will not operate properly. After installing the board, clear the tables by accessing the Diagnostics Menu from the SmartPAC 2 Main Initialization Menu (see page 4-1), and selecting the CLEAR TABLES item (see page 4-61).
Page 101: Figure 2-28. Dipropac And Procampac Boards Installed On Smartpac 2 Board
To replace an existing DiProPAC or ProCamPAC board, do the following: Turn off power to the SmartPAC 2. On the SmartPAC 2 board, locate the board that you wish to replace (see Figure 2-28). TB102 282 283 284 285 286 287 288 289 290...
Page 102: Figure 2-29. Dipropac Boards (8-, 16-, And 32-Sensor): Location Of Components
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Making sure you are grounded, remove the connector(s) attached to the board, one connector for an 8-sensor or 8-cam unit, two connectors for a 16-sensor or 16-cam unit (see Figure 2-29 and Figure 2-30).
Page 103 Remove the four screws that hold the board to the standoffs, and put them aside. Mark the board to identify it so you don’t re-install it by mistake. Remove the board by pulling it straight up from the SmartPAC 2 board and out of its connector.
Page 104 1128600 SmartPAC 2 with WPC 2000 Integration User Manual CAUTION DAMAGE TO BOARD FROM STATIC DISCHARGE Ground yourself before touching circuit boards or chips by touching a large metal object such as the press. Static electricity can destroy electronic components.
Page 105: Connecting Dipro Sensor Interface To Smartpac 2
If any of your sensors are low-impedance types, they must be wired directly to DiProPAC. Low-impedance sensors cannot be wired to DSI 2. Table 2-18. DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 1-8 Wire color* 1st DSI 2 (TB2)
Page 106: Table 2-19. Dipro Sensor Interface (Dsi) 2 To Smartpac 2 Wiring, Sensors 9-16
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Table 2-19. DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 9-16 Wire color* 2nd DSI 2 (TB2) DiProPAC (TB554) Pin # Pin Designation Pin # Pin Designation Brown SENSOR 1...
Page 107: Connecting Programmable Cam Channels
If you have purchased the ProCamPAC option with SmartPAC 2, you have received a separate output assembly for wiring up to sixteen cam channels to your equipment. The assembly contains the relays that open and close at the angles you set in SmartPAC 2, turning Installation...
Page 108 To mount the ProCamPAC Output Assembly and wire it to the ProCamPAC board inside the SmartPAC 2 control, follow the instructions below. These instructions may be used with either the 8- or 16-channel ProCamPAC board. Refer to Table 2-22 and Table 2-23, page 2-67 for wiring connections.
Page 109: Figure 2-31. Procampac Output Assembly
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Cam output 6.00 (152.4) 0.312 (7.9) dia. enclosure 4 places 10.00 (254.0) 10.75 (273.1) 3.50 (88.9) XX.XX = inches (XX.X) = mm 8.00 (203.2) 6.00 (152.4) Cam output board TB301 Connections to control...
Page 110: Figure 2-32. Cam Outputs Board
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Connection to press control TB301 DS301 Solid State Relays Channels 5-8 LEDs for channels Use only one relay (mechanical or solid state) for each channel Relay 6 Relay 5 Relay 4...
Page 111: Table 2-22. Procampac To Cam Output Assembly Tb301 Wiring, Cams 1-8
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Table 2-22. ProCamPAC to Cam Output Assembly TB301 Wiring, Cams 1-8 8-cam: ProCamPAC TB401 (cams 1-8) 1 st Cam Output Board 16-cam: ProCamPAC TB451 (cams 1-8) Wire TB301 (Pin #) (Pin #)
Page 112: Figure 2-33. Connector Tb302 And Tb303 For Wiring Relays To Equipment
SmartPAC 2. If you connect to “N/C,” the equipment will be on except for the number degrees set. Generally, you should use the “N/O” terminal so that equipment is off except when you use SmartPAC 2 to turn it on. Use the “N/C” terminal only if it is more practical to do the reverse.
Page 113: Figure 2-34. Installing Suppressors Across An Ac Load
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 To reduce electrical noise and to extend the life of the relays, do the following: a. AC loads: Install arc suppressors across each inductive load (motors, coils, etc.) that is connected to a cam relay (see Figure 2-34). Suppressors are supplied with each relay.
Page 114: Setting Up High-Speed Version Of Smartpac 2 With Wpc 2000
SmartPAC 2 can reset faults for both controls. If you would like to be able to reset the SmartPAC 2 and WPC 2000 from a location remote from their enclosures, the SmartPAC 2 board provides a terminal (i.e., pin #249 on TB107) for wiring a remote Reset switch.
Page 115: Setting Up Smartpac 2 With Wpc 2000
Turn the Program/Run key switch to the PROG position. Power up the SmartPAC 2 and WPC 2000. The green Power light on the SmartPAC 2 front panel illuminates, and a red SmartPAC 2 screen (see Figure 2-36, page 2-72) appears for a few seconds.
Page 116: Figure 2-36. Smartpac 2 Startup Screen
Stroke Select key switch to OFF, then to one of the other operating modes. • If another error message displays when SmartPAC 2 starts up, press RESET. • If the error message continues to appear after you press RESET, find the message in Chapter 7 and follow the instructions for correcting the problem.
Page 117: Problems At Startup
Turn off power to SmartPAC 2 and WPC 2000, and recheck all power connections. Check to make sure that the connectors at both ends of the cables between the SmartPAC 2 board and the display are correctly seated. Power up SmartPAC 2 and WPC 2000 again. If the display remains off, contact Wintriss Tech.
Page 118: Verifying Installation Of Dipropac And Procampac
If “PRESS CONTROL” is not displayed, go to step 2. Leaving power on, open the door of the SmartPAC 2 enclosure, and check the state of the LEDs labelled “Tx6” and “Rx6” on the SmartPAC 2 board (see Figure 2-25, page 2-51).
Page 119: Initializing Wpc 2000 Parameters
SmartPAC 2 with WPC 2000 or install new WPC 2000 firmware. When you first set up your SmartPAC 2 with WPC 2000 or when you install new WPC 2000 firmware, initialize press parameters on the Press Control Parameter Menu (see page 4-34 for instructions).
Page 120: Creating And Loading A Test Tool
If you install new WPC 2000 firmware in an existing system, record the WPC 2000 parameters before you install the new firmware. Re-enter the parameters after you re-initialize the WPC 2000. See Chapter 3 for help using the SmartPAC 2 keyboard and displays.
Page 121: Checking And Setting The Direction Of Resolver Rotation
• If you turn the Program/Run key switch and nothing happens, press RESET repeatedly until the screen changes color, indicating that the SmartPAC 2 has changed to the mode you selected. • If the message “PRESS CONTROL IS IN LOCKOUT MODE” is displayed on the screen, turn the Stroke Select key switch to OFF, then to one of the other operating modes to clear it.
Page 122: Zeroing The Resolver
Verify that the press is at top dead center (i.e., 0° ± 2°) before you zero the resolver. If the press is not at TDC, your timing settings may be wrong. You must perform this procedure the first time you power up SmartPAC 2 and whenever you install a new resolver. Zeroing the resolver ensures that SmartPAC 2 maintains an accurate “zero”...
Page 123 Pin #13 on the WPC 2000 Main Processor board should not be connected. When pin • #13 is unwired, Top-stop in Inch is enabled (see page 6-42). Micro-inch should be disabled (see page 4-29 for instructions). • Power down, then power up the SmartPAC 2 to enable the new settings. Installation 2-79...
Page 124 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Clear the “PRESS CONTROL IS IN LOCKOUT MODE” message on the SmartPAC 2 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.
Page 125: Figure 2-40. Overrun Sensor Magnet Installation Worksheet
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Overrun Sensor Magnet Installation Worksheet angle at which the press top-stops Avergage angle at which press top-stops Top-stop “On” Angle Top-stop “On” Angle angle at which to install the overrun magnet option switch 1 and 2 settings Figure 2-40.
Page 126: Table 2-26. Overrun Sensor Magnet Mounting Angle And Option Switch Settings
Top-stop “On” Angle you calculated and set in the previous procedure, allowing the Top-stop cam to turn off before the overrun limit sensor turns on. Otherwise, an “80” series fault will display on the SmartPAC 2 LCD (see Top-stop and Overrun Setting Faults, page 7-21.)
Page 127 CLOSED setting to enable it (see step 1 of the Setting the Top-stop “On” Angle procedure). Power down, then power back up SmartPAC 2 to enable the new option switch settings. With the press in Inch mode, press the Run/Inch palm buttons until you have inched the press to the angle you determined in step 1 (i.e., 270°, 300°, 330°, or 359°).
Page 128 If another fault code displays, look up the fault in Chapter 7 and follow the suggested • remedy. After correcting the problem, press RESET and run the press again for a few strokes, checking for faults. If you need assistance, contact Wintriss Tech. Support. WARNING INJURY FROM MAGNETS THAT DETACH Mount the magnet with the brass screws provided.
Page 129: Installing Revised Firmware In Wpc 2000
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Installing Revised Firmware in WPC 2000 DANGER MACHINE MALFUNCTION AFTER INSTALLING REVISED SOFTWARE Perform the final checkout (see page 2-87) tests after performing the firmware installation. Failure to comply with these instructions could result in death or serious injury.
Page 130 If the chip still doesn't fit, repeat this procedure. To verify that both chips are installed correctly, power up the WPC 2000 and SmartPAC 2. If the units power up normally, go to step 8.
Page 131: Performing Checkout Tests
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Re-initialize the system, following the instructions starting on page page 4-34. DANGER 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.
Page 132 WPC 2000 setup. Use the “test” tool you created for setup procedures (see page 2-76). If your WPC 2000 fails a test, you will be directed to follow step-by-step procedures to isolate and correct the problem. If you are unable to correct a problem, contact Wintriss Tech. Support for assistance.
Page 133: Figure 2-41. Wpc 2000 Led Indicator Map (Center- Or Right-Mounted Board)
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 86 - User input 10 + 5 Logic B 85 - User input 8 84 - User input 6 83 - User input 4 + 24 VDC 82 - User input 2...
Page 134: Wpc 2000 Power Supply Test
If all three LEDs are unlit, check to make sure that line voltage is being applied to the • system (see step 3), and correct any problems. If the LEDs are still unlit, call Wintriss Tech. Support. If one or both of the +5 Logic LEDs are unlit, call Wintriss Tech. Support.
Page 135: Checking Dual Safety Valve (Dsv) Wiring
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. Close the guard you just tested, reset the press control, and repeat step 2 for each moveable guard.
Page 136: Checking The Emergency-Stop Circuit
Power up the press and SmartPAC 2 with WPC 2000, select INCH with the Stroke Select switch, and push both Run/Inch buttons. Observe what happens. If the ram does not move and the SmartPAC 2 display shows F79 or one of the DSV •...
Page 137: Checking The Top-Stop Circuit
If the press does not top-stop, check the wiring of your Top-stop circuit, correcting any • problems, and run the test again. If the press still does not top-stop, call Wintriss Tech. Support. Do not continue with this checkout procedure until the press top-stops correctly.
Page 138 • Turn the Stroke Select key switch to INCH. • Check to see whether the Interrupted Stroke message flashes on the SmartPAC 2 display. If the Interrupted Stroke message displays, go to the next step. • If the Interrupted Stroke message does not display, check to see whether the “INCH •...
Page 139 WPC 2000 Main Processor board is unlit. If the LED is unlit, check the wiring of the system air pressure switch input and correct any problems. Press both Run/Inch palm buttons again. If F48 still does not display, call Wintriss Tech. Support. Apply system air pressure to the press.
Page 140: Anti-Tiedown Test
• Ensure that the 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 both buttons at the same time and no one can press both buttons with one hand or with one hand and one elbow.
Page 141: Anti-Repeat Test
• Ensure that the 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 both buttons at the same time and no one can press both buttons with one hand or with one hand and one elbow.
Page 142: Shadow Light Curtain Test
Power up again.) If there is still no power to the unit, call Wintriss Tech. Support. At the Shadow receiver, check to see whether the green (Curtain Unobstructed) indicator is lit.
Page 143: Single-Stroke Mode Test With Light Curtain(S)
If the receiver’s green indicator stays on when the curtain is blocked, check receiver • wiring, and repeat step 4. If the green indicator is still lit, call Wintriss Tech. Support. Remove the obstruction from the light curtain. At the receiver, verify that the red indicator goes off and the green indicator comes on.
Page 144 1128600 SmartPAC 2 with WPC 2000 Integration User Manual WARNING ELECTRIC SHOCK HAZARD WHEN WORKING INSIDE ENCLOSURE WITH POWER ON • DO NOT touch electrical connections or circuit boards. • Ensure that this test is performed by qualified personnel. Failure to comply with these instructions could result in death or serious injury.
Page 145 • any problems; then, inch the ram to the top of the stroke and re-run the test, starting with step 6. If the ram again moves when the light curtain is interrupted, call Wintriss Tech. Support. Clear the Interrupted Stroke by holding the Run/Inch palm buttons until the ram stops at top dead center.
Page 146: Single Stroke Mode Test Without Light Curtain(S)
2. If the ram still does not make a complete stroke or does not stop at top dead center, call Wintriss Tech. Support. If the SmartPAC 2 display shows no error or an error other than an overrun limit switch •...
Page 147: Continuous Mode Test With Light Curtain(S)
If the ram moves when you press the Run/Inch buttons, then stops when you release • them, and the Interrupted Stroke message flashes on the SmartPAC 2 display, go to the next step. If the ram does not move, or if it moves but does not stop immediately when you release •...
Page 148 Interrupted Stroke message should display. If these conditions are not present, check the wiring of the Operator Station, particularly the E-stop wiring, and correct any problems. Rerun this test from step 4. If the conditions are still not present, call Wintriss Tech. Support.
Page 149 If the ram does not stop at TDC, check the wiring of the Operator Station, particularly the top-stop wiring, and correct any problems. Rerun this test from step 7. If the ram still does not top-stop, call Wintriss Tech. Support. Restart the press in Continuous mode.
Page 150: Continuous Mode Test Without Light Curtain(S)
If the press continues to run, go to the next step. • If the press stops, check the wiring of the palm buttons, and correct any problems. Run • the test again. If the press still stops, call Wintriss Tech. Support. 2-106 Installation...
Page 151 Rerun this test from step 6. If the ram still does not top-stop, call Wintriss Tech. Support. If the die space is safeguarded with doors or gates with interlocking circuits, open a door/ gate and try starting the press.
Page 152: Foot Switch Test
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Foot Switch Test DANGER 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.
Page 153 If the press does not stop, check the wiring of the Foot Switch, making any necessary • corrections, and repeat step 8. If the press still does not stop, call Wintriss Tech. Support. Press and hold both Run/Inch buttons to return the press to TDC.
Page 154: One-Hand Control Test
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Press the Prior Act button on the Operator Station, and, before the indicator lamp goes out, depress and hold down the Foot Switch. The press should run as long as the Foot Switch is depressed, stopping at Top-stop after completion of the stroke when the Foot Switch is released.
Page 155 Mode Select Menu (ONE HAND should be selected). Make any necessary corrections, and repeat step 4. If the press still fails to make a complete stroke or input status is still incorrect, contact Wintriss Tech. Support. Set option switch 3 to CLOSED.
Page 156: Bar Mode Control Test
If the press strokes, check the wiring of the One-hand Control, correcting any problems, • and repeat step 9. If the press still makes a stroke, call Wintriss Tech. Support. Go to the next applicable test. Bar Mode Control Test...
Page 157: Checking Operation Of The User Inputs
What Next? To program and use your SmartPAC 2, follow the instructions in the remaining chapters of this manual. Go to Chapter 4 to make Initialization settings for your SmartPAC 2. Wiring Tables Tables showing WPC 2000 and SmartPAC 2 wiring connections are provided on the following pages.
Page 158: Table 2-27. Wpc 2000 Main Processor Board, Tb101-Tb104: Wiring Connections
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Table 2-27. WPC 2000 Main Processor Board, TB101-TB104: Wiring Connections Signal Signal TB104 Top TB104 Bottom Analog ground Light curtain B2 input ** Counterbalance air (Analog 2) input Light curtain A2 input ** +24 Vdc output User input 10 –...
Page 159: Table 2-28. Wpc 2000 Power Supply (Tb105) Wiring Connections
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Table 2-28. WPC 2000 Power Supply Table 2-32. SmartPAC 2 SFI Port (1) (TB105) Wiring Connections and Module Port (2) (TB103) Wiring Connections Pin # Signal Pin # Signal Port +24 Vdc input...
Page 160: Table 2-34. Smartpac 2 Spare 1 Port (5) And Wpc Port (6) (Tb105) Wiring Connections
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Table 2-34. SmartPAC 2 Spare 1 Port (5) Table 2-36. SmartPAC 2 Aux I/O (TB107) and WPC Port (6) (TB105) Wiring Connections Wiring Connections Pin # Signal Pin # Signal Port +15 V –TXD6...
Page 161: Chapter 3. Smartpac 2 Keyboard, Displays And Operating Modes
SmartPAC 2 front panel, which is shown in Figure 3-1. It is a good idea to learn how to use SmartPAC 2 before you install it. Set up the unit on a bench and wire a power cord and a resolver to it, then try making settings on the displays.
Page 162: Comparing Smartpac 2 With Original Smartpac
SmartPAC 2 with WPC 2000 Integration User Manual Comparing SmartPAC 2 with Original SmartPAC If you are familiar with the original SmartPAC, you will find using the SmartPAC 2 very similar. Figure 3-2 shows the differences between SmartPAC 1 and SmartPAC 2 front panels.
Page 163: Smartpac 2 Keyboard
Off, Inch, Single-stroke, or Continuous (see page 6-39). This key switch is also used to clear the Lockout message when it appears on the SmartPAC 2 display (see page 7-3). To do so, turn the key to the “OFF” position, then back to the operating mode you want.
Page 164: Number Keys
ENTER. The window closes when you are finished, and the number you entered appears on the SmartPAC 2 screen next to the item you selected. You can also use the cursor keys to enter information on these entry screens (see Cursor Keys, page 3-6).
Page 165: Clear Key
CLEAR Key The CLEAR key, shown in Figure 3-8, is used to delete digits or characters in a SmartPAC 2 entry window (see Figure 3-6 and Figure 3-7). You also use the CLEAR key as directed in other procedures, such as deleting a tool.
Page 166: Cursor Keys
Increase or decrease numeric values in SmartPAC 2 entry windows and screens • Move the highlight box over a letter you want to enter in a SmartPAC 2 entry window • Set the Ready signal for sensors and timing for cams (see page 3-23) •...
Page 167 The Up () and Down () cursor keys can be used to increase and decrease numeric values displayed in SmartPAC 2 entry windows (see Figure 3-6 and Figure 3-7, page 3-5) and on some SmartPAC 2 screens. To increase the value, press the Up () cursor; to decrease the value, press the Down () cursor.
Page 168 1128600 SmartPAC 2 with WPC 2000 Integration User Manual The two cursors define the endpoints of a highlighted arc that indicates graphically the duration of the On signal. The four cursor keys function in the following manner: Right () cursor key increases the On setting, moving the On cursor clockwise.
Page 169 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 ° ° Figure 3-12. Cam Channel Timing: On=239 , Off=0 To set the Off angle, you use the Up () and Down () cursor keys. With the cam channel timing set as in Figure 3-12, press the Down () cursor key and hold it down until the Off cursor, moving counterclockwise, reaches 270°...
Page 170: Help Key
SmartPAC 2 display. After you have highlighted the item with the cursor keys (see Cursor Keys, page 3-6), pressing the ENTER key displays the SmartPAC 2 screen for that item. You also use the ENTER key for other functions, such as to accept a number you have keyed in, to start loading settings for a tool, etc.
Page 171: Reset Key
RESET Key The RESET key, shown in Figure 3-16, has two functions: to exit from the current display and return to the previous display and to reset SmartPAC 2 when an error is generated or a counter preset is reached.
Page 172: Function Keys
The switch has a removable key so that access to Run mode can be controlled. NOTICE SmartPAC 2 changes from Run to Program mode or from Program to Run when the display shows the Main menu in the mode you are leaving. If you turn the key and nothing happens, press RESET repeatedly until you see the new mode appear on the display.
Page 173: Smartpac 2 Display Layout In Run Mode
SmartPAC 2 Display Layout in Run Mode The layout of the SmartPAC 2 display in Run mode is shown in Figure 3-20, page 3-14. At the top of the display is a status box that contains information such as the press name and the press speed or angle.
Page 174: Selecting An Item On A Display
Selecting an Item on a Display To select an item on a SmartPAC 2 display, highlight the item you want, using the cursor keys (see page 3-6), and press ENTER. Figure 3-21 shows the Main Run Menu with the “CAM SWITCH”...
Page 175: Smartpac 2 Operating Modes
1128600 SmartPAC 2 Operating Modes SmartPAC 2 has three modes of operation: Initialization mode, Program mode, and Run mode. The Main, or top, menu for each mode is shown in Figure 3-22 along with a physical description of the display, a summary of what you can do in that mode, and a reference to the chapter in which that mode is documented.
Page 176: Table 3-2. Initialization, Program And Run Modes: Entry And Exit Procedures
* If you turn the key and nothing happens, press RESET repeatedly until SmartPAC 2 changes modes. Before you turn the Program/Run key, make sure SmartPAC 2 is in the Main (or top) menu for the mode it is in. If it is not, press RESET repeatedly until the Main menu appears.
Page 177: Initialization Mode
Initialization mode is used extensively when you install a new SmartPAC 2, but you will likely use it only occasionally after SmartPAC 2 is set up and the press is running. The Main Initialization Menu is shown in Figure 3-23. Figure 3-24, page 3-18 shows you how to navigate through the SmartPAC 2 menus in Initialization mode.
Page 178: Figure 3-24. Navigation Example: Initialization Mode
1128600 SmartPAC 2 with WPC 2000 Integration User Manual INITIALIZATION MODE MAIN MENU Figure 3-24. Navigation Example: Initialization Mode Press ENTER to go in direction of arrow. Press RESET to return to previous menu. This illustration includes some optional features. Your menus may be different.
Page 179: Program Mode
SmartPAC 2 menus in Program mode. Figure 3-25. Program Mode Main Menu See Chapter 5 for detailed instructions on how to use SmartPAC 2 in Program mode. NOTICE For help with an item on the Main Program Menu, press the HELP key when that screen is displayed.
Page 180: Figure 3-26. Navigation Example: Program Mode
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Figure 3-26. Navigation Example: Program Mode Press ENTER to go in direction of arrow. Press RESET to return to previous menu. This illustration includes some optional features. Your menus may be different.
Page 181: Run Mode
If security access settings in Program mode permit, you may be able to adjust cam timing and perform other operations in Run mode (see CAM SWITCH (Optional), page 6-18). Figure 3-28, page 3-22 shows you how to navigate through the SmartPAC 2 menus in Run mode.
Page 182: Figure 3-28. Navigation Example: Run Mode
1128600 SmartPAC 2 with WPC 2000 Integration User Manual F3 - Figure 3-28. Navigation Example: Run Mode Press ENTER to go in direction of arrow. Press RESET to return to previous menu. This illustration includes some optional features; your menus may be different.
Page 183: Screen Capture
1128600 Screen Capture SmartPAC 2 allows you to save a copy of one or more SmartPAC 2 screens to aid in troubleshooting or maintain records of tool settings such as cam on/off angles. Your screen capture options depend on your SmartPAC 2 Main firmware version, which you can easily determine by accessing the Installed Options screen (see page 4-9.)
Page 184 Saving a Screen Capture to a USB Disk You can save a copy of the current screen residing in SmartPAC 2 memory to a USB disk inserted in the USB connector on the SmartPAC 2 processor board. A USB disk allows you to transfer the screen capture to another computer when your SmartPAC 2 is not networked.
Page 185: Screen Capture In Smartpac 2 Main Versions V 5.3.1 And Later
USB disk. If you choose to continue saving screen captures to SmartPAC 2 memory, you can still copy the screen capture to an e-mail message or to a USB disk as described in Screen Capture in SmartPAC 2 Main Versions Earlier than V 5.3.1, above.
Page 186 1128600 SmartPAC 2 with WPC 2000 Integration User Manual 3-26 Keyboard, Displays, Etc.
Page 187: Chapter 4. Smartpac 2 Initialization Mode
INITIALIZE WPC 2000 PARAMETERS BEFORE PROGRAMMING SMARTPAC 2/WPC 2000 You should already have initialized press parameters when you set up your new SmartPAC 2 with WPC 2000 (see page 2-75). If you haven’t, do so now, following the instructions starting on page 4-34.
Page 188: Entering And Exiting Initialization Mode
* If you turn the key and nothing happens, press RESET repeatedly until SmartPAC 2 changes modes. Make sure SmartPAC 2 is in the Main (or top) menu for the mode it is in before you turn the Program/Run key. If SmartPAC 2 is not in a top-level menu, press RESET repeatedly until the Main menu appears.
Page 189: Initializing Wpc 2000 Parameters
NOTICE Initializing press control parameters resets them to their default values. Initialize press parameters only when you set up a new SmartPAC 2 with WPC 2000 or install new WPC 2000 firmware. NOTICE RECORD WPC 2000 SETTINGS BEFORE INITIALIZING PARAMETERS Use the Press Parameters Setup Sheet at the end of the manual to record your WPC 2000 settings before installing new firmware or initializing parameters.
Page 190: Setting The Resolver Zero Position
NOTICE USE A DIAL INDICATOR TO DETERMINE TDC Do not rely on the SmartPAC 2 display to indicate when the press has reached TDC. Until the resolver is zeroed, displayed values are inaccurate. Use a dial indicator or some other means to determine 0°.
Page 191: Position Sensor
DISABLE POSITION SENSOR ON SMARPAC 2 WITH WPC 2000 INTEGRATION An overrun limit sensor is required for SmartPAC 2 with WPC 2000 Integration (see page 2-29). You cannot use a position sensor. Make sure to disable the POSITION SENSOR MODE setting as instructed below.
Page 192: Resolver Motion Mode (Normal Motion - Link Motion)
Tool Number Mode (INITIALIZATION – POSITION SENSOR) NOTICE Before you set up your SmartPAC 2, decide which tool number mode you will use, Numeric or Alphanumeric. Set up your SmartPAC 2 in that mode, and do not change tool number modes afterward.
Page 193: Table 4-2. Numeric And Alphanumeric Tool Number Modes
NOTICE UPGRADING FROM ORIGINAL SMARTPAC See Appendix F for more information about upgrading from original SmartPAC to SmartPAC 2. When you replace an original SmartPAC with SmartPAC 2 and transfer tool setup information, the existing tools will default to Numeric mode. If you want to switch to...
Page 194: Counter Setup Mode
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Counter Setup Mode (INITIALIZATION – POSITION SENSOR) This item allows you to enable or disable counter setup mode. To set this parameter, do the following: Press ENTER to toggle between three settings: “IS INCREMENTED IN ALL MODES”–Parts and batch counters will increment on...
Page 195: Installed Options
1128600 INSTALLED OPTIONS (INITIALIZATION – INSTALLED OPTIONS) This item enables you to view the options that are installed on your SmartPAC 2 (see Figure 4-4), including the number of cam channels and sensors. Figure 4-4. Installed Options Screen Your screen will look different.
Page 196: Press Name
You can use a separate computer keyboard to enter the press name. See page 4-68. This item enables you to name the press on which SmartPAC 2 is installed. When you select PRESS NAME, the Alphabetic Entry window opens (see Figure 4-6), allowing you to enter the characters composing the press name you want, using any combination of alphabetic characters, numbers and symbols.
Page 197: Figure 4-7. Cam Channel Name Menu (16-Channel Procampac)
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Select SELECT CAM NAMES on the Main Initialization Menu. The Cam Channel Name Menu, shown in Figure 4-7, displays. The first time you access this screen, all channels have the entry “UNNAMED.”...
Page 198: Auto Advance And Slow Rpm (Optional)
1128600 SmartPAC 2 with WPC 2000 Integration User Manual If none of the names in the list seems suitable but you still want to name the cam channel, you can select “CUSTOM NAME.” If you do so, the Alphabetic Entry window (see Figure 4-6, page 4-10) displays.
Page 199: Calculating The Auto Advance Constant
NOTICE IMPORTANT TO SET SLOW RPM SmartPAC 2 uses the Slow RPM value as a starting point in the auto advance process. If the value you enter for Slow RPM is inaccurate, SmartPAC 2 will not auto advance programmed cam channels at the right time.
Page 200: Setting Auto Advance Constants And Slow Rpm
NOTICE AUTO ADVANCE IS ADJUSTABLE SmartPAC 2 allows you to adjust Auto Advance and Slow RPM settings in Initialization mode while the press is running. The angle at which an Auto Advance cam turns on is shown in the upper right corner of the screen under the caption PRESS ANGLE, enabling you to see the effect of different settings.
Page 201: Set Global Cams (Optional)
SmartPAC 2. These cam channels are called “global” cams, and they are used to program events that remain the same on all tools. Setting global cams saves programming the same cam information for each tool and ensures that the cam always operates in the same way.
Page 202: Figure 4-10. Global Cams Menu
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Figure 4-10. Global Cams Menu Asterisk (*) Indicates Global Cams Select the cam you want to program. The Global Cam Timing Type screen, shown in Figure 4-11 displays. Figure 4-11. Global Cam Timing Type Screen Select the type of cam timing you want to program for this channel, referring to CAM SWITCH (Optional), page 5-38 for instructions.
Page 203: Custom Sensor Names (Optional)
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 CUSTOM SENSOR NAMES (Optional) (INITIALIZATION – CUSTOM SENSOR NAMES) This item, which appears on the Main Initialization Menu only when DiProPAC is installed, allows you to create “custom” names for up to 32 die protection sensors. The custom names you create in Initialization provide the options available to you in Program mode when you select names for your sensors.
Page 204: Sensor Enable Mode (Optional)
1128600 SmartPAC 2 with WPC 2000 Integration User Manual the custom name you created displayed to the right of the selected item number. To cancel your selection, press RESET. Repeat steps 2 and 3 for each item you want to name. To access CUSTOM 17 through CUSTOM 32 items, move the highlight bar down past “CUSTOM 16.”...
Page 205: Enabling Setup Mode
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 AUTO BY SENSOR. When this option is selected, DiProPAC automatically re-enables • each sensor programmed for a specific tool, sensor by sensor. You specify in Program mode for each sensor the number of strokes to allow after the press is restarted before DiProPAC re-enables that sensor (see Setting the “Auto Enable by Sensor”...
Page 206: Figure 4-14. Tool Information Setup Screen
1128600 SmartPAC 2 with WPC 2000 Integration User Manual NOTICE This feature is not available if you have the optional PLC interface installed. To set up items you wish to document for each tool, do the following: Select TOOL INFORMATION on the Main Initialization Menu. The Tool Information Setup screen, shown in Figure 4-14, displays.
Page 207: Figure 4-16. Tool Information Units Selection Screen
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 If you want to use a name that is not in the list, select the “CUSTOM” item. When the Alphabetic Entry window (see Figure 4-6, page 4-10) displays, key in a custom name of up to 12 characters, following the directions on the screen, then press F6 to accept your entry.
Page 208: Table 4-3. Abbreviations For Units On Tool Information Setup Screen
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Table 4-3. Abbreviations for Units on Tool Information Setup Screen On-screen Units On-screen Units Abbreviation Abbreviation Inches METERS Meters Feet FT/MIN Feet per minute Millimeters FT/SEC Feet per second Centimeters MM/SEC...
Page 209: Press Control
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Repeat steps 2-9 for other Tool Information items you want to set up. A Tool Information Setup screen with sample entries filled in is shown in Figure 4-17. Figure 4-17. Tool Information Setup Screen with Sample Entries When you are finished, press RESET to return to the Main Initialization Menu.
Page 210: User Interlocks
1128600 SmartPAC 2 with WPC 2000 Integration User Manual User Interlocks (INITIALIZATION – PRESS CONTROL – USER INTERLOCKS) DANGER 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.
Page 211 When one of these inputs issues a Stop command by opening a normally closed (N/C) relay, a fault code for the input appears on the SmartPAC 2 display. The type of stop is determined by the setting you make on this screen. For inputs 1 through 7, you can set the stop type to E-stop, Top-stop, or E-stop/Lockout.
Page 212: Figure 4-20. Select Stop Name Screen
8/9 can be set to E STOP or E LOC, cross-checked pair 10/11 to E LOC only. NOTICE If you have SmartPAC 2 firmware version 3.32 or higher and WPC 2000 firmware version 1.70 or higher, an additional stop type option, T LOC (Top-stop/Lockout), is available for inputs 1-7.
Page 213: Press Parameters
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 To access a name beneath the MORE NAMES indicator, move the highlight bar down past the last item in the list. Additional Custom Name entries display sequentially, one at a time.
Page 214 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Key in a new value in the Numeric Entry window (see Figure 3-6, page 3-4), using the numeric keypad or the Up () and Down () cursor keys, then press ENTER.
Page 215 2-13. The value you enter in the MAIN AIR LIMIT field sets the low limit for Clutch Air Pressure. If clutch pressure drops below the limit, an F45 fault displays on the SmartPAC 2 LCD (see page 7-14).
Page 216 10 milliseconds of the Stop-time Limit you set on this screen, the Brake Warning LED on the SmartPAC 2 front panel flashes. This warning alerts maintenance personnel to perform the necessary repairs on the press.
Page 217 The greater part of this interval is the time it takes for the clutch mechanism to activate and engage. Whenever the start time exceeds the Start-time Limit you set on the Press Control Parameter Menu, SmartPAC 2 displays an F79 (Loss of Rotation) fault on the SmartPAC 2 LCD (see Initialization Mode 4-31...
Page 218 DSV is not re-energized after the specified length of time. An F10 fault code (see page 7-7) is displayed on the SmartPAC 2 LCD when the press has been stopped. You can set the Shutdown Time to any value between 0 and 100 minutes.
Page 219 However, in top knock-out applications, the angle might be set after 0°, while in some high-speed applications, it might be set before 0°. SmartPAC 2 will only accept ACTS Angle entries between 330° and 30°. If you have questions about where to set the ACTS Angle, contact Wintriss Tech.
Page 220: Figure 4-22. Initialize Parameters Warning Message
NOTICE Initializing press parameters resets WPC 2000 to its default settings. Initialize WPC 2000 parameters only when you set up a new SmartPAC 2 with WPC 2000 or install new WPC 2000 firmware. When you first set up your SmartPAC 2 with WPC 2000 or when you install new WPC 2000 firmware, initialize WPC 2000 parameters by following the steps below.
Page 221: Press Options
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Press Options (INITIALIZATION – PRESS CONTROL – PRESS OPTIONS) The Press Options item on the WPC Initialization Menu gives you access to the Press Control Option Switch Menu, on which you can set the positions of eight switches on switch block S101 on the WPC 2000 Main Processor board and make three operator mode settings.
Page 222: Table 4-5. Switches 1 And 2 Settings (S101): Top-Stop "On" Angle Range
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Switches 1 and 2 – Top-stop Angle Range Options switches 1 and 2 control the range of angles within which the Top-stop “On” Angle falls (see Installing the Overrun Sensor Magnet, page 2-82). WPC 2000 uses these switch 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.
Page 223: Table 4-7. Switch 3 Settings (S101): Enabling Foot Control
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 ENABLING FOOT CONTROL IN A FOOT SWITCH When “FOOT” is highlighted on the Mode Select Menu, switch 3 controls how the Foot Switch must be activated in order to initiate and complete a stroke, as shown in Table 4-7.
Page 224: Table 4-9. Switch 5 Settings (S101): Prior Act Times For Automatic Modes
1128600 SmartPAC 2 with WPC 2000 Integration User Manual If you use the ACTS feature, it is critical that you set the Stop-time Limit on your Brake Monitor correctly so that you have advance warning of the need for brake maintenance (see Setting the Stop-time Limit, page 4-30).
Page 225: Table 4-11. Switch 8 Settings (S101): Top-Stop Mode For F And H Errors
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Switch 7 – Not Used Switch 8 – Top-stop Mode for F and H Errors and Auxiliary Output 1 Response to Interrupted Stroke Switch 8 has two different functions. It controls how quickly the press top-stops when an F or an H fault occurs, and if Auxiliary Output 1 on the WPC 2000 Main Processor board has been wired, it also specifies how that output responds to an Interrupted Stroke condition.
Page 226: Table 4-12. Switch 8 Settings (S101): Auxiliary Output 1 Response To Interrupted Stroke
1128600 SmartPAC 2 with WPC 2000 Integration User Manual AUXILIARY OUTPUT 1 RESPONSE TO INTERRUPTED STROKE DANGER NON-SAFETY OUTPUTS 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.
Page 227 • Station is selected via a remote three-position switch. If you use this setting, you must wire a remote selector switch. You can order such a switch from Wintriss (part no. 4256601). Automatic Mode This item allows you to enable Automatic Single-stroke or Automatic Continuous On-demand operating mode if you have installed one of these options.
Page 228: Figure 4-24. S102 Option Switch Off And On Settings
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Setting Option Switches on S102 NOTICE Switches 1, 3 through 5, 7, and 8 on switch block S102 are not used. This section shows you how to make settings on option switches 2 and 6 on switch block S102 on the WPC 2000 Main Processor board (see Figure 2-14, page 2-28 for location).
Page 229: Table 4-14. Switch 6 Settings (S102): Selecting Concurrent Time For Multiple Op. Stations
Operator Stations installed, as shown in Table 4-14. NOTICE Do not attempt to install more than two Operator Stations until you have contacted Wintriss Tech. Support. All Operator Stations in a mutli-Op.-Station configuration except the Op. Station wired to the “A”...
Page 230: Input Status
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Input Status (INITIALIZATION – PRESS CONTROL – PRESS OPTIONS) The Input Status item on the WPC Initialization Menu gives you access to the Display WPC Input Status screen (see Figure 4-25), from which you can view the status of WPC inputs, including buttons, switches, E-stops, Top-stops, interlocks, and transducers.
Page 231: Figure 4-26. Wpc Buttons And Switches Input Status Screen
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Figure 4-26. WPC Buttons and Switches Input Status Screen When you press F3 (Estops/Top Stops), the WPC Estop and Top Stop Input Status screen displays (see Figure 4-27). Figure 4-27. WPC Estop and Top Stop Input Status Screen When you press F4 (Interlocks), the WPC Interlock Group 1 Input Status screen displays (see Figure 4-28, page 4-46).
Page 232: Figure 4-28. Wpc Interlock Group 1 Input Status Screen
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Figure 4-28. WPC Interlock Group 1 Input Status Screen When you press F5 (Transducers), the WPC Transducer Input Status screen displays (see Figure 4-29). Figure 4-29. WPC Transducer Input Status Screen...
Page 233: Security Access
(INITIALIZATION – TOOL INFORMATION) The SECURITY ACCESS item on the Main Initialization Menu allows you to control user access to SmartPAC 2 operating modes and settings. You set user access on the Security Access Menu, which is shown in Figure 4-30.
Page 234: Table 4-15. Security Access Settings
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Table 4-15. Security Access Settings Optional modules included; your menu may be different Security Access Menu Item Security Access Settings LOAD TOOL # PROGRAM AND RUN MODES PROGRAM MODE ONLY PASSWORD REQUIRED...
Page 235: Setting Security Access
IF YOU FORGET OR DO NOT KNOW YOUR PASSWORD(S) Call Wintriss Tech. Support at the telephone number on the cover of this manual. Give the Tech. Support person the 5-digit number from the bottom of the “Enter your password” display.
Page 236: Changing Passwords
BE CAREFUL WHEN SETTING RESET MODE SECURITY ACCESS If you select the PROGRAM MODE ONLY or PASSWORD REQUIRED setting for the RESET MODE item, the operator will not be able to reset SmartPAC 2 in Run mode when the press stops as the result of a malfunction.
Page 237: Figure 4-32. Set Passwords Menu
NOTICE DEFAULT PASSWORDS Your SmartPAC 2 comes from the factory with all passwords set to the default password “1234.” If you have upgraded your SmartPAC 2 in the field, your passwords may be different. To change passwords, perform the following steps: On the Security Access Menu (see Figure 4-30, page 4-47), press F1 (Change Passwords) to display the Set Passwords Menu (see Figure 4-32).
Page 238: Additional Security
V5.32 or higher, enables you to back up and restore tools programmed on your SmartPAC 2. Tools may be backed up to a network drive, or, if you have ordered the USB Backup/Restore option (part no. 9679619), to a USB disk inserted in the SmartPAC 2 board.
Page 239: Figure 4-34. Backup/Restore Control Menu
To back up tools on a SmartPAC 2, do the following: Make sure a USB disk with the necessary free space is installed in the USB connector in the lower left corner of the SmartPAC 2 board (component J121 in Figure 2-25, page 2-51).
Page 240: Restoring Tools From A Usb Disk
SmartPAC 2 with WPC 2000 Integration User Manual NOTICE If the SmartPAC 2 detects that the USB disk does not have enough free space to store the tool and initialization backup information, a message like the following displays There is NOT enough space available...
Page 241: Setup Data Comms (Optional)
Set Communications Menu, which is shown in Figure 4-36. This screen is fully documented starting on page H-7 for SmartPAC 2 users with the SFC firmware option. If you have the LETS firmware option, refer to page I-7 for Set Communications Menu documentation.
Page 242: Setup Network
(INITIALIZATION – SETUP NETWORK) NOTICE • Your network administrator must connect SmartPAC 2 to your computer network before you can use e-mail messaging or the SmartView remote viewing utility. For e-mail, your network must have a valid SMTP mail server.
Page 243: E-Mail Function
• Use the SmartView remote viewing utility (see next item) to set up e-mail messages and recipients. SmartPAC 2’s E-mail function allows you to send e-mails to individuals in your SmartPAC 2 network and to other recipients, such as Wintriss Tech. Support, via the Internet. If you plan...
Page 244: Smartview Function
• Use the SmartView remote viewing utility (see previous item) to set up e-mail messages and recipients. If you have enabled the SmartPAC 2 E-mail function, you should use the SETUP E-MAIL item on the Network Setup Utility screen to enter E-mail settings. Settings are made on the Setup E-mail screen, which is shown in Figure 4-38.
Page 245: Figure 4-39. Alphanumeric Entry Window With Default Mail Server Displayed
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 To setup up E-mail, do the following: Select SETUP E-MAIL on the Main Initialization Menu. The Setup E-Mail screen displays. With the highlight bar in the Mail Server: field, press ENTER. The Alphanumeric Entry window, shown in Figure 4-39, displays with the default mail server shown at the top of the window.
Page 246: Change Network Settings
SMARTVIEW FUNCTION, page 4-58) to select the graphic it uses to illustrate the type of press (i.e., straight side or gap frame) on which SmartPAC 2 is installed. This graphic appears in the press information summary on the SmartView Main Page.
Page 247: Diagnostics
COMMUNICATIONS, which allows you to run a communications loopback test • SET CLOCK, which allows you to set SmartPAC 2’s internal clock to local time • SAVE TO USB DISK, which allows you to save screen captures and other items to a USB •...
Page 248: Communications
Communications Data Viewer screen, shown in Figure 4-41, displays. Figure 4-41. Communications Data Viewer Screen This screen allows you to verify communications between SmartPAC 2 and its installed modules, including SFI and WPC. When you press ENTER with the highlight bar resting on one of the communications ports (e.g., PORT 1 (SFI)), the Transmit and Receive Data screen...
Page 249 MESSAGE PORT X” displays, where “x” is the number of the port you selected. If you need help performing the loopback test, contact Wintriss Tech. Support. Be prepared to provide the following information: product name (e.g., SmartPAC 2 standard); installed options (e.g., DiProPAC, ProCamPAC, etc.);...
Page 250: Set Clock
1128600 SmartPAC 2 with WPC 2000 Integration User Manual SET CLOCK (INITIALIZATION – DIAGNOSTICS – SET CLOCK) When you select the SET CLOCK item on the Diagnostics Menu, the Set the Clock screen, shown in Figure 4-43, displays. Figure 4-43. Set the Clock Screen On this screen you can set the date in month/day/year (mm/dd/yy) format and the time in military hours/minutes (hh:mm) format (i.e., 1:30 p.m.
Page 251: Save To Usb Disk
This item enables you to save the error/event log (see page 6-34), screen captures (see page 3-23), and other data maintained in a special SmartPAC 2 buffer to a USB disk. Once the data has been saved, you can remove the USB disk, transfer the information to a computer, and e-mail it to Wintriss Tech.
Page 252: Setting Link Motion
LINK MOTION, WaveFormPAC comparison screens will not display the Ram Velocity. Using a ServoFeed Interface with Link Motion If you have a link-motion press and are using a servofeed with a Wintriss Servofeed Interface (SFI), you can compensate for the change in speed between the upstroke and downstroke. In a link-motion press, the upstroke is substantially faster than the downstroke, the downstroke being slowed to improve forming operations.
Page 253 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Settling Time Compensation for Link Motion If SETTLING TIME is a Feed Control Initialization parameter, follow the instructions below to compensate for speed variation. Once you have set the Settling Time to the appropriate value for one tool, you can use the Feed Advisor for all other tools on this press.
Page 254: Using A Computer Keyboard To Enter Names
Using a Computer Keyboard to Enter Names When entering the name for your press and custom names for cams and sensors, you can use a computer keyboard connected to SmartPAC 2. To connect the keyboard and use it to key in names, proceed as follows: Power down SmartPAC 2.
Page 255: Chapter 5. Smartpac 2 Program Mode
This chapter shows you how to make settings in SmartPAC 2 Program mode. Program settings, which are entered via the Main Program Menu (see Figure 5-1), control SmartPAC 2 operation for an individual tool. (You make settings that control operation of all tools in Initialization mode–see Chapter 4).
Page 256: Tool Manager
* If you turn the key and nothing happens, press RESET repeatedly until SmartPAC 2 changes modes. Make sure SmartPAC 2 is in the Main (or top) menu for the mode it is in before you turn the Program/Run key. If SmartPAC 2 is not in a top-level menu, press RESET repeatedly until the Main menu appears.
Page 257: Creating A New Tool
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Figure 5-2. Tool Manager Screen NOTICE The Tool Manager screen sorts the tool list based on the setting for TOOL NUMBER MODE in Initialization (see page 4-6). • If the setting is NUMERIC, tools are sorted by tool number •...
Page 258: Copying An Existing Tool
Alphanumeric tool number mode in Initialization. NOTICE If there are more tools in SmartPAC 2’s memory than can be displayed in two columns, press the Left () or Right () cursor key to display the additional hidden column(s). Key in the desired tool number, following the directions displayed in the applicable window.
Page 259: Copying Tool Template To A New Tool
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 NOTICE The first item on the Tool Program Menu is TOOL NAME if Numeric mode has been specified for tool numbers in Initialization. The first item is TOOL ID if Alphanumeric mode has been selected.
Page 260: Changing Settings For A Loaded Tool
1128600 SmartPAC 2 with WPC 2000 Integration User Manual On the Tool Manager screen, highlight the tool you want to load, and press F5 (Load Tool). The window shown in Figure 5-6 displays, ENTER YOUR PASSWORD USE THE KEYPAD TO ENTER NUMBERS.
Page 261: Deleting A Tool
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 With the currently loaded tool highlighted on the Tool Manager screen, press F4 (Edit Tool). ENTER YOUR PASSWORD USE THE KEYPAD TO ENTER NUMBERS. USE THE UP/DOWN CURSOR KEYS TO INCREASE/DECREASE. PRESS ENTER WHEN DONE.
Page 262: Tool Program Menu
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Tool Program Menu The Tool Program Menu, which is shown in Figure 5-9, displays whenever you Create a new tool • Copy settings from an existing tool (e.g., Tool Template) to a new tool •...
Page 263: Counters
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 This item on the Tool Program Menu allows you to assign a name to a tool created with a numeric tool number. To do so, perform the following steps: NOTICE If you have selected alphanumeric tool number mode in Initialization (see Tool Number Mode, page 4-6), a tool ID is automatically generated by the system.
Page 264: Figure 5-11. Counters Screen
Top Stop, Toggle, and Pulse. When a Batch counter is set to TOP STOP, SmartPAC 2 top-stops the press and displays a message, as it does for Strokes and Good Parts counters. This setting is useful when stopping the press to change bins or chutes before resuming production.
Page 265: Setting Preset Values
Setting Preset Values Counter presets specify the count at which SmartPAC 2 initiates one of three programmed actions (i.e., Top-stop, Toggle, or Pulse). To enter counter presets, do the following: On the Tool Program Menu, select COUNTERS to display the Counters screen.
Page 266: Clearing The Total Hits Counter
1128600 SmartPAC 2 with WPC 2000 Integration User Manual NOTICE ARE YOU “LOCKED OUT”? If you cannot change count values, security access for the CHANGE COUNT function may be set to NO CHANGES ALLOWED. See SECURITY ACCESS, page 4-47. On the Counters screen, select the setting displayed in the COUNT column of the counter you want to adjust.
Page 267: Setting Batch Counter Output And Increment Modes
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Setting Batch Counter Output and Increment Modes If you set a Batch counter preset value on the Counters screen, you must also specify the output and increment modes for that counter if they differ from the factory settings. By default, output mode is set to TOP STOP, increment mode to STROKE.
Page 268: Setting Counter Increment Angle
Setting Parts per Stroke or Strokes per Part SmartPAC 2 allows you to control how the Strokes and Good Parts counters increment in relation to each other. You can specify the number of parts made during each stroke, in which case the Good Parts counter will increment in multiple units (e.g., 2, 3, etc.) for each...
Page 269: Setting Batch Pre-Load Counts
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Figure 5-15. Advanced Counter Mode Selections Screen Select the value displayed for the item you want to program (i.e., PARTS MADE PER EACH STROKE or STROKES TO MAKE EACH PART). The Numeric Entry window (see Figure 5-3, page 5-3) displays.
Page 270: Die Protection (Optional)
SmartPAC 2 switches from open to closed-to-ground. N/O sensors are either “yellow” or “green” (see page 5-18). In a normally closed (N/C) sensor, the sensor circuit to SmartPAC 2 is closed to ground in its normal state. The sensor actuates when the circuit opens. Normally closed sensors are “red”...
Page 271 “ready off”) angles of the range of angles during which the sensor must actuate. If the sensor does not actuate (i.e., closure to ground does not occur) during this window, SmartPAC 2 sends a stop command to the press. The type of stop (i.e., top stop, emergency stop, or smart stop) is programmable.
Page 272: Figure 5-17. Ready Signal Programming For A "Green" Sensor
Green sensors, which are normally open, are used to monitor events that must occur during a certain portion of each stroke or intermittently every designated number of strokes. Examples are part ejection, stock feed, and part transfer. SmartPAC 2 stops the press when the green sensor closes to ground.
Page 273: Figure 5-18. Ready Signal Programming For A "Green Quick Check" Sensor
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Green Quick Check Sensors A sensor input set to “green quick check” must turn on, at least momentarily, within the Ready signal and may not turn on outside the Ready signal (see Figure 5-18). In other words, the sensor must turn on and turn off within the Ready signal.
Page 274: Programming Sensor Settings
Green Special sensor input for a six-stroke window. If no slugs are ejected after six strokes, SmartPAC 2 sends a Stop command to the press. Example: How a Green Special Sensor May Not Detect a Problem Referring to the case cited above, assume that the press makes five strokes without ejecting a slug.
Page 275: Figure 5-20. "Enter Your Password" Screen
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 You are also shown how to change sensor settings (see page 5-30), view the sensor summary (see page 5-31), and delete sensors (see page 5-31). Setting the “Auto Enable by Tool” Counter Value...
Page 276: Figure 5-22. Sensor Names Screen
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Select the AUTO ENABLE COUNTER field. The Numeric Entry window (see Figure 5-3, page 5-3) displays. Key in the value you want (maximum is 99), following the directions in the window, and press ENTER.
Page 277: Figure 5-23. Custom Sensor Names Screen
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Figure 5-23. Custom Sensor Names Screen Select a “custom” name from the list. (The number of the custom name–e.g., CUSTOM 1–does not have to match the number of the sensor being programmed–e.g., SENSOR 1.) If Sensor Enable Mode is set to AUTO BY SENSOR (see page 4-18), you are taken to the Auto Enable by Sensor Counter screen (see next section).
Page 278: Figure 5-25. Sensor Type Screen
1128600 SmartPAC 2 with WPC 2000 Integration User Manual This screen allows you to set the Auto Enable by Sensor counter, which specifies the number of press strokes necessary to re-enable the sensor following a DISABLE SENSORS command (see SENSOR ENABLE/DISABLE & STATUS (Optional), page 5-52 and DISABLE (ENABLE) SENSORS, page 6-6).
Page 279: Figure 5-26. Sensor Stop Type Screen
Setting this sensor to an Emergency Stop ensures that the ram will stop on the next stroke before the die closes. Top Stop. SmartPAC 2 stops the press at the top of its stroke after a sensor fault is •...
Page 280 Setting the Critical Angle for a Sensor Set to SMART STOP When you program a sensor for a Smart Stop, you must also set the critical angle SmartPAC 2 uses to determine whether an Emergency Stop or Top Stop command is sent to the press. The critical angle you program for the first sensor set to Smart Stop is used as the critical angle for all sensors set to Smart Stop for that tool.
Page 281: Figure 5-27. Critical Angle Programming Screen
1128600 Figure 5-27. Critical Angle Programming Screen Decrement the CRITICAL ANGLE default value of 185°, using the Down () cursor key, until the value you want is displayed. SmartPAC 2 accepts Critical Angle values between 0° and 184°. NOTICE The Critical Angle default of 185° cannot be used as your Smart Stop critical angle setting.
Page 282: Figure 5-28. Ready Signal Programming Screen
The Ready signal is the timing window during which the sensor must actuate to prevent SmartPAC 2 from sending a stop signal to the press. In the example shown in Figure 5-28, the Ready On signal is set to 180°, the Ready Off signal to 265°.
Page 283: Figure 5-29. Green Special Sensor Stroke Count Screen
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 On the Ready Signal Programming screen, set the Ready On angle on the crank angle clock, using the Left () and Right () cursor keys. As you press the Left () cursor key, the On cursor moves counterclockwise around the display, and the On angle value decreases.
Page 284: Figure 5-30. Sensor Settings Screen
1128600 SmartPAC 2 with WPC 2000 Integration User Manual NOTICE For more information about Green Special sensors, refer to Understanding Sensor Terminology, page 5-16. To set the Green Special sensor stroke count, do the following: On the Green Special Sensor Stroke Count screen, increment or decrement the stroke counter (maximum value is 99), using the Up () or Down () cursor key, until the value...
Page 285: Figure 5-31. Sensor Summary Screen
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Change the setting on the displayed screen. Press RESET when you are finished to return to the Sensor Settings screen. Repeat steps 1 through 3 for each setting you want to change.
Page 286: Programming Dipropac 32 Sensors
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Programming DiProPAC 32 Sensors When DiProPAC 32 is an installed option, two menu choices appear on the Tool Program Menu in place of the DIE PROTECTION item: DIPROPAC 1-16 and DIPROPAC 17-32 (see Figure 5-32).
Page 287: Figure 5-33. Die Protection Sensor 17-32 Menu
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Figure 5-33. Die Protection Sensor 17-32 Menu Select the sensor number that you want to program. The Sensor Names screen (see Figure 5-34) displays. Figure 5-34. Sensor Names Screen with Stripper Function Highlighted Select a function for the sensor.
Page 288: Figure 5-35. Sensor Type Screen With "Green" Highlighted
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Figure 5-35. Sensor Type Screen with “GREEN” Highlighted Select the sensor type (i.e., GREEN, GREEN QUICK CHECK, or GREEN CONSTANT). The Sensor Stop Type screen (see Figure 5-36) displays. Figure 5-36. Sensor Stop Type Screen Select the stop type you want.
Page 289: Figure 5-37. Sensor Summary Screen Showing Ready Signals For Green Sensors
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Figure 5-37. Sensor Summary Screen Showing Ready Signals for Green Sensors Select the Ready signal you want. The Sensor Settings screen displays (see Figure 5-38), showing the sensor name, sensor type, stop type, and Ready signal On and Off angles you have selected.
Page 290: Figure 5-39. Sensor Names Screen With Slug Detection Function Highlighted
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Programming a Sensor as Green Special To program one of the sensors in the group of sensors 17-32 as a green special sensor, perform the following steps, referring to the appropriate sections of Programming Sensor Settings (see...
Page 291: Figure 5-41. Sensor Summary Screen Showing Stroke Counts For Green Special Sensors
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 When the Sensor Stop Type screen displays, select a stop type. The Sensor Summary screen (see Figure 5-41) displays with the stroke count shown for each green special sensor programmed in the group of sensors 1-16.
Page 292: Cam Switch (Optional)
DANGER PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE Use SmartPAC 2’s programmable cam switch to control auxiliary functions only. The SmartPAC 2 programmable cam capability should never be used to provide timing signals for any safety use including clutch/brake control or muting of light curtains.
Page 293: Selecting A Cam Channel
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Channel numbers that are missing from the menu have been programmed as “global” cams in Initialization (see SET GLOBAL CAMS (Optional), page 4-15). To view global cam channels, press F5 (View Global Cam Summary) (see page 5-47).
Page 294: Making An On/Off Setting
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Instructions for programming cam channels, using each of the program types shown on the Cam Channel Program Type Menu, are provided in the following sections. Making an ON/OFF Setting The PROGRAM ON/OFF ANGLES item on the Cam Channel Program Type Menu enables you to program the crankshaft angles at which a selected cam channel turns on and off.
Page 295: Setting Multiple On/Off Cycles
1128600 Setting Multiple ON/OFF Cycles SmartPAC 2 with ProCamPAC enables you to set more than one On/Off event (or cycle) for selected cam channels. You can program up to four On/Off events for a single channel and up to six additional On/Offs for all channels. The six-cycle maximum applies to both 8-channel and 16-channel ProCamPAC.
Page 296: Figure 5-48. Cam Channel On/Off Program Screen: Two On/Off Arcs
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Press F6 (Add a New Arc) on the Cam Channel On/Off Program screen to program a second On/Off cycle. The arc you set in step 1 (i.e., Arc 1) turns dark gray. A new arc appears as a green line at the zero (0) position on the crank-angle clock, and the caption at the left of the screen changes to SELECTED ARC–2.
Page 297: Figure 5-49. Cam Channel On/Off Program Screen: Three On/Off Arcs
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Selected (active) arc shown here and colored green on crank angle clock diagram Inactive arcs are grey Figure 5-49. Cam Channel On/Off Program Screen: Three On/Off Arcs Making a Timed Output Setting...
Page 298: Figure 5-50. Cam Channel Timed Output Program Screen
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Figure 5-50. Cam Channel Timed Output Program Screen Set the On time in milliseconds (maximum is 500 mS, or 0.5 seconds), using the Up () cursor key to increment the Time value displayed in the window and the Down () cursor key to decrement the Time value.
Page 299: Figure 5-51. Cam Channel Auto Advance Program Screen
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 The PROGRAM AUTO ADVANCE item on the Cam Channel Program Type Menu enables you to program up to two cam channels as Auto Advance and to set On and Off angles for those channels.
Page 300: Figure 5-52. Cam Channel Dsv On Program Screen
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Setting DSV ON Channel Timing The PROGRAM DSV ON item on the Cam Channel Program Type Menu enables you to set the amount of time (in seconds) after the press stops that a DSV On cam channel remains on.
Page 301: Figure 5-53. Cam Channel Deletion Confirmation Window
(Optional), page 4-15), are cam channels that can be used with any tool set up on your SmartPAC 2. Global cams can be programmed for any channel except channels 6, 7 and 8 and, once set, cannot be programmed for individual tools. You cannot change global cam settings in Program mode, but you can view them as you are programming other cams.
Page 302: Press Control
1128600 SmartPAC 2 with WPC 2000 Integration User Manual To view global cams, do the following: Press F5 (View Global Cam Summary) on the Cam Channel Menu. The Global Cam Summary screen (see Figure 5-55) displays with the name, program type, and programmed settings shown for each channel set as a global cam.
Page 303: Figure 5-56. Press Control Parameters Screen
2 stops the press and displays the fault message “Maximum press speed exceeded.” When press speed drops below the minimum limit, SmartPAC 2 stops the press and displays the fault message “Minimum press speed exceeded.” These fault message are documented in Chapter 7 (see page 7-30).
Page 304: Tool Information
• The value you enter in the MAXIMUM PRESS SPEED field must be greater than the Minimum Press Speed value. If the Maximum Speed setting is less than or equal to the Minimum Speed value, SmartPAC 2 changes the Maximum Speed to one Stroke per Minute greater than the Minimum Speed.
Page 305: Figure 5-58. Tool Information Screen
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Figure 5-58. Tool Information Screen To enter tool information, do the following: Select TOOL INFORMATION on the Tool Program Menu. The Tool Information screen displays. ENTER YOUR PASSWORD USE THE KEYPAD TO ENTER NUMBERS.
Page 306: Sensor Enable/Disable & Status (Optional)
1128600 SmartPAC 2 with WPC 2000 Integration User Manual When you have finished entering tool information, press RESET to return to the Tool Program Menu. SENSOR ENABLE/DISABLE & STATUS (Optional) [PROGRAM - SENSOR ENABLE/DISABLE & STATUS] NOTICE For help with this menu item, press the HELP key.
Page 307: Enabling Or Disabling All Sensors
1128600 Press RESET to return to the Main Program Menu. NOTICE When a tool is loaded, or when SmartPAC 2 is powered up, all sensors are turned on and enabled. Enabling or Disabling All Sensors When you access the Sensor On/Off Status screen, a message is displayed on the second line of the screen beneath the screen title indicating whether sensors are enabled or disabled.
Page 308: Figure 5-61. "Sensor Turned Off" Message
1128600 SmartPAC 2 with WPC 2000 Integration User Manual If you select a sensor with an “Off” status in Run mode, SmartPAC notifies you with the following message: Figure 5-61. “Sensor Turned Off” Message 5-54 Program Mode...
Page 309: Chapter 6. Smartpac 2 Run Mode
Chapter 6. SmartPAC 2 Run Mode This chapter shows you how to use the displays in SmartPAC 2 Run mode, which is the mode you select to run the press. You learn how to adjust programmed settings (see Chapter 5 for programming instructions) for individual tools and monitor press parameters such as speed and sensor status.
Page 310: Entering And Exiting Run Mode
* If you turn the key and nothing happens, press RESET repeatedly until SmartPAC 2 changes modes. Make sure SmartPAC 2 is in the Main (or top) menu for the mode it is in before you turn the Program/Run key. If SmartPAC 2 is not in a top-level menu, press RESET repeatedly until the Main menu appears.
Page 311: Programming Hot Keys
On the Main Program Menu, press RESET to clear the message. Load a tool (see Loading a Tool, page 5-5). Turn the Program/Run key to RUN. SmartPAC 2 switches to Run mode. Programming Hot Keys Hot keys are function keys that you can program to take you directly from the Main Run Menu to screens you use frequently.
Page 312: Settings Locked, Or Password Required
SmartPAC 2 with WPC 2000 Integration User Manual NOTICE If you add or remove a SmartPAC 2 option (e.g., DiProPAC, ProCamPAC, etc.), the Hot keys you have programmed previously may not navigate correctly. If one or more Hot keys no longer take you to desired screens, delete and re-program those Hot keys.
Page 313: Displaying Multiple Faults
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 ENTER YOUR PASSWORD USE THE KEYPAD TO ENTER NUMBERS. USE THE UP/DOWN CURSOR KEYS TO INCREASE/DECREASE. PRESS ENTER WHEN DONE. PRESS RESET TO CANCEL. 60599 If this display appears, you need to enter the general password to access the desired item.
Page 314: Opening The Crankshaft Angle Window
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Opening the Crankshaft Angle Window You can open a window displaying the crankshaft angle at a magnification comparable to that on the crank angle clock on the Main Run Menu for use on Run mode screens where a prominent crankshaft angle display is useful such as angle adjustment screens for cams and die protection sensors.
Page 315: Figure 6-8. Main Run Menu With Sensors Enabled Display
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Figure 6-8. Main Run Menu with SENSORS ENABLED Display To disable or enable sensors, do the following: Press ENTER with the highlight bar on the DISABLE/ENABLE SENSORS item. If you are enabling sensors, the message at the left of the Status Box changes from SENSORS DISABLED to SENSORS ENABLED.
Page 316: Counters
1128600 SmartPAC 2 with WPC 2000 Integration User Manual COUNTERS (RUN – COUNTERS) NOTICE For help with the Counters screen and screens accessible from it, press the HELP key when the applicable screen is displayed. This item allows you to make adjustments to counter settings made in Program mode.
Page 317: Die Protection (Optional)
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 F2. Pre-load values display in the Count field for the batches you have programmed with those values. Figure 6-11. Counters Screen with “Reload Batch Counters” Function When messages display indicating that counter presets have been reached, press RESET to clear the message (see Counter Preset Reached Messages, page 7-23).
Page 318: Figure 6-12. Die Protection Menu (Run Mode)
NOTICE FOR MORE INFORMATION For a detailed description of the different types of sensors available in SmartPAC 2 with die protection, refer to Understanding Sensor Terminology, page 5-16. Refer to Programming Sensor Settings, page 5-20 for detailed instructions on programming sensors.
Page 319: Adjusting The Ready Signal For Green Sensors
The On/Off actuation angles displayed in the Sensor window are not updated on every stroke. For green and green quick check sensors, SmartPAC 2 displays the earliest On and latest Off angles for the current sequence of press strokes (until the F5 (Update the Sensor Arc) function key is pressed), updating the display only when the sensor turns on before the previous earliest On signal or turns off after the previous latest Off signal.
Page 320 To clear the actuation angles displayed for a sensor, press the F5 (Update the Sensor Arc) function key. If the press is stopped, the Sensor window displays zeros. If the press is running, SmartPAC 2 displays the actuation angles for the next stroke. NOTICE Pressing F5 will not properly update sensor actuations when you are using a mechanical sensor, which vibrates constantly during the stroke.
Page 321: Adjusting The Stroke Preset For Green Special Sensors
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 NOTICE To update the sensor’s On/Off readings, press F5 (Update the Sensor Arc). To change the reference angle from 0° to 180°, press F4. The reference angle is used to determine earliest and latest On/Off readings.
Page 322: Show Sensor Status
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Show Sensor Status (RUN – DIE PROTECTION – F7-SHOW SENSOR STATUS) You can view the status of your sensors by pressing F7 (Show Sensor Status). When you do so, the Sensor Status screen, shown in Figure 6-15, displays.
Page 323: Adjusting Dipropac 32 Sensors
Adjusting DiProPAC 32 Sensors You access DiProPAC 32 sensors on the SmartPAC 2 Main Run Menu via the DIPROPAC 1-16 and DIPROPAC 17-32 items, as shown in Figure 6-16. Figure 6-16. Main Run Menu with DIPROPAC 1-16 and DIPROPAC 17-32 Items Shown When you select the DIPROPAC 1-16 item, the Die Protection Sensor menu for sensors 1-16 displays.
Page 324: Figure 6-17. Die Protection Sensor Menu For Sensors 17-32
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Figure 6-17. Die Protection Sensor Menu for Sensors 17-32 When programmed as green sensors, sensors 17-32 cannot be adjusted in Run mode since they share their Ready signals or stroke counts with one of the first sixteen sensors. You can, however, adjust the Ready signal or stroke count for the sensor on which settings are based.
Page 325: Figure 6-19. Green Special Sensor Stroke Count Screen, Run Mode
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 When you select a sensor programmed as green special on the Die Protection Sensor Menu for Sensors 17-32, the Green Special Sensor Stroke Count screen displays with a message, located at the bottom of the screen, indicating that you cannot change the green special stroke count for this sensor (see Figure 6-19).
Page 326: Cam Switch (Optional)
DANGER PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE Use SmartPAC 2’s programmable cam switch to control auxiliary functions only. The SmartPAC 2 programmable cam capability should never be used to provide timing signals for any safety use including clutch/brake control or muting of light curtains.
Page 327: Viewing Cam Timing
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 NOTICE ARE YOU LOCKED OUT? Access to items on this screen may be limited to Program mode or may require a password. The security access settings in Initialization mode determine when changes can be made.
Page 328: Viewing The Global Cam Summary
1128600 SmartPAC 2 with WPC 2000 Integration User Manual On/Off Channel: Dark blue bar whose end points are the channel’s On and Off settings • Auto Advance Channel: Green bar with the letter “A” at each end. The bar’s end points are •...
Page 329: Determining The Stopping Time Of Your Press
Starting time is the time it takes for the crankshaft to start turning after the DSV has been energized. Instructions for setting Start-time and Stop-time Limits and documentation of SmartPAC 2’s responses to start-time and stop-time faults are provided in Press Parameters, page 4-27.
Page 330: Performing The 90× Stop-Time Test
90 DEGREE BRAKE TEST ARMED PRESS RESET TO CANCEL TEST When SmartPAC 2 emergency-stops the press, which occurs the next time the press reaches 90°, record the STOP TIME value displayed on the Stop Time Status screen. Repeat the test at least 5 more times.
Page 331: Calculating The Safety Distance
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Calculating the Safety Distance DANGER PRESS MAY NOT STOP BEFORE OPERATOR REACHES PINCH POINT • Calculate the safety distance according to the applicable safety regulations, the instructions in this chapter and in your light curtain user manual.
Page 332 (or another object) reaches the hazard. • Call Wintriss Tech. Support if you are not sure how to calculate the safety distance. Failure to comply with these instructions will result in death or serious injury.
Page 333: Table 6-2. Shadow Light Curtain Response Time And Object Sensitivity
In the 90° stop-time test used by SmartPAC 2 (see page 6-22), the calculated stop time includes both Ts and Tc values. Response time, Tr, for Shadow light curtains is shown in Table 6-2.
Page 334 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Table 6-2. Shadow Light Curtain Response Time and Object Sensitivity (Cont.) Shadow Model Head Length * Response Time Object Sensitivity Shadow 8 Up to 42 in. 23 mS Up to 85 in.
Page 335 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Example: Calculating the Safety Distance for a Light Curtain Using the ANSI Formula The ANSI formula is Ds = K x (Ts + Tc + Tr + Tbm) + Dpf The following value is a constant:...
Page 336 (see Table 6-2, page 6-25). The value calculated by SmartPAC 2 at the end of the 90° stop time test includes the stop time of the press and response time of the press control (see page 6-22).
Page 337 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Example: Calculating the Safety Distance for a Light Curtain Using the OSHA Formula The OSHA formula is Ds = K x Ts The following value is a constant: K = 63 inches per second We will use the following values for the variables in the formula: Stopping time of press + response time of press control = 0.190 sec.
Page 338: Press Control
1128600 SmartPAC 2 with WPC 2000 Integration User Manual PRESS CONTROL (RUN – PRESS CONTROL) NOTICE For help with the Press Control Parameters screen, press the HELP key when the screen is displayed. This item enables you to adjust the top-stop angle, maximum and minimum press speed limits, and counterbalance setpoint established for the selected tool in Program mode (see page 5-48).
Page 339: Figure 6-24. Press Control Parameters Screen
They apply to all Run operating modes–Continuous, Single-stroke, and Inch. When the speed of the press exceeds the maximum limit, SmartPAC 2 stops the press and displays the fault message “Maximum press speed exceeded.” When press speed drops below the minimum limit, SmartPAC 2 stops the press and displays the fault message “Minimum press speed exceeded.”...
Page 340: Displaying Overrun Sensor On/Off Angles
• The value you enter in the MAXIMUM PRESS SPEED field must be greater than the Minimum Press Speed value. If the Maximum Speed setting is less than or equal to the Minimum Speed value, SmartPAC 2 changes the Maximum Speed to one Stroke per Minute greater than the Minimum Speed.
Page 341: Tool Information
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 TOOL INFORMATION (RUN – TOOL INFORMATION) NOTICE IF INFO IS CENTER INSTALLED If you have ordered Info Center as an installed option, the TOOL INFORMATION item will not appear on the Main Run Menu. Instead, INFO CENTER will be displayed. Documentation of the Info Center option is available at www.smartpac2.com/SmartView/InfoCenterSetupHelp.htm...
Page 342: Error/Event Log
When a new tool is loaded, the log displays the tool number. If SmartPAC 2 is connected to a computer network and e-mail is enabled, the log also shows messages sent by SmartPAC 2. When SmartPAC 2 is networked, you can send the Error/Event Log to Wintriss Tech.
Page 343: Load New Tool
This item enables you to load a new tool when the press is stopped. (You cannot load a new tool when the press is running. If you attempt to do so, SmartPAC 2 will display an error message, indicating that the press must be stopped before a tool can be loaded.) When you select LOAD NEW TOOL, the Tool Manager screen, shown in Figure 6-28, page 6-36, displays.
Page 344: Figure 6-28. Tool Manager Screen
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Figure 6-28. Tool Manager Screen Follow these steps to load a new tool: Select LOAD NEW TOOL from the Main Run Menu. The Tool Manager screen displays. NOTICE ARE YOU LOCKED OUT? Loading a new tool number may be limited to Program mode or may require a password.
Page 345: Messaging
Initialization (see E-MAIL FUNCTION, page 4-57), allows you to send e-mail messages to recipients accessible via your SmartPAC 2 computer network. Before you can use the e-mail messaging function, you must set up the e-mail recipients and messages using the SmartView remote viewing utility (see Appendix E).
Page 346: Sending E-Mail To Wintriss Technical Support
If you select “Wintriss Technical Support” as your recipient, and “Error Log Files” as your message, you can send an e-mail to Wintriss Tech. Support that includes error logs, a list of installed options, and other useful information. An example is shown in Figure 6-32.
Page 347: Toggle Hot Keys
TOGGLE HOT KEYS (RUN – TOGGLE HOT KEYS) This item enables you to switch between the two sets of Hot keys available in SmartPAC 2. When you select this item with the TOGGLE HOT KEYS 1 caption displayed, the second set of Hot Keys is shown;...
Page 348: Selecting Operating Mode
SmartPAC 2 with WPC 2000 Integration User Manual When the Emergency-stop is caused by a system fault, you must first clear the error by pressing the RESET key on the SmartPAC 2 front panel; then you can return the press to top dead center.
Page 349: Operating The Press In Inch Mode
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Select the desired operating mode by pressing the appropriate function key: Press F4 to enable Micro-inch • Press F5 to select One-hand mode • Press F6 to select Two-hand mode •...
Page 350 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Top-stop in Inch NOTICE Top-stop in Inch is enabled when there is no connection to pin #13 on the WPC 2000 Main Processor board. This is the factory setting. Top-stop in Inch is the default Inch mode. To run the press in Top-stop in Inch, do the...
Page 351: Operating The Press In Single-Stroke Mode
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Micro-inch Micro-inch allows finer adjustments than are possible in Top-stop in Inch or Top-stop Bypass and is designed to facilitate setup on high-speed or short-stroke presses. In Micro-inch, the distance the ram moves is controlled by the time setting you make on the Press Control Parameter Menu in Initialization mode (see Setting Micro-inch Time and Angle, page 4-29).
Page 352 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Select one of the following options on the Mode Select Menu (see page 6-40): Choose “TWO HAND” if you want to run the press in Two-hand mode • Choose “ONE HAND” if you want to run the press in One-hand mode •...
Page 353 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 With “TWO HAND” highlighted on the Mode Select Menu, initiate a stroke by pressing both Run/Inch buttons, holding them until the ram reaches the Auto Carry-up Angle, then releasing them (see Setting the Auto Carry-up Angle, page 4-28). The ram completes its stroke automatically, stopping at Top-stop.
Page 354 Station while the press is in One-hand mode. All other modes work normally as described in this manual. 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 running Two-hand/One-hand/Foot firmware and employing a Shadow light curtain to guard the point of operation.
Page 355 One-hand Control, page 4-36). Set switch 3 to CLOSED to operate in Light Curtain Break mode. NOTICE If the “Interrupted Stroke” message flashes on the SmartPAC 2 display, press and hold the Run/Inch palm buttons on the Operator Station to return the press to Top-stop. The “Interrupted Stroke” message should disappear.
Page 356 Auto Carry-up Angle, the press will stop, the “Interrupted Stroke” message will flash on the SmartPAC 2 display, and WPC 2000 will switch to Two-hand Maintained Single-stroke mode for the remainder of the stroke. To clear the “Interrupted Stroke”...
Page 357: Operating The Press In Automatic Single-Stroke Mode
(NPN, open collector). See Figure 3 at the end of the manual. If you intend to use Automatic Single-stroke, contact Wintriss Tech. Support. To run the press in Automatic Single-stroke, first install the sensors and other components...
Page 358: Operating The Press In Continuous Mode
1128600 SmartPAC 2 with WPC 2000 Integration User Manual To initiate the first stroke, depress the Prior Act button–the Prior Act lamp will blink when Prior Act is armed–then press and hold the Run/Inch palm buttons until the ram passes bottom dead center.
Page 359 If the press is Emergency-stopped, WPC 2000 automatically changes to Two-hand Maintained Single-stroke mode and the “Interrupted Stroke” message flashes on the SmartPAC 2 display. To clear the “Interrupted Stroke” message, press and hold both Run/ Inch buttons to complete the stroke and return the ram to Top-stop.
Page 360: Operating The Press In Automatic Continuous On-Demand Mode
Maintained Single-stroke mode and the “Interrupted Stroke” message flashes on the SmartPAC 2 display. To clear the “Interrupted Stroke” message, press and hold both Run/ Inch buttons on the Operator Station to complete the stroke and return the ram to Top Stop.
Page 361: Operating The Press In Bar Mode
6 SPM, WPC 2000 will stop the ram and fault code F26 will appear on the SmartPAC 2 display. Press the RESET key to continue barring the press. If an F26 error appears in the display, press the Reset/Select button to clear it, and continue with the barring operation.
Page 362: Multiple Operator Stations
5-second “concurrent time” window. NOTICE Do not attempt to install more than two Operator Stations until you have contacted Wintriss Tech. Support. All Operator Stations in a mutli-Op.-Station configuration except the Op. Station wired to the “A” inputs must contain a Two-hand Control module.
Page 363: Chapter 7. Fault Messages
• Ensure that all safety procedures are followed during installation, operation, and repair of SmartPAC 2 and WPC 2000. • Ensure that SmartPAC 2 and WPC 2000 are installed, tested, and repaired by qualified personnel. • Perform the final checkout tests (see page 2-87) after every modification, repair, or change to the press, press control or other equipment.
Page 364: Responding To Fault Messages
• If your SmartPAC 2 is networked, you can e-mail files directly from the control. See page 6-38. • If your SmartPAC 2 is not networked, you can load the files onto a USB disk (see page 4-65), take them to a networked computer, and e-mail them.
Page 365: Lockout Message
Certain press control faults, called Lockout faults, generate the message “PRESS CONTROL IS IN LOCKOUT MODE” on the SmartPAC 2 display after the fault is cleared. These are serious error conditions and require an additional step. When the problem has been corrected and the fault cleared, perform the following steps to clear the Lockout condition, following the instructions in the message.
Page 366 If you try to run the press without first repairing the brake, WPC 2000 will stop the press on the next stroke and again display the Stop Time Exceeded fault on the SmartPAC 2 display. The fault will continue to appear until the brake has been repaired.
Page 367: Messages For Press Control Problems
Whenever WPC 2000 detects a problem with the clutch/brake control, the press, or peripheral equipment, it sends a Stop command to the press and generates a fault on the SmartPAC 2 display. Most of these faults include a three-character alphanumeric code (see Figure 7-3 for an example).
Page 368: Resolver Faults
Correct the problem that caused the fault. Clear the fault code or message on the SmartPAC 2 display by doing one of the following: To clear F and H faults, press the RESET key on the display or a Remote Reset switch if •...
Page 369: Operational Faults
Remedy: on bare wire and not on insulation (see Wiring the Resolver, page 2-25). Also check the resolver. If necessary, contact Wintriss Tech. Support for assistance or replacement of the resolver. Problem: During zeroing, the resolver has been set outside the range of 330° to 30°.
Page 370 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Problem 2: If the message accompanying the fault code is “ENERGY SAVER SHUT DOWN,” the main motor has been turned off by WPC 2000 to save energy. You will only get this message if you have wired the lockout relay to the motor starter (see page 2-34) and specified a shutdown time on the Press Control Parameter Menu in SmartPAC 2 Initialization (see page 4-32).
Page 371 • Remove the WPC 2000 from operation immediately and replace the Auxiliary E-stop Relay board before operating the press again. Failure to comply with these instructions will result in death or serious injury. Press RESET. If the problem persists, contact Wintriss Tech. Support for Remedy: assistance or replacement of the relay board,...
Page 372 Check to make sure that the palm buttons are the correct switch type. Check and Remedy: correct the palm switch wiring. If the error persists, call Wintriss Tech. Support. Problem: The operating mode was changed while the press was running.
Page 373 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Problem: Both Run/Inch palm buttons on the Operator Station were pressed in One-hand mode Run/Inch buttons on an unselected Operator Station were pressed in a dual-Operator-Station setup. Press only one Run/Inch palm button when running the press in One-hand mode...
Page 374: Inter-Processor Failures
No reply to Compare Input Buffers message received from second processor Second processor did not receive Power-up information correctly Second processor did not receive Mode information correctly Try pressing RESET. If error persists, contact Wintriss Tech. Support. Remedy: 7-12 Fault Messages...
Page 375: Input Buffer Test Failures
Remedy: Air Pressure Limits Exceeded F45 or H45 Problem: Clutch Air Pressure is below the setpoint established in SmartPAC 2 Initialization. Check your Clutch Air Pressure level. You may need to adjust the Main Air Limit Remedy: setting (see page 4-29 for instructions).
Page 376: Component Failures
Problem: Failures have occurred to standard equipment connected to WPC 2000. Dual Safety Valve (DSV) monitor switch input open Clutch air pressure switch input open Correct the problem, then press RESET. If the error persists, contact Wintriss Remedy: Tech. Support.
Page 377: Table 7-2. Fault Codes For User Inputs
E-Stop/Lockout. All inputs except input pair 10/11 can be reconfigured by the user. If you have SmartPAC 2 firmware version 3.32 or higher and WPC 2000 firmware version 1.70 or higher, an additional stop type option, Top-stop/Lockout, is available for user inputs 1-7.
Page 378: Light Curtain Faults
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Light Curtain Faults F60 or H60 -and- F61 or H61 Problem: Light curtain A (fault #60) or light curtain B (fault #61) failed the WPC 2000 internal test. Remedy: Check to make sure that the light curtain is wired correctly, referring to figures 4, 14, 15, 20, 21, 23, and 24 at the back of the manual if you have Shadow light curtains, referring to the appropriate user manual if you have another product.
Page 379: Emergency-Stop Circuit Driver Failure
Remedy: Remove the Two-hand Only firmware, and install a firmware version intended for use with a light curtain, referring to Installing Revised Firmware in WPC 2000, page 2-85. Contact Wintriss Tech. Support for help in selecting the right firmware for your application.
Page 380: Shadow Light Curtain Input Faults
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Shadow Light Curtain Input Faults F68 or H68 -and- F69 or H69 Problem: Shadow light curtain A (fault #68) or B (fault #69) inputs to WPC 2000 are not in the same state (i.e., one input is “on,” the other is “off”).
Page 381: Dsv Interface And Lockout Relay Failures
Lockout relay check contacts were not closed before lockout relay was turned on The position of the DSV poppets is incorrect (Minster version only). Press RESET. If the error persists, contact Wintriss Tech. Support for assistance Remedy: or replacement of either board.
Page 382: Loss Of Rotation
Check the Start-time Limit setting, and increase if necessary. Check the resolver Remedy: and resolver drive, and replace the resolver if necessary. Check the clutch and repair if necessary. If these solutions do not work, contact Wintriss Tech. Support. Internal Timing Input Failures F80 or H80...
Page 383: Top-Stop And Overrun Setting Faults
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Top-stop and Overrun Setting Faults F81, F83, F84, F86 and F87 - and - H81, H83, H84, H86 and H87 Problem: The overrun limit switch has turned on before the Top-stop “On” Angle timing has turned off.
Page 384: Overrun Limit Switch Test Angle Fault
1 and 2 on the Press Control Option Switch Menu. Set switches 1 and 2 for the correct Top-stop “On” Angle window, referring to Remedy: Table 2-26, page 2-82. If the error persists, contact Wintriss Tech. Support. 7-22 Fault Messages...
Page 385: Internal Memory Failures
F98 or H98 The option switch image changed during operation F99 or H99 +24 Vdc failed, or the fuse blew Press RESET. If the error persists, contact Wintriss Tech. Support for assistance Remedy: or replacement of the Main Processor board or firmware chip.
Page 386: Messages For Equipment Or Brake Monitor Problems
Problem: The resolver did not start rotating within the start time limit set in Initialization (see page 4-31) or stopped rotating while the press was running. SmartPAC 2 knows when the Dual Safety Valve (DSV) is energized. If it sees that the DSV is energized but the resolver is not turning, this message appears.
Page 387 1128600 “Angle Resolver Failure” Problem: The wiring in the resolver circuit to SmartPAC 2 may be loose or bad, or the resolver may have failed. Another possible cause is that the press may be going faster than 800 SPM (or 1600 SPM, depending on the speed setting in SmartPAC Remedy: Check the resolver wiring and connections for shorts, breaks, or loose connections (see Wiring the Resolver, page 2-25).
Page 388 “Stop time exceeded” Problem: The stopping time of the press has exceeded the limit set in SmartPAC 2 Initialization. You should have been pre-warned of this condition by the brake warning LED, which flashes whenever the stopping time is within 10 milliseconds of the stop-time limit.
Page 389: Messages For Programming Problems
Problem: The programming for the loaded tool has become corrupted. This error can occur when SmartPAC 2 has been turned off while you are in the middle of programming a setup, or when you have not properly exited (i.e., by pressing RESET) from a Program or Run menu.
Page 390: Messages For Sensor Faults
If a green or green quick check sensor does not come on during its Ready signal, SmartPAC 2 continues to look for the sensor signal. If it sees the sensor come on within 50 milliseconds after the Ready signal, this message displays. The angle at which the sensor turned on is shown in the message.
Page 391 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 “Green constant fault” Problem: A green constant sensor was not on at the beginning of its Ready signal or turned off during the Ready signal. Green constant sensors must stay on throughout the Ready signal.
Page 392: Miscellaneous Fault Messages
“One of the sensor auto enable counters is greater than 99” Problem: Normally, this fault will never occur since SmartPAC 2 does not let you enter a value greater than 99. However, this message could display if there is an internal problem with SmartPAC 2.
Page 393: Troubleshooting Using The Error/Event Log
1128600 “Loss of Communication at Address X” Problem: SmartPAC 2 is unable to communicate with the optional module identified by “X” in the message (see Table 7-3). Remedy: Check the wiring of the specified module. If you continue to get this error message, call Wintriss Tech.
Page 394: Figure 7-4. Ross Dm2 Dsv Showing Reset Button
Figure 7-4. Ross DM2 DSV Showing Reset Button If the fault occurs after the unit has been wired, an F47 error will appear on the SmartPAC 2 display. To clear the fault and reset the DSV, press RESET and turn the Stroke Select key switch to OFF, then to one of the other operating modes (see page 7-14).
Page 395: Appendix A. Extracts From Osha Regulations And Ansi
PMA are shown in the right-hand column. Wintriss makes no claim for the accuracy or effectiveness of the PMA interpretations, and persons making use of this material do so at their own risk. PMA interpretations should not be relied upon for use in any specific application.
Page 396 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Extracts from OSHA Regulation 1910.217 OSHA Regulations PMA Interpretation OSHA 1910.217 (c). TABLE 0-10 (c) SAFEGUARDING THE POINT OF Distance of opening Maximum width of OPERATION. – from point of operation...
Page 397 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Extracts from OSHA Regulation 1910.217 OSHA Regulations PMA Interpretation (d) Muting (bypassing of the protective Top of stroke is the point at which muting shall function) of such device, during the...
Page 398 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Extracts from OSHA Regulation 1910.217 OSHA Regulations PMA Interpretation OSHA 1910.217 (c) (3) (vii) (c) (c) The safety distance (Ds) between each two hand control device and the point of operation shall be greater than the distance...
Page 399: Controls
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Extracts from ANSI Standards for Presence-sensing Devices and Two-hand Controls WARNING REFER TO CURRENT REVISIONS OF OSHA/ANSI DOCUMENTS The following extracts from OSHA and ANSI documents are provided for the user’s convenience only.
Page 400 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Extracts from ANSI B11.1-2009 8.6.2.1 Standards Requirements Explanatory Information 8.6.2.1.7 Each operator’s hand controls shall be E8.6.2.1.7 The total stopping time of the press located at a distance from the point-of-operation...
Page 401 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3 Presence-sensing safeguarding device 8.6.3.1 A presence-sensing device, when used E8.6.3.1 Various presence-sensing devices for safeguarding, shall protect the operator as employ different sensing and adjustment specified in E8.6.1 (a).
Page 402 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.7 Muting of the device shall be E8.6.3.7 Muting is typically accomplished by accomplished in a manner that conforms to the interface circuits or auxiliary controls. The requirements of 6.11 and 8.8.
Page 403 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.11 (cont) Means of supplemental safeguarding can include completely filling the fixed blanked area to restrict access to the hazard, installing the device at a distance that accounts for the worse case object sensitivity (see 8.6.3.16), or...
Page 404 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.16 (cont) Tbm = the additional stopping time allowed by the stopping-performance monitor before it detects stop time deterioration. Dpf = the added distance due to the penetration factor as recommended in ANSI B11.19, Annex...
Page 405 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.17 If the position of the device will allow E8.6.3.17 Additional means may include the operator or others to place themselves manual reset outside of the sensing field of the...
Page 406 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Extracts from ANSI B11.19-2010 8.3 Standards Requirements Explanatory Information 8.3 Electro-optical, RF, and area scanning presence-sensing safeguarding devices 8.3.1 Design and construction 8.3.1.1 The presence-sensing device shall be E8.3.1.1 The presence-sensing device should...
Page 407 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Extracts from ANSI B11.19-2010 8.3 Standards Requirements Explanatory Information 8.3.1.5 The presence-sensing device shall E8.3.1.5 Indicators, (usually red and green), incorporate visual means to indicate that the displays or meters should be provided to...
Page 408 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Extracts from ANSI B11.19-2010 8.3 Standards Requirements Explanatory Information 8.3.2 Installation, operation and maintenance 8.3.2.1 Exposure to the hazard(s) shall not be E8.3.2.1 The user should select a presence- possible by reaching over, under or around the sensing device adequate to prevent individuals sensing field of the presence-sensing device.
Page 409 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Extracts from ANSI B11.19-2010 8.3 Standards Requirements Explanatory Information Where objects are placed within the defined sensing field of an area scanner presence- sensing device, care should be taken to ensure that: •...
Page 410 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Extracts from ANSI B11.19-2010 8.3 Standards Requirements Explanatory Information RF presence-sensing devices have sensing fields that can vary due to: • antenna(e) design; • effects of adjacent machinery and equipment; • field sensitivity adjustments; and •...
Page 411 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Extracts from ANSI B11.19-2010 8.3 Standards Requirements Explanatory Information For fixed blanking, the desensitized area does not move or change once configured. Means to identify the desensitized area may include but are not limited to: •...
Page 412 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Extracts from ANSI B11.19-2010 8.3 Standards Requirements Explanatory Information 8.3.2.10 The total tolerance in the range E8.3.2.10 When the area scanning presence- measurement of an area scanning presence- sensing device is horizontally mounted, the...
Page 413: Appendix B. Specifications For User-Built Operator Stations
• Ensure that the 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.
Page 414: Switch Requirements
1128600 SmartPAC 2 with WPC 2000 Integration User Manual NOTICE A Run-button timer is built into the WPC 2000. If the Run buttons on a standalone Operator Station are not pressed within the 1/2-second “palm time” (“synchronous time” in ANSI terminology) or the Run buttons on multiple Op.
Page 415: Appendix C. Smartpac Preventive Maintenance (Pm) Monitor
NOTICE UPGRADING FIRMWARE If you have a SmartPAC 2 system with AutoSetPAC, you must upgrade the firmware to accept PM Monitor functionality. Check the version of your AutoSetPAC firmware at “Installed Options” in Initialization mode. If the firmware version number is less than 1.26 for a 2-channel AutoSetPAC or less than 1.22 for a 4-channel AutoSetPAC, contact Wintriss Tech.
Page 416: How The Pm Monitor Works
SmartPAC 2 with WPC 2000 Integration User Manual How the PM Monitor Works In the previous example, the SmartPAC 2 PM monitor would keep track of machine stops and could be set to signal a PM alert for the braking system after 50,000 machine stops, for example.
Page 417: Installing The Pm Monitor
Installing the PM Monitor For New Systems from the Factory If you purchased a SmartPAC 2 system with the PM Monitor pre-installed at the factory, you can proceed directly to the section, “Using the PM Monitor in Initialization mode.” For Existing Systems...
Page 418: Using The Pm Monitor In Initialization Mode
SWITCH TO RUN WHEN PM MONITOR DONE. SECURITY ACCESS Figure C-1. “PM Monitor” Highlighted on SmartPAC 2 Initialization Menu Select “PM Monitor” from the main Initialization menu (see Figure C-1). A screen will appear asking for your password. Preventive Maintenance Monitor...
Page 419: Figure C-2. Pm Password Screen
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 NOTICE The password prompt will appear EVERY time that you select “PM Monitor” from the Initialization mode. ENTER THE PASSWORD USE THE KEYPAD TO ENTER NUMBERS. USE THE UP/DOWN CURSOR KEYS TO INCREMENT/DECREMENT.
Page 420: Initializing The Pm Monitor
1128600 SmartPAC 2 with WPC 2000 Integration User Manual For Existing Systems If you ordered the PM Monitor options separately, you must initialize this option before you can actually use it. Complete all the steps in this section to initialize the PM Monitor.
Page 421: Figure C-4. Pm Entry Screen
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Enter the password that you obtained from Wintriss Controls, using the numeric keypad. This will take you to the PM Entry Screen (see below). Don't worry if erroneous information appears on the screen, as it will disappear once you have completed step 5.
Page 422: Assigning A New Pm Password Number
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Notice the “Warning” message and accompanying instructions appearing on the screen (see below). Press the “Clear” key to initialize. (If you decide not to, then press Reset.) ! ! !! WARNING ! ! !! THIS WILL CLEAR OUT ALL THE PM MONITOR INFORMATION .
Page 423: Figure C-7. Pm Monitor Screen
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Select “New item” from this display. (You may be asked for a password before getting to this screen. If so, enter it.) YOUR PRESS NAME PM MONITOR ITEM ALERT EVERY NEW ITEM USE THE CURSOR KEYS TO MAKE SELECTION.
Page 424: Figure C-9. Alphanumeric Display Superimposed Over Pm Names Screen
1128600 SmartPAC 2 with WPC 2000 Integration User Manual symbols, etc. Pressing the CLEAR key clears the text. To create a custom name, do the following: a. To select letters or symbols: Use the up, down, left, and/or right cursor keys to highlight the desired letter;...
Page 425: Figure C-11. Superimposed Number Display
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Next, the number display appears superimposed over the previous display (see the next illustration). Use the number keys or cursor keys to set the tracking frequency for the PM item. YOUR PRESS NAME...
Page 426: Using The Pm Monitor In Run Mode
CAM SWITCH item. PM MONITOR PM MONITOR LOAD NEW TOOL Figure C-13. “PM Monitor” Highlighted on SmartPAC 2 Run Menu (Your list of options may be different, depending on the features you have installed.) C-12 Preventive Maintenance Monitor...
Page 427: Viewing And Modifying Pm Alerts
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Viewing and Modifying PM Alerts Select “PM Monitor” from the first display in Run mode. You will see the list of PM items that you previously assigned in Initialization. The first item is highlighted in the next example.
Page 428: Figure C-15. Run Mode Screen Showing "Slide Adjust Motor" In "Alert" Mode
1128600 SmartPAC 2 with WPC 2000 Integration User Manual The next display shows that one of the items, “Slide Adjust Motor,” is now in “alert” status mode. It flashes on the screen. Also, the number of items in alert status mode appears at the top of the screen.
Page 429: Appendix D. Updating Smartpac 2 Firmware
The serial number is located on the top-mounting flange of the SmartPAC 2 enclosure and on the Boot Loader chip (U124) on the SmartPAC 2 board (see Figure 2-25, page 2-51). If you have a panel mount unit, the serial number can be found on the other side of the plate on which the AC input terminal block is mounted.
Page 430: Installing Updated Firmware From Usb Disk To Smartpac 2
• A USB disk with at least 4 MB of available space Installing Updated Firmware from USB Disk to SmartPAC 2 Follow these steps to load new firmware from a USB disk to your SmartPAC 2. NOTICE If you downloaded your firmware from Wintriss, go to page D-7 and follow the instructions in Downloading Updated Firmware from the Wintriss Server to load the firmware onto a USB disk.
Page 431: Figure D-1. Firmware Load Menu With "Xfer From Usb Disk" Highlighted
Power down your SmartPAC 2. Press and hold down the F1 function key while powering up the SmartPAC 2, releasing F1 when the red Wintriss SmartPAC 2 screen displays. After about a minute the FIRMWARE LOAD MENU will appear (see Figure D-1).
Page 432: Figure D-2. Firmware Load Menu With "Load New Firmware" Highlighted
USB disk into the connector when it is in the wrong orientation. Making sure that the USB disk is oriented correctly, carefully insert the USB disk into the USB connector. Wait about a minute for the SmartPAC 2 to recognize the USB disk. Close the door of the enclosure or console.
Page 433: Figure D-3. Firmware Load Menu With Yellow Status Window
1128600 NOTICE If the USB disk does not contain the correct folder for this SmartPAC 2 serial number, you will first see a message at the bottom of the screen that says “SP2nnnnnnnn DIRECTORY NOT FOUND” and then a red window with the message “THERE WAS NO RESPONSE TO THE USB DISK FILE TRANSFER REQUEST.”...
Page 434: Figure D-4. Smartpac 2 Display With "Loading Firmware" Message
SmartPAC 2 again, then power the unit back up. If the message still appears, contact Wintriss Tech. Support. If you suspended a job in order to load SmartPAC 2 firmware, reload the tool and enter the counts for your job-in-progress from Table D-1, page D2 as follows: a.
Page 435: Downloading Updated Firmware From The Wintriss Server
To download firmware from the Wintriss server, perform the following steps: Click on the link provided in the e-mail you received from Wintriss in response to your firmware order. If the link has been disabled by your security settings, copy the link, paste it into a Browser window, and press ENTER.
Page 436 If you are using Windows XP, you do not need to “unplug” or “eject” the USB disk. Remove the USB disk from the USB drive. To install downloaded firmware from the USB disk to SmartPAC 2, follow the instructions in Installing Updated Firmware from USB Disk to SmartPAC 2, page D-2.
Page 437: Installing Firmware From A Replacement Compact Flash (Cf) Card
The serial number is located on the top-mounting flange of the SmartPAC 2 enclosure and on the Boot Loader chip (U124) on the SmartPAC 2 board (see Figure 2-25, page 2-51). If you have a panel mount unit, the serial number can be found on the other side of the plate on which the AC input terminal block is mounted.
Page 438: Figure D-5. Firmware Load Menu With "Reload Current Firmware" Highlighted
Using the cursor keys, highlight “RELOAD CURRENT FIRMWARE,” as shown in Figure D-5, and press ENTER. A yellow status window appears with the message “YOU ARE ABOUT TO REPROGRAM THE SMARTPAC 2 RTS UNIT . . .” (see Figure D-6). Figure D-6. Firmware Load Menu with Yellow Status Window Press ENTER to continue.
Page 439: Figure D-7. Smartpac 2 Display With "Loading Firmware" Message
Figure D-7. SmartPAC 2 Display with “Loading Firmware” Message NOTICE If power is lost to SmartPAC 2 during installation of the firmware, SmartPAC 2 will default to the Firmware Load Menu display when the unit is powered back up. Repeat steps 4 and 5 to install the firmware again.
Page 440 1128600 SmartPAC 2 with WPC 2000 Integration User Manual D-12 Updating SmartPAC 2 Firmware...
Page 441: Appendix E. Smartview Remote Viewing And E-Mail Setup
LAN (Local Area Network) is set up, whether the SmartPAC 2 will have a fixed IP (Internet Protocol) address or use DHCP (Dynamic Host Configuration Protocol), and how email will be sent. They will also be able to offer advice regarding network hardware issues such as cabling, hubs and mail servers.
Page 442: Plugging In The Network Cable
Do not run Cat5 cable inside conduits containing AC high voltage wires. Ideally, run Cat5 cable in a separate conduit away from sources of electrical noise. With SmartPAC 2 turned off, open the enclosure and plug your network (CAT5) cable with the RJ45 connector into the Ethernet connector (J122) on the SmartPAC 2 board (refer to Figure 2-25, page 2-51 for location).
Page 443: Changing Network Settings
Changing Network Settings NOTICE Perform this procedure only if you want to change your SmartPAC 2 from the default DHCP setting (Dynamic Host Configuration Protocol) to a Static or Fixed IP address or if you want to change your SmartPAC 2’s default network computer name (i.e., SPAC2-nnnnnnnn, where nnnnnnnn is the serial number of your SmartPAC 2).
Page 444: Table E-1. Smartpac 2 Board: Ps 2 And Y-Cable Configuration
Rev. 5 and lower boards, you will need to plug a Y-cable into J120 and then plug the mouse into the connector on the arm of the Y labeled MOUSE. SmartPAC 2 Rev. 3 boards require that you reverse the connection and plug the mouse into the Y-cable connector labeled KEYBOARD.
Page 445 Control Panel Entered with the words Re-Start System and Save Changes. Single-left- click on the button to restart the SmartPAC 2 and save your new network settings. To test these changes, try launching SmartView and viewing the press. Also, go to the Setup Page in SmartView (see page E-10) and see if the IP address you entered is displayed.
Page 446: Installing Smartview
SmartPAC 2 with WPC 2000 Integration User Manual NOTICE SmartPAC 2 is configured at the factory to be part of a Workgroup. If your IT department requires that SmartPAC 2 be part of a Domain, you must change this setting. Contact your IT department for help.
Page 447: Figure E-2. Internet Options Screen
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 On the Internet Options screen (see Figure E-2), click on the Security tab. Figure E-2. Internet Options Screen On the Security tab (see Figure E-3), click on the Custom Level button.
Page 448: Installing Smartview On Your Computer
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Installing SmartView on your Computer Enter http://www.smartpac2.com in the Internet Explorer address window, and click on button to launch SmartView. If you are installing SmartView for the first time, the SmartView introductory page (see Figure E-4) will display. Otherwise, you will be taken directly to the SmartView Setup Page (see Figure E-5.
Page 449: Figure E-6. Mabry Winsock Activex Control Window
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Click in the Press Name window, and type “Demo Press 1” as shown in Figure E-5. Click on the button. Your entries are displayed in the large window beneath the Network Name and Press Name windows.
Page 450: Smartview Operation
SmartPAC 2 8-digit serial number, if you have assigned your SmartPAC 2 a DHCP address Enter in the Network Name window the SmartPAC 2 IP address if you have assigned your SmartPAC 2 a fixed or static IP address. Enter in Press Name window a name for your press, using up to 25 characters (e.g., Press 8, Press 9, etc.).
Page 451: Main Page
Submit Changes sure that you have entered the correct SmartPAC2 serial number or IP address. NOTICE If the “No Connection” message persists, you may need to Ping your SmartPAC 2. See page E-15 for instructions. Main Page The SmartView Main Page, shown in Figure E-8, page E-12, lets you view a summary of information about the presses you have networked.
Page 452: Press Status Information Page
You can view the Error/Event Log or Installed Options screen by clicking on the Error Log or Installed Options link at the top of the page. To return to the Main Page, click on the Main link. To go to the Wintriss.com web site, click on the Wintriss.com link.
Page 453: Remote Messaging
Send your computer to let you know if the transmission was successful. Your message will display as a post-it note on the SmartPAC 2 to which you have directed it (see Figure E-10, page E-14). Once the message is read, it can be cleared by going to the Error/Event Log (click on the Error Log link) and pressing the F4 key.
Page 454: E-Mail Setup
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Figure E-10. SmartPAC 2 Remote Message E-mail Setup You can enter new or edit existing recipient email addresses and messages on the E-mail Setup Page (see Figure E-11, page E-15), which you access from the SmartView Setup Page by clicking on the Email Setup link.
Page 455: Smartview Ping Utility
Setup Page on another SmartPAC2. SmartView Ping Utility The Ping utility is an administrator’s tool that is used to check whether a SmartPAC 2 is connected to the network and communicating properly. This utility is a good resource if you get a “No Connection”...
Page 456: Figure E-12. Mabry Internet Ping Window
Figure E-12. Mabry Internet Ping Window To Ping your SmartPAC2 from SmartView, follow these steps: Make sure your SmartPAC 2 is turned on and the network cable is plugged into the Ethernet connector (J122). On the SmartView Setup Page, click on the Ping Utility link. The Ping Utility window, shown in Figure E-13, displays.
Page 457: Figure E-14. Ping Utility Window With Example Of A Successful Ping
“The current connection has timed out” is typical of what you might find if the SmartPAC 2 is turned off or the physical network connection is faulty (e.g., the RJ45 connector is not plugged in or seated correctly or the Cat 5 cable between the SmartPAC 2 and the Hub is cut or defective).
Page 458 1128600 SmartPAC 2 with WPC 2000 Integration User Manual If you continue to get results like those shown in Figure E-15, you may want to contact your IT department. To clear the message(s) from the Ping Utility Window, click on the button.
Page 459: Appendix F. Upgrading From Original Smartpac To Smartpac 2
USING ALPHANUMERIC TOOL NUMBERS IN SMARTPAC 2 If you convert from an original SmartPAC, the tool number mode in your SmartPAC 2 will default to the Numeric mode. If you want to be able to use Alphanumeric mode in SmartPAC 2, you must first do the following in SmartPAC 1: 1.
Page 460: Figure F-1. Backup/Restore Control Menu
When setting up SmartPACs in SBR, make sure to identify the control you are backing up as a “SmartPAC 1” and the control you are restoring to as a “SmartPAC 2.” With these settings, SBR will back up all tools and Initialization settings from the SmartPAC 1, then, when it detects that a SmartPAC 2 is connected, restore only the tool settings, ignoring the Initialization parameters.
Page 461: Removing Smartpac 1 And Mounting Smartpac 2
The SmartPAC 2 enclosure is 1 in. taller than SmartPAC 1. For a panel mount, the SmartPAC 2 cutout is the same size as for SmartPAC 1, but there must be at least a 1 in. clearance from the bottom of the panel to the nearest switch plate. See see Table 1-1.
Page 462: Wiring The Smartpac 2
Mount your new SmartPAC 2. If you are installing a SmartPAC 2 enclosure, the two upper or two lower shock mounts will have to be moved to accommodate the 1 in. increase in size. It may be a good idea to replace all four shock mounts if they look worn.
Page 463 (see step 3), and DSI 2 and the Cam Output assembly. See Figures 9, 10, and 11 at the back of the manual. If you plan to network your SmartPAC 2, run Cat 5 cable with an RJ-45 connector into the enclosure.
Page 464: Table F-1. Smartpac 1 To Smartpac 2 Wiring Changes: Main Power
SmartPAC 2 to boot up. Then Turn the Prog/Run key to PROG. NOTICE After SmartPAC 2 has booted up, you may see a message about the resolver position being different. Press RESET to clear the message. Table F-1. SmartPAC 1 to SmartPAC 2 Wiring Changes: Main Power →...
Page 465: Table F-4. Smartpac 1 To Smartpac 2 Wiring Changes: Resolver Port
TB106 TB101 → TB106 TB101 → TB106 TB101 → TB106 TB101 Table F-5. SmartPAC 1 to SmartPAC 2 Wiring Changes: Position Sensor (If Used) → Original SmartPAC SmartPAC 2 Signal Type Connector Pin Number Connector Pin Number Done (√) →...
Page 466: Table F-7. Smartpac 1 To Smartpac 2 Wiring Changes: Dipropac, 16-Channel
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Table F-7. SmartPAC 1 to SmartPAC 2 Wiring Changes: DiProPAC, 16-Channel → Original SmartPAC SmartPAC 2 Signal Type Connector Pin Number Connector Pin Number Done (√) → SENSOR 1 TB551 TB554 →...
Page 467: Table F-9. Smartpac 1 To Smartpac 2 Wiring Changes: Procampac, 16-Channel
TB452 + 5 VDC TB452 TB452 TB452 TB452 RELAY PWR. TB452 TB452 Table F-10. SmartPAC 1 to SmartPAC 2 Wiring Changes: WPC Port (Integration Only) Original SmartPAC → SmartPAC 2 Signal Type Connector Pin Number Connector Pin Number Done (√) →...
Page 468: Table F-13. Smartpac 1 To Smartpac 2 Wiring Changes: Remote Reset (Optional)
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Table F-11. SmartPAC 1 to SmartPAC 2 Wiring Changes: Remote Dual Op. Station Select (Optional Remote Switch) → Original SmartPAC SmartPAC 2 Signal Type Connector Pin Number Connector Pin Number Done (√) →...
Page 469: Table F-15. Smartpac 1 To Smartpac 2 Wiring Changes: Sfi (Optional)
+TXD1 TB102 TB103 → -TXD1 TB102 TB103 → TB102 TB103 Table F-16. SmartPAC 1 to SmartPAC 2 Wiring Changes: MultiPAC (Special Port - Optional) → Original SmartPAC SmartPAC 2 Signal Type Connector Pin Number Connector Pin Number Done (√) →...
Page 470: Ac Wiring On Smartpac 2
Restoring Tools to SmartPAC 2 You can use SBR to restore backed-up tools from a SmartPAC 1 to a SmartPAC 2 via a connected laptop, or, if the SmartPAC 2 is on a network, you can restore tool settings from a network server.
Page 471: Figure F-3. Backup/Restore Control Menu With Restore Confirmation Message Displayed
Restore Instruction Sheet, which is provided with the SBR software. NOTICE Make sure to identify the control you are restoring to as a “SmartPAC 2.” When SBR detects that a SmartPAC 2 is connected, it will restore only the backed-up tool settings, ignoring the Initialization parameters.
Page 472: System Checkout
Position Sensor: Tool Number Mode should be set to Numeric Only • Setup Network: If SmartPAC 2 is going to be networked, see page E-1 for detailed • instructions on how to enter network settings.
Page 473: Appendix G. Replacing Smartpac 2 Pc Board
Appendix G. Replacing SmartPAC 2 PC Board The following procedures show you how to unpack and install a replacement SmartPAC 2 PC board that you have received through the Wintriss Board Exchange (EX) program. NOTICE Under the board exchange program, a replacement board can usually be shipped to you overnight if you contact Wintriss Tech.
Page 474: Installing The Replacement Board
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Installing the Replacement Board To remove the old SmartPAC 2 PC board and install the new replacement board, perform the following steps: WARNING ELECTRIC SHOCK HAZARD • Ensure that the power source is off before you replace electronic components in a control.
Page 475: Figure G-1. Smartpac 2 Pc Board
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 INSERT Figure G-1. SmartPAC 2 PC Board Using both hands, carefully lift the PC board out of the enclosure, or from the mounting plate if your unit is a panel mount.
Page 476 Reinstall the ProCamPAC and DiProPAC PC boards, if necessary, in their proper locations on the SmartPAC 2 board. Plug all the connectors you removed in step 3 back into the SmartPAC 2 board, including connectors on the ProCamPAC and DiProPAC boards (if installed). Make sure to insert the display connector (J115 in Figure G-1) into the SmartPAC 2 board with the correct orientation.
Page 477: Figure G-2. Firmware Load Menu With "Reload Current Firmware" Highlighted
When the reload process has been completed, you are ready to resume normal operation. NOTICE Before setting up and running a job, it is a good idea to test a few SmartPAC 2 modes and menus to make sure the unit is operating normally. If you have swapped the Battery Backed Up Ram chip in step 10, go into the Tool Manager (enter from the Main Program Menu) and verify that all your tools have been restored.
Page 478 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Replacing SmartPAC 2 PC Board...
Page 479: Appendix H. Reporting Downtime And Scrap To Sfc
Wintriss’s ShopFloorConnect Asset Utilization Software (SFC). The appendix discusses the six machine states to which SFC logs press time, explains the downtime reporting features of SmartPAC 2, shows you how to set up SmartPAC 2 to report downtime to SFC, and provides instructions for reporting downtime.
Page 480: Smartpac 2 Downtime Reporting Features
SmartPAC 2, a downtime reason must be reported manually by the operator since SmartPAC 2 is unable to detect the reason for the interruption (see Forced Idle Dialog Mode, below). Downtime reasons may also be assigned manually to provide additional detail for periods documented automatically with specific error conditions (see Forced Error Dialog Mode, page H-4).
Page 481: Putting The Press "Back On Line
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 If SmartPAC 2 is set up for automatic downtime reporting, the option window does not display following selection of the downtime reason, and downtime is automatically backfilled. Putting the Press “Back on Line”...
Page 482: Forced Error Dialog Mode
SmartPAC 2 error but may actually have a different cause. For example, SmartPAC 2 may be set up to generate an “End of Stock” error whenever the press runs out of material. This downtime reason is applied to the period of time during which a new coil is located and brought to the press unless the operator selects a more appropriate downtime reason, such as “Waiting for Coil,”...
Page 483: Persist Dialog Mode
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 downtime reason is backfilled (see Figure H-3 for a schematic time line), SmartPAC logs one second to the initial error (e.g., “Sensor 5–End of Stock”), assuring that the fault is documented, and the remaining time to the new downtime reason (e.g., “Waiting for Coil”).
Page 484: Single-Stroke Mode
OEE ratings unfairly downward. When you make this cycle time setting, SmartPAC 2 no longer looks for a change of state to determine whether the press is running but rather expects to see the press stroke at least once during the pre-programmed interval.
Page 485: Setting Up Smartpac 2 To Report Downtime
Wintriss recommends that you select the “32 CUSTOM” setting if your shop floor uses only SmartPAC 2 controls. The “16 / 16” setting should be selected only if you have a mix of SmartPAC 2s and SmartPAC 1s and want to maintain consistency in your downtime reporting method The “32 CUSTOM”...
Page 486: Figure H-4. Smartpac 2 Main Initialization Menu
Figure H-5. Set Communications Menu NOTICE Wintriss recommends that you take advantage of the additional features provided by the “32 Custom” dialog screen mode setting. The “16 / 16” setting should be selected only when you have both SmartPAC 1s and SmartPAC 2s and, even then, only if complete consistency is required.
Page 487: Table H-1. Set Communications Menu Settings
To specify a value for an item (with the exception of IDLE TIMER), press ENTER to • display the Numeric Entry window, key in your entry with the SmartPAC 2 keypad, and press ENTER again. To select an option for DIALOG SCREEN MODE, press ENTER until the desired •...
Page 488 Dialog Menu in order to restart the press. This setting allows time that elapses after the press is stopped due to a SmartPAC 2 fault to be assigned a different downtime reason. There are two settings:...
Page 489 Single-stroke Mode enabled DISABLED Single-stroke Mode disabled IDLE TIMER Specifies the number of seconds during which SmartPAC 2 counts the number of press strokes in Single-stroke mode to determine a production rate for hand-fed applications. This value should be twice the cycle time for the slowest hand-fed job run on a press.
Page 490: Programming Downtime Reasons
“Canned” names are downtime reasons whose text has been pre-programmed into the SmartPAC 2. “Special” names are downtime reasons whose text you assign. You can select up to 14 “canned” names and create up to 16 “special” names. The Dialog Menu can include both “canned”...
Page 491: Figure H-6. Dialog Fixed Name Choice Menu
“Canned” names that will appear on the Dialog Menu. “Canned” names are downtime reasons whose text has already been programmed into the SmartPAC 2. You can select up to 14 of these pre-programmed entries for inclusion in the Dialog Menu.
Page 492 1128600 SmartPAC 2 with WPC 2000 Integration User Manual To select the pre-programmed downtime reasons that will appear on the Dialog Menu and the order in which they will appear, do the following: On the Set Communications Menu, highlight the SET CANNED NAMES item, using the Up () or Down () cursor key, and press ENTER.
Page 493: Figure H-7. Dialog Special Choice Name Menu
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Figure H-7. Dialog Special Choice Name Menu Press ENTER, and when the Alphabetic Entry window displays, type the text (12 characters maximum, including spaces) of the downtime reason that you want to appear on the Dialog Menu;...
Page 494: Documenting Downtime On The Dialog Menu
Press RESET to clear the message. The Dialog Menu displays. If dialog screen mode is set to “16/16” (see Setting up SmartPAC 2 to Report Downtime, page H-7), the Dialog Menu looks like the example shown in Figure H-9, page H-17. If “32 CUSTOM” is the dialog screen mode setting, the Dialog Menu looks like the example shown in Figure H-10.
Page 495: Figure H-9. Dialog Menu ("16/16" Dialog Screen Mode)
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Figure H-9. Dialog Menu (“16/16” Dialog Screen Mode) Figure H-10. Dialog Menu (“32 CUSTOM” Dialog Screen Mode) Highlight the downtime reason you want (in Figure H-9, MECH PROBLEM is selected as an example), using the Up () or Down () cursor key, and press ENTER.
Page 496: Figure H-11. Dialog Menu With F2/F3 Option Window Displayed
“forward fill” the selected downtime reason, in other words, assign it to the period from the present up to entry of the next downtime reason or the BACK ON LINE selection. The SmartPAC 2 will display a message stating that the downtime reason has been sent to the host computer. H-18...
Page 497: Documenting Downtime In Other Situations
BACK ON LINE selection). If a SmartPAC 2 fault has already been assigned to this period of press inactivity, that fault will be documented as having consumed 1 second and the remainder of the period filled with the downtime reason you selected.
Page 498: Ending A Job
When an End Job function is executed, the SmartPAC 2 will report the tool number to SFC as Tool Number “0” to indicate that the machine is in a “No Job” condition. All time logged during the No Job condition can be assigned machine states (Planned Downtime, Unplanned Downtime, or Changeover) and downtime reasons just as if a tool were actually loaded.
Page 499: Creating Hot Keys For Dialog Menu Functions
On the Main Run Menu, select the DIALOG MENU item. NOTICE The SmartPAC 2 must be in an Idle state when you program Hot Keys. Make sure to select BACK ON LINE before attempting to make Hot Key assignments. On the Dialog Menu, highlight the BACK ON LINE item and press ENTER to place the SmartPAC 2 in an Idle state.
Page 500: Reporting Scrap And Good Parts To Sfc
SmartPAC 2 with WPC 2000 Integration User Manual Reporting Scrap and Good Parts to SFC If you are running SFC-compatible firmware, SmartPAC 2 enables you to document scrap so that scrap counts can be reported to SFC. The scrap counter, which appears on the Counters screen in Run mode, maintains a cumulative total of all user scrap entries for the currently running job, resetting to zero when the job is complete.
Page 501: Figure H-14. Counters Screen With "Scrap Value" Function (F3) Shown
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 With the tool loaded and running, select “COUNTERS” on the Main Run Menu (see Figure H-12, page H-19) to display the Counters screen (see Figure H-14). Figure H-14. Counters Screen with “Scrap Value” Function (F3) Shown Press F3 (Scrap Value).
Page 502: Figure H-16. Counters Screen With Scrap Value Updated To 30 Items
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Figure H-16. Counters Screen with Scrap Value Updated to 30 Items NOTICE INDIVIDUAL SCRAP ENTRIES ARE ADDED TO THE CURRENT SCRAP TOTAL The Scrap Value counter maintains a cumulative total of the scrap items documented for each job.
Page 503: Adjusting The Good Parts Counter
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Figure H-18. Counters Screen with Scrap Value Updated to 40 Items Repeat step 2 for the remaining scrap entries associated with the current job until the job is completed. Adjusting the Good Parts Counter NOTICE You can only increase the value maintained by the Good Parts counter.
Page 504: Figure H-19. Good Parts Counter Adjustment Confirmation Window
1128600 SmartPAC 2 with WPC 2000 Integration User Manual When the Good Parts Entry window (like the window shown in Figure H-15) displays, key in the number of good parts you want to add (1,000 parts maximum), and press ENTER. A Confirmation window like the one shown in Figure H-19 displays.
Page 505: Appendix I. Reporting Downtime And Scrap To Lets
Wintriss’s Line Efficiency Tracking Software (LETS). The appendix discusses the six machine states to which LETS logs press time, explains the downtime reporting features of SmartPAC 2, shows you how to set up SmartPAC 2 to report downtime to LETS, and provides instructions for reporting downtime.
Page 506: Smartpac 2 Downtime Reporting Features
SmartPAC 2. Since Overall Equipment Effectiveness (OEE) and other efficiency metrics assign high ratings to machines with low Idle Time values, SmartPAC 2 has been designed to allow very precise reporting of downtime to LETS and may be programmed to require the operator to select a specific downtime reason each time the press enters an Idle state.
Page 507: Putting The Press "Back On Line
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 If SmartPAC 2 is set up for manual downtime reporting, the operator selects how the downtime is to be assigned in an option window that displays following selection of the downtime reason (see Figure I-10, page I-16). One option, which is called “backfilling,” is to assign the downtime reason to all time that has elapsed since the press was stopped (see Figure I-1).
Page 508: Forced Error Dialog Mode
SmartPAC 2 error but may actually have a different cause. For example, SmartPAC 2 may be set up to generate an “End of Stock” error whenever the press runs out of material. This downtime reason is applied to the period of time during which a new coil is located and brought to the press unless the operator selects a more appropriate downtime reason, such as “Waiting for Coil,”...
Page 509: Persist Dialog Mode
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 logs one second to the initial error (e.g., “Sensor 5–End of Stock”), assuring that the fault is documented, and the remaining time to the new downtime reason (e.g., “Waiting for Coil”).
Page 510: Single-Stroke Mode
Single-stroke mode without the operator having to enter a downtime reason at the end of each stroke, when the SmartPAC 2 considers the press to be stopped. Instead of looking for a change of state (i.e., from Running to Stopped), SmartPAC 2 looks for at least one press cycle during a pre-programmed interval and, if it detects no stroke, considers that the press is stopped, reporting subsequent time as Idle Time.
Page 511: Making Downtime Reporting Settings
To enable and configure the SmartPAC 2 downtime reporting features described in the previous section, perform the following steps: At the SmartPAC 2, turn the Program/Run key to “PROG,” then press the “1” and “CLEAR” keys simultaneously for a second or two until the Main Initialization Menu (see Figure I-4) displays.
Page 512: Table I-1. Set Communications Menu Settings
• To specify a value for an item (with the exception of IDLE TIMER), press ENTER to • display the Numeric Entry window, key in your entry with the SmartPAC 2 keypad, and press ENTER again. NOTICE Make sure that the DIALOG SCREEN MODE item is set to “16 / 16.” If DIALOG SCREEN MODE is set to “32 CUSTOM,”...
Page 513 Dialog Menu in order to restart the press. This setting allows time that elapses after the press is stopped due to a SmartPAC 2 fault to be assigned a different downtime reason. There are two settings:...
Page 514 Single-stroke Mode enabled DISABLED Single-stroke Mode disabled IDLE TIMER Specifies the number of seconds during which SmartPAC 2 counts the number of press strokes in Single-stroke mode to determine a production rate for hand-fed applications. This value should be twice the cycle time for the slowest hand-fed job run on a press.
Page 515: Programming Downtime Reasons
“Canned” names that will appear on the Dialog Menu. “Canned” names are downtime reasons whose text has already been programmed into the SmartPAC 2. You can select up to 14 of these pre-programmed entries for inclusion in the Dialog Menu.
Page 516 1128600 SmartPAC 2 with WPC 2000 Integration User Manual You select a “canned” name by entering a sequence number to the right of the name’s text entry. The sequence number specifies the position in which that item will appear on the Dialog Menu.
Page 517: Figure I-7. Dialog Special Choice Name Menu
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 When you are finished setting the sequence of “canned” names, press RESET to save your entries and return to the Set Communications Menu. Creating Special Names on the Dialog Special Choice Name Menu When you select the SET SPECIAL NAMES item on the Set Communications Menu, the Dialog Special Choice Name Menu (see Figure I-7) displays.
Page 518: Documenting Downtime On The Dialog Menu
With Forced Idle Dialog mode or Forced Error Dialog mode enabled (see Making Downtime Reporting Settings, page I-7), the operator is prompted to enter a downtime reason on the Dialog Menu whenever SmartPAC 2 detects that the press has stopped under the appropriate circumstances. This message is shown in Figure I-8, page I-15.
Page 519: Figure I-8. Smartpac 2 Run Mode Main Menu With Forced Dialog Message Displayed
BACK ON LINE selection). If a SmartPAC 2 fault has already been assigned to this period of press inactivity, that fault will be documented as having consumed 1 second and the remainder of the period filled with the downtime reason you selected.
Page 520: Figure I-10. Dialog Menu With F2/F3 Option Window Displayed
“forward fill” the selected downtime reason, in other words, assign it to the period from the present up to entry of the next downtime reason or the BACK ON LINE selection. The SmartPAC 2 will display a message stating that the downtime reason has been sent to the host computer. I-16...
Page 521: Documenting Downtime In Other Situations
BACK ON LINE selection). If a SmartPAC 2 fault has already been assigned to this period of press inactivity, that fault will be documented as having consumed 1 second and the remainder of the period filled with the downtime reason you selected.
Page 522: Creating Hot Keys For Dialog Menu Functions
SmartPAC 2 fault has been assigned to this period, the downtime reason you selected will replace it. If a SmartPAC 2 fault has been assigned to this period, that fault will be documented as having consumed 1 second and the remainder of the period filled with the downtime reason you selected.
Page 523: Reporting Scrap And Good Parts To Lets
1128600 Reporting Scrap and Good Parts to LETS If you are running LETS-compatible firmware, SmartPAC 2 enables you to document scrap so that scrap counts can be reported to LETS. The scrap counter, which appears on the Counters screen in Run mode, maintains a cumulative total of all user scrap entries for the currently running job, resetting to zero when the job is complete.
Page 524: Making Scrap Entries
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Making Scrap Entries To document scrap for a currently running job, do the following: With the tool loaded and running, select “COUNTERS” on the Main Run Menu (see Figure I-11, page I-17) to display the Counters screen (see Figure I-13).
Page 525: Figure I-15. Counters Screen With Scrap Value Updated To 30 Items
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 When you press ENTER, the Scrap Value Entry window disappears, and the value you keyed in is displayed beneath the “Scrap Value” caption to the left of the F3 function key, as shown in Figure I-15, where a scrap value of “30”...
Page 526: Figure I-16. Counters Screen With Scrap Value Entry Window Displayed (40 Items Shown)
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Figure I-16. Counters Screen with Scrap Value Entry Window Displayed (40 Items Shown) You are returned to the Counters screen. The value you entered in the Scrap Value Entry window is displayed beneath the “Scrap Value” caption to the left of the F3 function key (see Figure I-17, in which a scrap total of “40”...
Page 527: Adjusting The Good Parts Counter
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Adjusting the Good Parts Counter NOTICE You can only increase the value maintained by the Good Parts counter. You cannot decrease the Good Parts counter except by entering scrap values. NOTICE You cannot adjust the Good Parts counter if the CHG GOOD PRTS CNT item on the Security Access Menu has been set to “NO CHANGES ALLOWED.”...
Page 528 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Adjusting the Good Parts Counter in Program Mode NOTICE In Program mode, you can increase the Good Parts count in increments greater than 1,000. To increase the Good Parts count in Program mode, do the following: On the Counters screen in Run mode, press RESET to return to the Main Run Menu.
Page 529: Appendix J. Option 1 User Inputs
Input stop types are set to E-stop at the factory (see Table J-1) but can be changed at SmartPAC 2 (see Changing User Input Stop Type, page J-8).
Page 530: Table J-1. Option 1 User Inputs: Input Type And Stop Type
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Table J-1. Option 1 User Inputs: Input Type and Stop Type User Input Number Input Type Default Stop Type * User input 12 E-stop User input 13 E-stop User input 14...
Page 531: Installing The Option 1 Board
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Installing the Option 1 Board To install the WPC 2000 Option 1 board (see Figure J-1, page J-4), perform the following steps: CAUTION DAMAGE TO BOARD FROM STATIC DISCHARGE Ground yourself before touching circuit boards or chips by touching a large metal object such as the press.
Page 532: Figure J-1. Option 1 Board Installed On Wpc 2000 Main Processor Board
1128600 SmartPAC 2 with WPC 2000 Integration User Manual DSV/Lockout Relay board Auxiliary E-Stop Relay board (Optional) WPC 2000 Main Processor board Standoffs and Phillips screws (4 places) WPC 2000 Option 1 board 438 439 440 441 442 443 444 445 446 447...
Page 533: Wiring Option 1 User Inputs
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Wiring Option 1 User Inputs Wiring connections for WPC 2000 Option 1 user inputs are made on terminal blocks TB601 and TB602 on the Option 1 board (see Figure J-2). Pin numbers are shown in Table J-2 and Table J-3, page J-6, and in Figure 25 at the end of the manual.
Page 534: Table J-2. Wpc 2000 Option 1 Board: Wiring Connections, Tb601
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Table J-2. WPC 2000 Option 1 Board: Wiring Connections, TB601 Terminal for Jumper Pin # User Input Bypass Connection Upper Row User input 32 + (cross-checked with user input 33) +24 Vdc...
Page 535: Figure J-3. Wpc 2000 Option 1 Board: Led Map
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Table J-3. WPC 2000 Option 1 Board: Wiring Connections, TB602 (Cont.) Terminal for Jumper Pin # User Input Bypass Connection User input 31 + +24 Vdc User input 37 + (cross-checked with user input 36)
Page 536: Changing User Input Stop Type
WPC 2000 Option 1 user inputs are set to E-stop at the factory (see Table J-1, page J-2) but can be modified on the Press Control User Interlock Menu in SmartPAC 2 Initialization. User inputs 12-31 can be set to Top-stop, Top-stop/Lockout (a new setting), E-stop, E-stop/ Lockout, or Unused.
Page 537: Viewing The Status Of User Inputs
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Figure J-4. Change User Interlock Screen Viewing the Status of User Inputs You can view the status of WPC 2000 Option 1 user inputs just as you can view the status of the standard user inputs 1-11.
Page 538: Troubleshooting
ON are highlighted. OFF inputs are not highlighted. In addition, an OFF input may generate the fault code specific to that input on the SmartPAC 2 display. “Unused” inputs show an OFF status but do not generate a fault code display.
Page 539 If the message “F148 OPTION BOARD NOT CORRECT” appears on your Problem: SmartPAC 2 display, it means either that the Option 1 board is not seated properly in the WPC 2000 board or has been removed from the WPC 2000 board.
Page 540: Option 1 User Input Setup Sheet
1128600 SmartPAC 2 with WPC 2000 Integration User Manual Option 1 User Input Setup Sheet Terminal Fault for Jumper Name of Auxiliary User Input Code Stop Type * Pin # Connection Equipment User 12 Ground User 13 Ground User 14...
Page 541: Glossary
Glossary NOTICE Cross-references to other glossary entries are shown in italics. ACTS See Auto-compensated Top Stop. actuation A change in the state or condition of a sensor. actuation angle See dwell. actuation block A graphical indicator on the Sensor Status screen in Run mode, showing whether a sensor is actuated.
Page 542: Smartpac 2 With Wpc 2000 Integration User Manual
A numeric value calculated when a tool is stored in memory and when it is loaded. The two values must match or SmartPAC 2 displays a fault message. communications Data sent by SmartPAC 2 to one of its installed options (e.g., WPC, SFI, etc.) or received from an installed option.
Page 543 During an interrupted stroke condition, the message “Interrupted Stroke” flashes in the status box at the top of the SmartPAC 2 screen. Glossary...
Page 544 A die protection mode in which sensors are manually enabled or disabled by the operator. messaging A SmartPAC 2 feature that allows e-mails to be sent from SmartPAC 2 to networked computers, pagers, text-enabled cell phones and other devices. This feature is set up in SmartView.
Page 545 A command issued by the operator that allows the press to resume operation after it has been stopped due to a malfunction. The “reset” command clears the fault message from the SmartPAC 2 display. The command is issued by pressing the RESET key. resolver...
Page 546 1128600 SmartPAC 2 with WPC 2000 Integration User Manual response time The length of time it takes SmartPAC 2 to activate the machine’s brake. safety distance The distance from the pinch point that OSHA requires safety equipment such as light curtains, two-hand controls, and type-B movable barriers to be mounted to assure the safety of the operator.
Page 547 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Tool Template A tool on the Tool Manager screen that you can program with settings shared by multiple tools, then use as a “template” to copy the common settings to those tools.
Page 548 1128600 SmartPAC 2 with WPC 2000 Integration User Manual GL-8 Glossary...
Page 549 Cam Output , A-5 , 2-66 angle wheel rotation, setting DiProPAC , 4-6 , 2-58 anti-repeat test DiProPAC installed on SmartPAC 2 board , 2-97 , 2-57 anti-tiedown test ProCamPAC , 2-96 , 2-58 auto advance ProCamPAC installed on SmartPAC 2...
Page 550 1128600 SmartPAC 2 with WPC 2000 Integration User Manual clock, setting setting green sensor ready signal on , 4-64 , 5-29 clutch air pressure setting rotational direction , 4-6 establishing low setpoint crankshaft angle window, opening , 4-29 , 6-6...
Page 551 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 Shadow light curtain input faults , 7-18 –E– tool programming faults , 7-27 e-mail top-stop and overrun setting faults , 7-21 adding/changing messages in SmartView , E-14 top-stop circuit driver failure...
Page 552 1128600 SmartPAC 2 with WPC 2000 Integration User Manual Info Center enabling dual light curtains , 1-3 , 4-38 Initialization mode enabling light curtain break mode , 4-36 entering and exiting faults , 4-2 , 7-16, 7-18 main menu increasing the safety distance for floating or...
Page 553 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 installing multiple operator stations , 2-21 –N– labelling dual operator stations , 2-22 name , 5-23 mounting and wiring , 2-16 name(s) setting concurrent time for multiple op. assigning to auxiliary equipment...
Page 554 1128600 SmartPAC 2 with WPC 2000 Integration User Manual adjusting top-stop "on" angle selecting relays for cam channels , 6-30 , 2-64 selecting press type in SmartView wiring , E-2 , 2-64 selecting pressure units Program mode , 4-33 setting counterbalance setpoint...
Page 555 SmartPAC 2 with WPC 2000 Integration User Manual 1128600 using to back up tool settings in SmartPAC 1 operating the press in automatic single- , F-1 using to restore SmartPAC 1 tool settings to stroke , 6-49 SmartPAC 2 operating the press in single-stroke foot...
Page 556 1128600 SmartPAC 2 with WPC 2000 Integration User Manual viewing top-stop mode for F and H errors, setting , 6-20 , 4-39 stop type (sensor), setting tracking frequency (preventive maintenance) , 5-25 stopping angle, viewing modifying , 6-20 , C-14...
Page 557: Index
SmartPAC 2 with WPC 2000 Integration User Manual 1128600 WPC 2000 main processor board (TB101- –Y– TB104) , 2-114 yellow sensors WPC 2000 board layout , 2-28 faults , 7-29 overview , 5-18 selecting as sensor type , 5-24 Index...
Page 558 1128600 SmartPAC 2 with WPC 2000 Integration User Manual IN-10 Index...
Page 559 SmartPAC 2 with WPC 2000 Setup Sheet Tool Name and Number: Counter Presets Batch 1 (Ch. 6) Batch 2 (Ch. 7) Batch 3 (Ch. 8) Preset Value Top Stop Top Stop Top Stop Output mode Toggle Toggle Toggle (circle one)
Page 561 ProCamPAC Cam Switch – SmartPAC 2 Setup Sheet Channels 1 - 8 Tool Name and Number: Ch. # Cam Name (function) Global Auto TIMED DSV-ON ON/OFF same for all tools cam? Adv.? 4 max. Time to Multiple arcs for ON/OFF shut-off only.
Page 563 ProCamPAC Cam Switch – SmartPAC 2 Setup Sheet Channels 9 - 16 Tool Name and Number: Ch. # Cam Name (function) Global Auto TIMED DSV-ON ON/OFF same for all tools cam? Adv.? 4 max. Time to Multiple arcs for ON/OFF shut off only.
Page 565 DiProPAC Die Protection – SmartPAC 2 Setup Form Sensors 1-16 Tool Name and Number: Sensor Sensor Name Sensor Type Stop Type Ready Signal Number (function) (circle one) (circle one) Timing E-STOP TOP STOP GS ______strokes SMART STOP E-STOP TOP STOP...
Page 567 DiProPAC Die Protection – SmartPAC 2 Setup Form Sensors 17-32 Tool Name and Number: Sensor Sensor Name Sensor Type Stop Type Ready Signal Number (function) (circle one) (circle one) Timing E-STOP Linked to TOP STOP Sensor #____ GS ______strokes SMART STOP...
Page 569 SmartPAC Initialization Setup Sheet Initialization Menu Item Initialization Setting Options Position Sensor Position Sensor Mode Enabled Disabled Counter Setup Mode Not incremented in Inch mode Is incremented in all modes Installed Options (e.g., PM Monitor, Feed Control, Press Control, Lube/Speed Control) Press Name Set Brake Monitor Stop Time Limit...
Page 571 SmartPAC Initialization Setup Sheet (Page 2) Initialization Menu Item Initialization Setting Options Custom Sensor Names (cont.) Custom 11 Custom 12 Custom 13 Custom 14 Custom 15 Custom 16 Sensor Enable Mode Sensor Enable Mode Manual Enable Auto by Tool Auto by Sensor Tool Information Tool 1 Name...
Page 573 SmartPAC Initialization Setup Sheet (Page 3) Initialization Menu Item Initialization Setting Options Security Access Load Tool # Program and Run Modes Program Mode Only Password Required Delete Tool # Program Mode Password Required Not Allowed Set Counter Preset Program and Run Modes Program Mode Only Password Required Change Count...
Page 575 Press Parameters Setup Sheet Press Parameters (INITIALIZATION–PRESS CONTROL–PRESS PARAMETERS) Parameter Setting TOP STOP DEFLT CARRYUP ANGLE MICRO TIME [ONLY WITH MICRO-INCH] MICRO ANGLE [ONLY WITH MICRO-INCH] MAIN AIR LIMIT CNTR BAL +/– STOP LIMIT START LIMIT SHUT DOWN TIME FLYWHEEL TIMER ACTS ANGLE [ONLY WITH AUTO COMPENSATED TOP STOP OPTION]...
Page 578 APPROVALS TITLE DRAWING NUMBER SIZE SCALE SHEET...
Page 579 APPROVALS TITLE DRAWING NUMBER SIZE SCALE SHEET...
Page 580 APPROVALS TITLE DRAWING NUMBER SIZE SCALE SHEET...
Page 581 APPROVALS TITLE DRAWING NUMBER SIZE SCALE SHEET...

This manual is also suitable for:

Smartpac 2

Save PDF