Wintriss SmartPAC PRO Integration Manual
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Wintriss SmartPAC PRO Integration Manual

Press automation control integration with wpc 2000 clutch/brake control
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  • Page 1 ® ® Wintriss Controls Group, LLC Tech Support Hotline 800-586-8324 8-5 EST 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: Table Of Contents

    Chapter 1 – Introduction to SmartPAC PRO with WPC 2000 Integration ...... 17 Chapter 2 – Installation ....................... 19 Use This Manual Along with Your SmartPAC PRO and WPC 2000 Manuals ......22 Install your SmartPAC PRO According to the SmartPAC PRO Installation Manual ....22 Install Your WPC 2000 According to WPC 2000 Installation Manual .........
  • Page 6 1143300 SmartPAC PRO - WPC 2000 Integration Manual Automatic Mode............................64 Two Hand Only ............................65 Additional Security ........................66 Wiring an Optional Keylock Switch to Prevent Changes to WPC 2000 Settings ........66 Chapter 4 – Program ......................67 Entering and Exiting Program Mode .....................
  • Page 7 SmartPAC PRO - WPC 2000 Integration Manual 1143100 Resolver Faults ..............................102 Operational Faults .............................. 103 Inter-processor Failures ............................109 Input Buffer Test Failures ..........................109 Air Pressure Limits Exceeded ........................... 110 Component Failures ............................110 Customized Status Codes ..........................111 Light Curtain Faults ............................
  • Page 8 Figure 2-2. SmartPAC PRO Board with Terminal Block Locations ........... 25 Figure 2-3. WPC 2000 Main Processor Board: Location of Important Components ......26 Figure 2-4. Location of the Master-Slave Jumper on SmartPAC PRO Board ........28 Figure 2-5. Main Program Menu ......................32 Figure 2-6.
  • Page 9 Table 2-2. Resolver Wiring, SmartPAC PRO and WPC 2000 ............. 28 Table 2-3. Communications Wiring, SmartPAC PRO to WPC 2000 ..........29 Table 2-4. Stop and Input Check Wiring SmartPAC PRO to WPC 2000 ..........30 Table 5-1. Instructions for Entering and Exiting Run Mode ..............73 Table 6-1.
  • Page 11 SmartPAC PRO – WPC 2000 integration. Chapter 5– Run shows you how operate the SmartPAC PRO – WPC 2000 integration. The wiring diagrams at the end of the manual show connections for the SmartPAC PRO – WPC 2000 integration. NOTICE Download Wintriss product documents for the SmartPAC PRO and WPC 2000 integration, at www.wintrissdocs.com...
  • Page 13 SmartPAC PRO - WPC 2000 Integration Manual 1143100 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 15 90 days from date of shipment. Wintriss’s obligations under this warranty are limited to repairing or replacing, at its discretion and at its factory or facility, any...

  • Page 17: Chapter 1 - Introduction To Smartpac Pro With Wpc 2000 Integration

    Clutch/Brake control, bringing a multitude of press automation functions to one central location. This manual gives you the information specific to the integration of SmartPAC PRO with WPC 2000. Most of the information you need to install and use the integrated system is in the following manuals: SmartPAC PRO Installation Manual •...

  • Page 18: Figure 1-1. Installation Overview

    1143300 SmartPAC PRO - WPC 2000 Integration Manual Figure 1-1. Installation Overview Chapter 1– Introduction to SmartPAC PRO with WPC 2000 Integration...

  • Page 19: Chapter 2 - Installation

    Chapter 2 – Installation Use This Manual Along with Your SmartPAC PRO and WPC 2000 Manuals ......22 Install your SmartPAC PRO According to the SmartPAC PRO Installation Manual ....22 Install Your WPC 2000 According to WPC 2000 Installation Manual ......... 22 Installing the Optional Flywheel Speed Sensor ....................
  • Page 20 1143300 SmartPAC PRO - WPC 2000 Integration Manual 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 21 NOTICE OPTIONAL MODULES PROCAMPAC AND DIPROPAC INCLUDED IN MANUAL When you order your SmartPAC PRO 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 22: Use This Manual Along With Your Smartpac Pro And Wpc 2000 Manuals

    See your SmartPAC PRO User Manual and Installation Manual. On the bench, see your SmartPAC PRO Installation Manual to connect your unit to a resolver and to AC power so that you can access all the menus and make settings.

  • Page 23: Installing The Optional Flywheel Speed Sensor

    A sensor mounted on a bracket with wiring for connection to the WPC 2000 Main Processor • board (Wintriss part numbers: 9610201 with 30 ft cable, 9610204 with 100 ft cable) Two magnets, one red, the other blue, for attachment to the flywheel •...

  • Page 24: Figure 2-1 . Installing The Lmcs And Magnets

    Table 2-1. Flywheel Speed Sensor Wiring Connections WPC 2000 Main Processor Bd. LMCS Wire Color Pin # White Black 6. Double-check wiring connections. Now, proceed to the next section in this manual, Wiring between WPC 2000 and SmartPAC PRO. Chapter 2 – Installation...

  • Page 25: Wiring Between Wpc 2000 And Smartpac Pro

    (such as AC, stop circuit, and input check circuit wiring). Refer to Figure 2-2 on page 25, Figure 2-3 on page 26, and wiring diagrams Figure 1 or Figure 2 at the end of this manual when making wiring connections. Figure 2-2. SmartPAC PRO Board with Terminal Block Locations Chapter 2 – Installation...

  • Page 26: Figure 2-3. Wpc 2000 Main Processor Board: Location Of Important Components

    1143300 SmartPAC PRO - WPC 2000 Integration Manual 10 3 1 02 10 1 1 00 +5V B processor TB 105 DS151 Power Light curtain A TB 303 TB 302 TB 301 TB 402 TB 401 + 24V I/O test mode...

  • Page 27: Connecting The Resolver Wiring Between Smartpac Pro And Wpc 2000

    Plug the connector back into TB1 when you are done. 5. Double-check connections when you are finished wiring. 6. Locate jumper JP101 on the SmartPAC PRO board (see Figure 2-4, page 28) and move it to the “Slave” position. Chapter 2 – Installation...

  • Page 28: Figure 2-4. Location Of The Master-Slave Jumper On Smartpac Pro Board

    Black 106 (S3) 217 (R2) Orange 105 (R2) 218 (S4) Brown 104 (S4) Terminate the cable shields to the ground stud nearest the cable entry. Figure 2-4. Location of the Master-Slave Jumper on SmartPAC PRO Board Chapter 2 – Installation...

  • Page 29: Connecting Communications Wiring

    NEMA 12 protection. 2. Locate connector TB4 on the SmartPAC PRO board (see Figure 2-2 page 25) and unplug it from its socket. Connect the wires for stop and input check circuits to TB4 pin locations, as shown in Table 2-4, below, and wiring diagrams Figure 1 or Figure 2 at the end of the manual.

  • Page 30: Setting The Input Check Voltage Switch

    Be sure to number all wires in a way consistent with your press’s electrical prints. Setting the Input Check Voltage Switch See your SmartPAC PRO Installation Manual for how to set the input check voltage switch. Chapter 2 – Installation...

  • Page 31: Setting Up Smartpac Pro With Wpc 2000

    If “PRESS CONTROL” appears in the menu and you have the DiProPAC and/or • ProCamPAC option(s), go to Verifying Installation of DiProPAC and ProCamPAC in your SmartPAC PRO Installation Manual. If you don’t have one of these options, go to Creating a New Tool Setup, page 37. Chapter 2 – Installation...

  • Page 32: Problems At Startup

    Figure 2-5. Main Program Menu NOTICE • If an error message displays when the SmartPAC PRO starts up, make note of the message before pressing EXIT or OK. • If the error message continues to appear after you press EXIT or OK, find the message in SmartPAC PRO Fault Messages in your SmartPAC PRO Installation Manual and follow the instructions for correcting the problem.

  • Page 33: Figure 2-6. Smartpac Pro Board, Rx And Tx Leds

    Figure 2-6. SmartPAC PRO board, Rx and Tx LEDs 2. Leaving power on, open the door of the SmartPAC PRO enclosure, and check the state of the WPC LEDS labelled Rx (DS24) and Tx (DS23) on the SmartPAC PRO board, Figure 2-6, above.

  • Page 34: Verifying The Installation Of Dipropac And Procampac

    SmartPAC PRO with WPC 2000 or install new WPC 2000 firmware. When you first set up your SmartPAC PRO with WPC 2000 or when you install new WPC 2000 firmware, initialize press parameters on the Press Control Parameter Menu (see the sections below for instructions).

  • Page 35: Figure 2-7. Main Program Menu

    SmartPAC PRO - WPC 2000 Integration Manual 1143300 NOTICE TO EXIT INITIALIZATION MODE Press EXIT repeatedly to enter Program mode. Turn the PROG/RUN keyswitch to RUN to enter Run Mode. Figure 2-7. Main Program Menu 1. Enter Initialization Mode by pressing INITIALIZATION MENU on the Main Program Menu screen.

  • Page 36: Figure 2-9. Initialize Smartpac System Screen

    1143300 SmartPAC PRO - WPC 2000 Integration Manual 2. Press System Init. The Initialize SmartPAC System screen appears. Figure 2-9. Initialize SmartPAC System Screen 3. Press Reset Initialization Data. The Modules to Initialize box appears (Figure 2-10). Figure 2-10. Modules to Initialize, Select Module 4.

  • Page 37: Creating A New Tool Setup

    6. Read the warning and press OK to initialize all the press control parameters. When initialization is complete, the Main Initialization Menu screen appears. Creating a New Tool Setup Follow the instructions in your SmartPAC PRO Installation Manual to create a test tool. Chapter 2 – Installation...

  • Page 38: Performing Brake Monitor Tests And Making Settings

    1143300 SmartPAC PRO - WPC 2000 Integration Manual Performing Brake Monitor Tests and Making Settings Refer to your WPC 2000 manual for Running Brake Monitor Tests and Making Settings • • Determining the Stopping Time of Your Press • Calculating the Stop-time Limit Setting the Stop-time Limit •...

  • Page 39: Installation Verification (Wpc 2000 Manual)

    For details, See Operating the Press in Inch Mode in your WPC 2000 manual. Perform the tests needed to verify that your SmartPAC PRO - WPC 2000 integration is installed and set up correctly. These tests must be performed before you proceed to Initialization procedures (Chapter 5 in your SmartPAC PRO manual, Chapter 3 in this manual).
  • Page 40 1143300 SmartPAC PRO - WPC 2000 Integration Manual attempt to replace any components in your new WPC 2000 unless instructed to by Wintriss Tech. Support. In order to run the tests, you need to know how to operate the press in Inch, Single-stroke, and Continuous modes using Two-hand, One-hand, or Foot control.

  • Page 41: Figure 2-13. Led Map, Wpc 2000 Main Processor Board

    SmartPAC PRO - WPC 2000 Integration Manual 1143300 Transmit Receive + 5 Logic A Receive Transmit 2 - Palm switch B N/C 1 - Palm switch A N/C Display bus Serial port 4 - Foot switch N/C 3 - One hand A...
  • Page 42 1143300 SmartPAC PRO - WPC 2000 Integration Manual Chapter 2 – Installation...

  • Page 43: Chapter 3 - Initialization

    SmartPAC PRO with WPC 2000 or install new WPC 2000 firmware. When you first set up your SmartPAC PRO with WPC 2000 or when you install new WPC 2000 firmware, initialize press parameters on the Press Control Parameter Menu, as shown below.

  • Page 44: Making Press Control Settings In Initialization Mode

    1143300 SmartPAC PRO - WPC 2000 Integration Manual NOTICE TO EXIT INITIALIZATION MODE • Press EXIT repeatedly to enter Program mode. • Turn the PROG/RUN keyswitch to RUN to enter Run Mode. Making Press Control Settings in Initialization mode The PRESS CONTROL item on the Main Initialization Menu gives you access to the WPC Initialization Menu (see Figure 3-3), which allows you to make settings specific to the WPC 2000 clutch/brake control.

  • Page 45: Figure 3-2. Main Initialization Menu

    SmartPAC PRO - WPC 2000 Integration Manual 1143300 Figure 3-2. Main Initialization Menu 2. If PRESS CONTROL does not appear on the screen, press the More and Back buttons to show it. 3. Press PRESS CONTROL. The WPC Initialization Menu appears.

  • Page 46: User Interlocks

    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 PRO 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 47: Figure 3-4. Wpc Initialization Menu

    See the Option 2 User Manual for details. If you are interested in this product, contact your local Wintriss representative or call Wintriss Tech. Support. To set the stop type and input name for each of the user inputs, do the following: Figure 3-4.

  • Page 48: Figure 3-5. Press Control User Interlock Menu

    1143300 SmartPAC PRO - WPC 2000 Integration Manual Figure 3-5. Press Control User Interlock Menu 2. Highlight the stop type for the input you want to program. Press ENTER to change the stop type. User Inputs 1 – 7 can be set to UNUSED, T STOP, E STOP or E LOC. Crosschecked pair 8/9 can be set to E STOP or E LOC, cross-checked pair 10/11 to E LOC only.

  • Page 49: Figure 3-7. Smartpac Pro On-Screen Keyboard

    SmartPAC PRO - WPC 2000 Integration Manual 1143300 NOTICE The name you enter for input 8 is applied to both inputs 8 and 9 in the cross-checked pair. The name you enter for input 10 is applied to both cross-checked inputs 10 and 11. Once you have established names for inputs 8 and 10, any name you attempt to enter for input 9 or 11 will be disregarded.

  • Page 50: Press Parameters

    1143300 SmartPAC PRO - WPC 2000 Integration Manual PRESS PARAMETERS Figure 3-8. WPC Initialization Menu Figure 3-9. Press Control Parameter Menu The Press Parameters item on the WPC Initialization Menu gives you access to the Press Control Parameter Menu, above, on which you can make the following WPC 2000 settings: Setting the Top-stop Angle, page 51 •...

  • Page 51: Setting The Top-Stop Angle

    SmartPAC PRO - WPC 2000 Integration Manual 1143300 Setting the Stop-time Limit and Start-time Limit, page 54 • Setting the Shutdown Time (Optional), page 54 • Setting Flywheel Timer (Optional Hardware Required), page 55 • • Setting the ACTS Angle (Optional), page 55 Selecting Pressure Units, page 55 •...

  • Page 52: Setting The Auto Carry-Up Angle

    1143300 SmartPAC PRO - WPC 2000 Integration Manual Setting the Auto Carry-up Angle NOTICE For a variable-speed press, you need to determine the latest Top-stop Angle, which is the angle at which the press top-stops at its slowest speed and with the shortest stopping angle/time.

  • Page 53: Setting Micro-Inch Time And Angle

    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 PRO screen (see Chapter 5, Troubleshooting, in your WPC 2000 manual).

  • Page 54: Setting The Stop-Time Limit And Start-Time Limit

    DSV is not re-energized after the specified length of time. A fault code F10 appears on the SmartPAC PRO display when the press has been stopped. You can set the Shutdown Time to any value between 0 and 100 minutes.

  • Page 55: Setting Flywheel Timer (Optional Hardware Required)

    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 PRO 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 56: Input Status

    1143300 SmartPAC PRO - WPC 2000 Integration Manual With the highlight bar on the current PRESSURE UNIT setting, press ENTER until the option you want is displayed. Note that the units in which the MAIN AIR LIMIT and CNTRBAL +/- settings are displayed change to the units you selected.

  • Page 57: Buttons/Switches

    Manual. NOTICE The TRANSDUCERS button opens a calibration screen required when using pressure transducers not supplied by Wintriss. Refer to the on-screen Help, or contact Wintriss Technical Support if you wish to use non-Wintriss pressure sensors. BUTTONS/SWITCHES Press BUTTONS/SWITCHES to see the WPC Buttons and Switches Input Status screen, Figure 3-13.

  • Page 58: Estops/Top Stops

    1143300 SmartPAC PRO - WPC 2000 Integration Manual ESTOPS/TOP STOPS To see the E-Stop and Top Stop input status, press ESTOPS/TOP STOPS in the Display WPC Input Status screen. Figure 3-14. E-Stops and Top Stops Status Screen INTERLOCKS To see Interlocks status, press INTERLOCKS in the Display WPC Input Status screen.

  • Page 59: Transducers

    SmartPAC PRO - WPC 2000 Integration Manual 1143300 TRANSDUCERS To see the status of the Transducers, press TRANSDUCERS in the Display WPC Input Status screen. Figure 3-16. WPC Transducer Input Status LUBE CONTROL I/O STATUS In the Display WPC Input Status screen, press LUBE CONTROL I/O STATUS.

  • Page 60: Press Options

    1143300 SmartPAC PRO - WPC 2000 Integration Manual PRESS OPTIONS The Press Options item on the WPC Initialization Menu, below, gives you access to the Press Control Option Switch Menu. Figure 3-18. WPC Initialization Menu Figure 3-19. Press Control Option Switch Menu...

  • Page 61: Making Settings For Option Switches

    SmartPAC PRO - WPC 2000 Integration Manual 1143300 Making Settings for Option Switches NOTICE CYCLE POWER AFTER CHANGING OPTION SWITCH SETTINGS Whenever you change an option switch setting, you must power down the WPC 2000 and power it back up again in order to enable the new setting. If you do not cycle power, the previous switch setting will remain in effect.

  • Page 62: Making Operator Mode Settings

    1143300 SmartPAC PRO - WPC 2000 Integration Manual Figure 3-21. Press Control Option Switch Menu – Showing Default Settings You can set the switches to OPEN or CLOSED. To set a switch, do the following: 1. On the Press Control Option Switch Menu, use the Up () and Down (  ) cursor keys to select the switch you want to set.

  • Page 63: Dual Operators

    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). Figure 3-22. WPC Initialization Menu – Dual Operators Screen Mode...

  • Page 64: Automatic Mode

    1143300 SmartPAC PRO - WPC 2000 Integration Manual Automatic Mode With this item you can enable Automatic Single-stroke or Automatic Continuous On-demand operating mode if you have installed one of these options. Refer to wiring instructions in your WPC 2000 manual. For operating procedures, refer to pages 90 and 93 in this manual.

  • Page 65: Two Hand Only

    SmartPAC PRO - WPC 2000 Integration Manual 1143300 Two Hand Only NOTICE One-hand/Two-hand/Foot firmware must be installed in order for this setting to be functional. Do not set this item if you are running standard firmware. With this item (see Figure 3-24) you can make One-hand and Foot operating modes unavailable if you are running One-hand/Two-hand/Foot firmware.

  • Page 66: Additional Security

    Wiring an Optional 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 PRO. For more information, refer to Additional Security, page 66.

  • Page 67: Chapter 4 - Program

    Figure 4-1. Main Program Menu Follow the instructions in your SmartPAC PRO User Manual for most programming operations. The instructions below cover programming operations that apply to your SmartPAC PRO – WPC 2000 integration. Refer to your SmartPAC PRO User Manual for other programming operations.

  • Page 68: Press Control

    1143300 SmartPAC PRO - WPC 2000 Integration Manual PRESS CONTROL (PROGRAM –TOOL MANAGER – select tool –EDIT TOOL – PRESS CONTROL) NOTICE For help with any screen, press in the upper left-hand corner. 1. In Program mode, press TOOL MANAGER. The Tool Manager screen appears.

  • Page 69: Smartpac Pro - Wpc 2000 Integration Manual

    SmartPAC PRO - WPC 2000 Integration Manual 1143300 3. Press PRESS CONTROL. The Press Control Parameters screen appears. This screen allows you to program the following for the selected tool: Top-stop angle • Max. press speed • Min. press speed •...

  • Page 70: Setting Top Stop Angle For The Selected Tool

    1143300 SmartPAC PRO - WPC 2000 Integration Manual Setting Top Stop Angle for the Selected Tool The top-stop angle is the crankshaft angle at which the Top-stop command is given on your press. This value is set by default to the Initialization Top Stop Default setting (see Setting the Top-stop Angle, page 51).

  • Page 71: Setting Maximum And Minimum Press Speed For The Selected Tool

    They apply to all Run operating modes–Continuous, Single-stroke, and Inch. When the speed of the press exceeds the maximum limit, SmartPAC PRO stops the press and displays the fault message “Maximum press speed exceeded.” When the speed of the press drops below the minimum limit, SmartPAC PRO stops the press and displays the fault message “Minimum...

  • Page 72: Setting Counterbalance Setpoint For The Selected Tool

    2. Key in the desired Counterbalance Setpoint for the tool. 3. Press ENTER. The Press Control Parameters screen appears with this tool’s new value for Counterbalance Setpoint. Refer to your SmartPAC PRO User Manual for other programming operations. Chapter 4 – Program...

  • Page 73: Chapter 5 - Run

    To go to Program mode: Turn the Program/Run key to RUN.* Turn the Program/Run key to PROG.* * If you turn the key and nothing happens, Press EXIT repeatedly until SmartPAC PRO changes modes. SmartPAC PRO - WPC 2000 Integration Manual 1143300...

  • Page 74: Settings Locked, Or Password Required

    When a Run mode setting is locked, the screen shown in Figure 5-2 displays if the PASSWORD REQUIRED is set for that item on the Security Access Menu in Initialization (see SECURITY ACCESS, in Chapter 3 of your SmartPAC PRO manual). Figure 5-2. Enter Password Screen Enter the correct password and press ENTER.

  • Page 75: Loading A Tool

    1143300 Loading a Tool See Loading a Tool in your SmartPAC PRO User Manual, Chapter 5. A tool must be loaded before SmartPAC PRO will allow the press to run. If you attempt to switch from Initialization or Program mode to Run mode with no tool loaded, the error message below appears.

  • Page 76: Show Overrun Angles

    1143300 SmartPAC PRO - WPC 2000 Integration Manual 7. Turn the Program/Run key to RUN. SmartPAC PRO switches to Run mode. Figure 5-5. Tool Screen Show Overrun Angles In the Tool Screen, press SHOW OVERRUN ANGLES. A small window opens showing the overrun angles.

  • Page 77: Brake Monitor

    Failure to comply with these instructions will result in death or serious injury. Determining the Stopping Time of Your Press See Determining the Stopping Time of Your Press in your SmartPAC PRO User Manual, Chapter 5. Performing the 90° Stop-time Test See Performing the 90°...

  • Page 78: Adjusting Program Settings

    Initialization (see Setting Clutch and Counterbalance Air Pressure Limits, page 53) to specify the pressure range outside of which an F46 (Counterbalance Air Outside Sensor Limits) error displays on the SmartPAC PRO. This field does not display if the Initialization tolerance value is set to zero (0), disabling the Counterbalance Setpoint feature.

  • Page 79: Figure 5-8. Main Run Menu

    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. See SECURITY ACCESS, in Chapter 3 of your SmartPAC PRO manual. Chapter 5 – Run...

  • Page 80: Figure 5-10. Numeric Entry Window

    If the press speed exceeds the maximum or goes below the minimum, an error message appears similar to Figure 5-11, below. This error is described in your SmartPAC PRO Installation Manual under Miscellaneous Fault Messages and in your SmartPAC PRO User Manual in Chapter 6.

  • Page 81: Displaying Overrun Sensor On/Off Angles

    SmartPAC PRO - WPC 2000 Integration Manual 1143300 Figure 5-11. Maximum Press Speed Exceeded Error Message Displaying Overrun Sensor On/Off Angles You can display the angles at which the overrun sensor turns on and off, in order to verify that you have installed the overrun sensor magnet correctly.

  • Page 82: Operating The Press

    Select Inch, Single-stroke, or Continuous operation with the Stroke Select key switch on the SmartPAC PRO front panel. To choose an operating mode for one of these stroke selections, go to the Mode Select Menu (Figure 5-13), which you access by turning the Stroke Select switch to OFF with SmartPAC PRO in Run mode.

  • Page 83: Operating The Press In Inch Mode

    SmartPAC PRO - WPC 2000 Integration Manual 1143300 2. Press to enable the desired operating mode: • MICRO-INCH • ONE-HAND MODE TWO-HAND MODE • FOOT MODE • • AUTOMATIC MODE 3. Turn the Stroke Select switch the desired setting (i.e., Inch, Single-stroke, or Continuous).

  • Page 84: Top-Stop In Inch

    1143300 SmartPAC PRO - WPC 2000 Integration 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 following: 1.

  • Page 85: Dead Motor Inch

    SmartPAC PRO - WPC 2000 Integration Manual 1143300 When that time has elapsed, the ram comes to a stop even though the Run/Inch palm buttons are still depressed. The ram can be stopped before the end of the Micro-inch time by releasing one or both Run/ Inch buttons.

  • Page 86: Single-Stroke, Two-Hand Operation

    1143300 SmartPAC PRO - WPC 2000 Integration Manual Instructions for operating the press in each Single-stroke mode are provided below. Single-stroke, Two-hand Operation OPERATOR STATION WIRED INCORRECTLY Run all necessary tests to verify that each Operator Station is wired correctly and provides proper anti-tie-down and anti-repeat protection.

  • Page 87: Single-Stroke, One-Hand Operation

    • Follow all applicable OSHA and ANSI regulations when installing a One-hand Control. • Ensure that proper safeguarding devices are installed and working properly. Wintriss takes no responsibility if safeguarding devices are not installed or working correctly.
  • Page 88 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. 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 89: Single-Stroke, Foot Operation

    8 seconds of removing your hand. NOTICE If the press does not run, turn off power to the press and WPC 2000. Recheck all wiring connections. Try One-hand Control again. If the press still does not run, call Wintriss Tech. Support. Single-stroke, Foot Operation...

  • Page 90: Operating The Press In Automatic Single-Stroke Mode

    Auto Carry-up Angle, the press will stop, the “Interrupted Stroke” message will flash on the SmartPAC PRO display, and WPC 2000 will switch to Two-hand Maintained Single-stroke mode for the remainder of the stroke. To clear the “Interrupted Stroke” message and return to Single- stroke, Foot operation, press both Run/Inch palm buttons on the Operator Station and hold them until the press returns to Top-stop.

  • Page 91: Operating The Press In Continuous Mode

    SmartPAC PRO - WPC 2000 Integration Manual 1143300 1. Set option switch 5 on the Press Control Option Switch Menu to OPEN to select 30 seconds as the prior act timing or to CLOSED to select 5 minutes (see Making Settings for Option Switches, page 61 and Switch 5 –...

  • Page 92: Continuous, Foot Operation

    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 PRO 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 93: Operating The Press In Automatic Continuous On-Demand Mode

    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 PRO 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 94: Multiple Operator Stations

    When barring the press, do not rotate the flywheel too quickly. If the crankshaft moves faster than 6 SPM, WPC 2000 will stop the ram and fault code F26 will appear on the SmartPAC PRO display. Press RESET or EXIT to continue barring the press. See your WPC 2000 manual for details about this fault code.
  • Page 95 WPC 2000 to enable either the first station, the second station, or both stations. For Fault Message information, see Chapter 6 SmartPAC PRO Fault Messages in your SmartPAC PRO User Manual • SmartPAC PRO Fault Messages in your SmartPAC PRO Installation Manual.
  • Page 96 1143300 SmartPAC PRO - WPC 2000 Integration Manual Chapter 5 – Run...

  • Page 97: Chapter 6 - Fault Messages

    • Ensure that all safety procedures are followed during installation, operation, and repair of SmartPAC PRO and WPC 2000. • Ensure that SmartPAC PRO 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 98: Responding To Fault Messages

    • If your SmartPAC PRO is networked, you can e-mail files directly from the control. See your SmartPAC PRO user manual. • If your SmartPAC PRO is not networked, you can load the files onto a USB disk (see your SmartPAC PRO user manual.), take them to a networked computer, and e-mail them.

  • Page 99: Lockout Message

    Certain press control faults, called Lockout faults, generate the message “PRESS CONTROL IS IN LOCKOUT MODE” on the SmartPAC PRO 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 100: 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 PRO display. Most of these faults include a three-character alphanumeric code (see Figure 6-3 for an example).

  • Page 101: Smartpac Pro - Wpc 2000 Integration Manual

    1. Correct the problem that caused the fault. 2. Clear the fault code or message on the SmartPAC PRO display by doing one of the following: To clear F and H faults, press RESET or EXIT on the display or a Remote Reset switch if one •...

  • Page 102: Resolver Faults

    (see Wiring the Resolver in your SmartPAC PRO User Manual, Chapter 2). If wiring is not the problem, the resolver is probably bad and will have to be replaced. If necessary, contact Wintriss Tech.

  • Page 103: Operational Faults

    (see Wiring the Lockout Relay in Chapter 2 of your WPC manual) and specified a shutdown time on the Press Control Parameter Menu in SmartPAC PRO Initialization (see page 50).
  • Page 104 Remedy: Press RESET or EXIT. If the problem persists, check the wiring from the Operator Station to WPC 2000. If necessary, Contact Wintriss Tech. Support. The Top Stop button on the Operator Station was depressed or the Top-stop Problem: circuit was open after initiation of the stroke.
  • Page 105 Failure to comply with these instructions will result in death or serious injury. Remedy: Press RESET or EXIT. If the problem persists, contact Wintriss Tech. Support for assistance or replacement of the relay board, Chapter 6 – Fault Messages...
  • Page 106 Remedy: Check to make sure that the palm buttons are the correct switch type. Check and 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 107 SmartPAC PRO - WPC 2000 Integration Manual 1143300 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. Remedy: Press only one Run/Inch palm button when running the press in One-hand mode Select both Operator Stations in a dual-Operator-Station setup, then initiate a stroke.
  • Page 108 1143300 SmartPAC PRO - WPC 2000 Integration Manual Problem: E-stops inputs were in different states (i.e., open or closed) for longer than 100 mS. Remedy: Check the E-stop circuit wiring and the E-stop buttons. The flywheel was still in motion when the motor was started in the opposite Problem: direction or Bar mode was selected.

  • Page 109: Inter-Processor Failures

    Second processor did not receive Power-up information correctly Second processor did not receive Mode information correctly Remedy: Try pressing RESET or EXIT. If error persists, contact Wintriss Tech. Support. Input Buffer Test Failures F41* through F44* The following errors may occur when WPC 2000 performs input buffer tests,...

  • Page 110: Air Pressure Limits Exceeded

    SmartPAC PRO - WPC 2000 Integration Manual Air Pressure Limits Exceeded F45 or H45 Problem: Clutch Air Pressure is below the setpoint established in SmartPAC PRO Initialization. Remedy: Check your Clutch Air Pressure level. You may need to adjust the Main Air Limit setting (see Setting Clutch and Counterbalance Air Pressure Limits, page 53).

  • Page 111: Customized Status Codes

    SmartPAC PRO - WPC 2000 Integration Manual 1143300 Correct the problem, then press RESET or EXIT. If the error persists, contact Remedy: Wintriss Tech. Support. For F47 errors, try resetting the unit by pressing RESET or EXIT and turning the Stroke Select key switch to OFF, then back to one of the other operating modes.

  • Page 112: Table 6-2. Fault Codes For User Inputs

    * 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 PRO firmware version 3.32 or higher and WPC 2000 firmware version 1.70 or higher, an additional stop type option,...

  • Page 113: Light Curtain Faults

    8 and 9 (see Table 6-2). One or both inputs are open. Remedy: Diagnose and correct the condition that the inputs are monitoring. If the error persists after you reset the unit, contact Wintriss Tech. Support. Light Curtain Faults F60 or H60...

  • Page 114: Emergency-Stop Circuit Driver Failure

    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, in Chapter 2 of your WPC manual. Contact Wintriss Tech. Support for help in selecting the right firmware for your application.

  • Page 115: Top-Stop Circuit Driver Failure

    The Top-stop input circuit driver has failed or is about to fail. Check Top-stop circuit wiring, and correct any problems. If the error persists after Remedy: you reset the unit, contact Wintriss Tech. Support for assistance or replacement of the driver. Shadow Light Curtain Input Faults...

  • Page 116: 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). Remedy: Press RESET or EXIT. If the error persists, contact Wintriss Tech. Support for assistance or replacement of either board. Chapter 6 – Fault Messages...

  • Page 117: Loss Of Rotation

    F82 or H82 Problem: There is an internal problem with the WPC 2000 timing inputs. Remedy: Press RESET or EXIT. If the error persists, contact Wintriss Tech. Support for assistance or replacement of the timing inputs. Chapter 6 – Fault Messages...

  • Page 118: Top-Stop And Overrun Setting Faults

    1143300 SmartPAC PRO - WPC 2000 Integration Manual Top-stop and Overrun Setting Faults F81, F83, F84, F86 and F87 - and - H81, H83, H84, H86 and H87 The overrun limit switch has turned on before the Top-stop “On” Angle timing has Problem: turned off.

  • Page 119: Overrun Limit Switch Test Angle Fault

    Set switches 1 and 2 for the correct Top-stop “On” Angle window, referring to Remedy: the table under Installing the Overrun Sensor Magnet in Chapter 2 of your WPC manual. If the error persists, contact Wintriss Tech. Support. Chapter 6 – Fault Messages...

  • Page 120: Internal Memory Failures

    F99 or H99 +24 Vdc failed, or the fuse blew Remedy: Press RESET or EXIT. If the error persists, contact Wintriss Tech. Support for assistance or replacement of the Main Processor board or firmware chip. NOTICE INFORMATION ON ERROR NUMBERS EQUAL TO OR GREATER THAN 120 Error numbers equal to or greater than 120 are covered in the WPC 2000 Option 2 Manual (1130700) and the WPC 2000 Option 2 Additional Inputs Only Instruction Sheet (1141900).

  • Page 121: Counter Preset Reached Messages

    SmartPAC PRO - WPC 2000 Integration Manual 1143300 Counter Preset Reached Messages “Good parts counter preset reached” Problem: The value set for the parts counter has been reached. The press should stop at top dead center. Remedy: Press RESET or EXIT to clear the message. If your part run is complete, you need to change tooling, material, etc.

  • Page 122: Messages For Equipment Or Brake Monitor Problems

    Contact the factory for assistance. NOTICE To clear this fault, you must power down SmartPAC PRO, then power the unit back up. Pressing RESET or EXIT does not work. “Input check circuit failure”...

  • Page 123: E-Stop Errors

    Remedy: Check both stop relay circuits. To reset SmartPAC PRO, turn the unit off, then on again. (You cannot use the RESET or EXIT key to reset this error.) If the error recurs, contact Wintriss Tech.

  • Page 124: Messages For Programming Problems

    Performing the 90° Stop-time Test in Chapter 6 of your SmartPAC PRO User Manual to perform the 90° stop- time test. If you change the limit, you may have to relocate your light curtains and/or two hand controls.

  • Page 125: Messages For Sensor Faults

    If a green or green quick check sensor does not come on during its Ready signal, SmartPAC PRO 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 126: Green Sensor Failure

    1143300 SmartPAC PRO - WPC 2000 Integration Manual “Green sensor failure” Problem: A green or green constant sensor has stayed on from the end of one Ready signal to the beginning of the Ready signal for the next stroke. No stroke angle is shown with this fault.

  • Page 127: Fault Message For Red Sensors: "This N/C Sensor Is Open

    Support. “One of the sensor auto enable counters is greater than 99” Normally, this fault will never occur since SmartPAC PRO does not let you enter Problem: a value greater than 99. However, this message could display if there is an internal problem with SmartPAC PRO.

  • Page 128: Loss Of Communication At Address X

    The Error/Event Log, which you can view in Run mode, is a useful troubleshooting aid. You can use the Error/Event log to help you diagnose the cause of a problem, or you can send the log to Wintriss Tech. Support to help them narrow down probable causes. See ERROR/EVENT LOG in Chapter 6 of your SmartPAC PRO User Manual and Sending E-mail to Wintriss Technical Support, also in Chapter 6 of that manual.

  • Page 129: Resetting Ross Dm2 Dsv Faults

    Figure 6-4. Ross DM2 DSV Showing Reset Button If the fault occurs after the unit has been wired, an F47 error will appear on the SmartPAC PRO display. To clear the fault and reset the DSV, press RESET or EXIT and turn the Stroke Select key switch to OFF, then to one of the other operating modes (see page 110).
  • Page 130 1143300 SmartPAC PRO - WPC 2000 Integration Manual Chapter 6 – Fault Messages...

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