Wintriss SmartPAC PRO Servo User Manual
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Wintriss SmartPAC PRO Servo User Manual

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Smartpacprologo
®
Wintriss Press Automation Control
1147100
Rev. A
April 2020
®
Wintriss Controls Group, LLC
100 Discovery Way
Unit 110
Acton MA 01720 USA
Phone (800) 586-8324
Fax (978) 263-2048
PRINTED IN USA
Servo
Tech Support Hotline
800-586-8324
8-5 EST
www.wintriss.com
®

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  • Page 1 ® Smartpacprologo Servo ® Wintriss Press Automation Control 1147100 Rev. A April 2020 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...
  • 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

    Checking the Press ......................... 31 Mounting the SmartPAC PRO Servo Control Enclosure .............. 32 Installing SmartPAC PRO Servo as a Panel Mount ..............33 Installing SmartPAC PRO Servo with Remote HMI ..............34 Installing the MTS Linear Transducer ................... 35 Mounting the Transducer ............................
  • Page 6 On-Screen Keyboard ............................67 The “ALT” Menu .......................... 68 Screen Captures ..............................68 Chapter 4 – SmartPAC PRO Servo Initialization Mode ........... 71 POSITION SENSOR ........................73 Position Sensor Mode ............................73 Resolver Motion Mode (Normal Motion – Link Motion) ................73 Angle Wheel Rotation (Clockwise –...
  • Page 7 SmartPAC PRO Servo User Manual 1147100 Chapter 5 – Program Mode ..................... 105 Entering and Exiting Program Mode ................... 106 TOOL MANAGER ........................106 Creating a New Tool ............................107 Copying an Existing Tool..........................108 Copying Tool Template to a New Tool ......................109 Loading a Tool ..............................
  • Page 8 Setup Sheets SmartPAC PRO Servo Setup Sheet ProCamPAC Cam Switch – SmartPAC PRO Servo Setup Sheet Channels 1 – 8 ProCamPAC Cam Switch – SmartPAC PRO Servo Setup Sheet Channels 9 – 15 DiProPAC Die Protection – SmartPAC PRO Servo Setup Form Sensors 1-16 DiProPAC Die Protection –...
  • Page 9 Figure 2-11. Location of Terminal Blocks TB1 to TB8 ............... 41 Figure 2-12. Input Check Voltage Switch (S101) in the Factory Default (60-250V) Position .... 43 Figure 2-13. SmartPAC PRO Servo Board – DiProPAC Board, Right, Outlined in Red ....44 Figure 2-14. ProCamPAC Output Assembly ..................50 Figure 2-15.
  • Page 10 1147100 SmartPAC PRO Servo User Manual Figure 4-3. Position Sensor Screen ...................... 73 Figure 4-4. Installed Options Screen....................75 Figure 4-5. Options Manager Screen ....................75 Figure 4-6. Main Initialization Menu ....................76 Figure 4-7. Preferences Screen ......................76 Figure 4-8. Select Language Screen ....................77 Figure 4-9.Press Name Entry Window ....................
  • Page 11 SmartPAC PRO Servo User Manual 1147100 Figure 5-26. Sensor Type Screen ....................... 129 Figure 5-27. Sensor Stop Type Screen ....................130 Figure 5-28. Critical Angle Programming Screen ................131 Figure 5-29. Ready Signal Programming Screen ................133 Figure 5-30. Green Special Sensor Stroke Count Screen ..............134 Figure 5-31.
  • Page 12 Table 2-2. Stop and Input Check Circuit Wiring Connections: TB4 ........... 42 Table 2-3. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Servo Wiring, Sensors 1-8 ....46 Table 2-4. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Servo Wiring, Sensors 9-16 ....47 Table 2-5.
  • Page 13 SmartPAC PRO Servo operation for individual tools. Chapters 6 shows you how to use SmartPAC PRO Servo in Run mode, which is the mode you select to run the press and make minor adjustments to programmed settings.
  • Page 15 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. WARNING A WARNING symbol indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.
  • Page 17 90 days from date of shipment. Wintriss’s obligations under this warranty are limited to repairing or replacing, at its discretion and at its factory or facility, any products which shall, within the applicable period after shipment, be returned to Wintriss Controls freight prepaid and which are, after examination, disclosed to the satisfaction of Wintriss to be defective.

  • Page 19: Chapter 1 - Introduction

    SmartPAC PRO, which is widely used on standard mechanical presses, SmartPAC PRO Servo tracks the position of the ram using a linear transducer instead of a resolver. “Ram Position” settings for top and bottom linear position (see page 154) determine the stroke length for each tool, which is converted to 0°...

  • Page 20: Smartpac Pro Servo Standard Features

    8 cams (15 cams with the ProCamPAC 15 Linear board option) and for up to 32 sensors if DiProPAC is installed. Because SmartPAC PRO Servo is microprocessor- based, it can monitor or control all these different functions during a press stroke. Additionally, it saves these settings for up to 2000 tools.

  • Page 21: Smartpac Pro Servo Options

    • SmartPAC PRO Servo upgrades and enhancements can be installed quickly and easily. Upgrades can be either downloaded from a Wintriss web site via an email with a link or mailed to you on a USB disk. SmartPAC PRO Servo Options...

  • Page 22: Sensors Available For Dipropac

    SmartPAC PRO Servo, contact Wintriss Controls. Wintriss offers a wide range of sensors. Those that can be used with SmartPAC PRO Servo with DiProPAC are shown below. Detailed application information is available. Many sensors made by other manufacturers can also be used.

  • Page 23: Programmable Cam Channels

    Failure to comply with these instructions will result in death or serious injury. With SmartPAC PRO Servo you received a separate assembly for wiring up to eight cam channels to your equipment. (If you ordered the ProCamPAC 15 Linear option, you received equipment that enables you to wire up to 15 channels.) The assembly contains the relays that open and close on...

  • Page 24: Smartpac Pro Servo Specifications

    1147100 SmartPAC PRO Servo User Manual SmartPAC PRO Servo Specifications Table 1-1. Specifications Main enclosure: 14.1 x 13.1 x 5.3 in (358 x 333 x 134 mm), NEMA 12, Equipment shock mounted. Weight 19.3 lb Panel mount: 13.7 x 12.8 in (348 x 324 mm) MTS linear position transducer: Magnetostrictive;...
  • Page 25 SmartPAC PRO Servo to be downloaded to SFC data collection software for generation of OEE and other reports. Requires purchase of SFC software. 3rd Party Comms This option allows SmartPAC PRO Servo to transmit real-time and status information to external software for reporting and other tasks * Consult product user manual.
  • Page 26 1147100 SmartPAC PRO Servo User Manual Chapter 1– Introduction...

  • Page 27: Chapter 2 - Installation

    NOTICE OPTIONAL DIPROPAC MODULE INCLUDED IN MANUAL When you order your SmartPAC PRO Servo, you may include the DiProPAC die protection option. This manual includes instructions for installing and using this option. Remember that it is an option and might not be included in your system.

  • Page 28: Before You Start

    LEARN TO USE SMARTPAC PRO SERVO BEFORE INSTALLING ON A PRESS If you have not used SmartPAC PRO Servo before, learn how to initialize and program it before installing it on a press. On the bench, wire the linear transducer to SmartPAC PRO Servo (see page 37), connect the transducer to a DC power source (see page 39), and wire AC power (see page 40).
  • Page 29 SmartPAC PRO Servo User Manual 1147100 The AC power supply wires to SmartPAC PRO Servo should be run separately from the DC control wires going to the ProCamPAC Output Assembly. Never use the SmartPAC PRO Servo power terminals as a junction point to provide power for external devices. In most cases, the AC power supply wires should be connected directly to the press control cabinet.

  • Page 30: Figure 2-1. Installation Overview

    1147100 SmartPAC PRO Servo User Manual Figure 2-1. Installation Overview Chapter 2 – Installation...

  • Page 31: Terminating Cable Shields

    NOTICE TERMINATE BOTH ENDS OF SHIELD Be sure to terminate cable shields at both ends (for example, at SmartPAC PRO Servo and DSI 2). For each shielded cable, perform the following steps. 1. Strip the cable jacket back about 3 inches.

  • Page 32: Mounting The Smartpac Pro Servo Control Enclosure

    SmartPAC PRO Servo User Manual Mounting the SmartPAC PRO Servo Control Enclosure NOTICE If your SmartPAC PRO Servo is a panel mount version, for mounting instructions go to the next section, Installing SmartPAC PRO Servo as a Panel Mount, page 33. NOTICE PLACE SMARTPAC PRO SERVO AT A CONVENIENT HEIGHT SmartPAC PRO Servo should be installed at a convenient height for all users.

  • Page 33: Installing Smartpac Pro Servo As A Panel Mount

    Installing SmartPAC PRO Servo as a Panel Mount If you have received the panel-mount configuration of SmartPAC PRO Servo, follow the steps below to install the panel mount in your enclosure. The panel mount is usually installed from the outside of the enclosure.

  • Page 34: Installing Smartpac Pro Servo With Remote Hmi

    1147100 SmartPAC PRO Servo User Manual Figure 2-4. SmartPAC PRO Servo Panel Mount Dimensions Installing SmartPAC PRO Servo with Remote HMI The Remote HMI version of the SmartPAC Pro consists of a panel mount screen with a separate Real Time SmartPAC (RTS) board. This version reduces the amount of wiring to the HMI portion of the SmartPAC PRO.

  • Page 35: Installing The Mts Linear Transducer

    SmartPAC PRO Servo User Manual 1147100 Figure 2-5. Real Time SmartPAC (RTS) Board Mounting Dimensions Installing the MTS Linear Transducer Make sure to install a magnetostrictive linear transducer (see page 21 for a description of transducer operation) that is at least as long as or longer than the sum of the maximum stroke length of your press and the maximum shut-height adjustment.

  • Page 36: Figure 2-6. Mts Linear Transducer Dimensions

    1147100 SmartPAC PRO Servo User Manual 3. Fabricate a bracket that will fit the length of the transducer and its mounting feet. Make sure the bracket mounting holes are elongated or oval-shaped so the transducer can be moved up and down during fine-tuning of the transducer’s mounting position.

  • Page 37: Wiring The Transducer

    1147100 Wiring the Transducer To wire the transducer to the SmartPAC PRO Servo board, perform the following steps: 1. Plug the connector on the transducer cable into the transducer if it is not already connected, twisting the locknut so the connection is tight. The connector plugs into the transducer only one way.

  • Page 38: Figure 2-8. Procampac Linear Boards, Location Of Components

    8-Channel (Left), 15-Channel (Right) 4. Unplug the connector from TB402, and attach transducer wires as shown in Figure 2-9, Table 2-1, and Figure 1. or Figure 2. SmartPAC Pro Servo Press ProCamPAC 15 MTS Transducer Wiring Diagram at the end of the manual.

  • Page 39: Wiring The Transducer To Dc Power

    SmartPAC PRO Servo User Manual 1147100 Figure 2-9. MTS Linear Transducer Pinout Table 2-1. MTS Linear Transducer Wiring Pin # on TB402 Wire Color * ProCamPAC Linear Board Shield Terminate shield drain wire at the ProCamPAC board under a screw in one of the standoffs.

  • Page 40: Connecting Power Wiring - Ac Powered Units

    75° C temperature rating is recommended for these circuits. Bring the conduit into the top right knockout of the SmartPAC PRO Servo enclosure. Then, to wire the AC input terminal block, follow these steps: 1.

  • Page 41: Connecting Power Wiring - 24 Vdc Powered Units

    Connecting Stop Circuits and Input Check Circuit You need four wires to connect SmartPAC PRO Servo to your press control stop circuits, two for the emergency-stop circuit and two for the top-stop circuit. You can wire these circuits at your press control.

  • Page 42: Making Wiring Connections

    To set voltage for the input check circuit, do the following: 1. Find the input check voltage switch, S101, on the SmartPAC PRO Servo board. It is located on the right side of the board just to the left of the E-stop relays.

  • Page 43: Connecting To The Network

    Adding or Upgrading DiProPAC or ProCamPAC ELECTRIC SHOCK HAZARD Turn off and disconnect power from SmartPAC PRO Servo and from the machinery it is connected to before making any wiring connections. This includes power to the machine control and motor.

  • Page 44: Figure 2-13. Smartpac Pro Servo Board Dipropac Board, Right, Outlined In Red

    Eight-, 16-, and 32-channel configurations of the same option are interchangeable. When a board is installed in the correct location, SmartPAC PRO Servo recognizes whether it is an 8-, 16-, or 32- channel version of DiProPAC or an 8- or 16-channel version of ProCamPAC.

  • Page 45: Connecting Dipro Sensor Interface To Smartpac Pro Servo

    5. Wire the connector(s) to the appropriate component(s). For the DiProPAC board, wire the connector(s) to the DiPro Sensor Interface, following the instructions in Connecting DiPro Sensor Interface to SmartPAC PRO Servo, page 45. For the ProCamPAC board, wire the connector(s) to the ProCam Output assembly, following the procedure in Connecting Programmable Cam Channels, page 49.

  • Page 46: Table 2-3. Dipro Sensor Interface (Dsi) 2 To Smartpac Pro Servo Wiring, Sensors 1-8

    NOTICE If there are extra wires in the cable, cut them off close to the end of the cable jacket. Table 2-3. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Servo Wiring, Sensors 1-8 1st DSI 2 (TB2) DiProPAC (TB554)

  • Page 47: Table 2-4. Dipro Sensor Interface (Dsi) 2 To Smartpac Pro Servo Wiring, Sensors 9-16

    SmartPAC PRO Servo User Manual 1147100 Table 2-4. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Servo Wiring, Sensors 9-16 2nd DSI 2 (TB2) DiProPAC (TB554) Wire color* Pin # Pin Designation Pin # Pin Designation Brown SENSOR 1 SENSOR 9...

  • Page 48: Table 2-5. Dipro Sensor Interface (Dsi) 2 To Smartpac Pro Servo Wiring, Sensors 17-24

    1147100 SmartPAC PRO Servo User Manual Table 2-5. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Servo Wiring, Sensors 17-24 3rd DSI 2 (TB2) DiProPAC (TB555) Wire color* Pin # Pin Designation Pin # Pin Designation Brown SENSOR 1 SENSOR 17...

  • Page 49: Connecting Programmable Cam Channels

    Connecting Programmable Cam Channels PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE Use SmartPAC PRO Servo’s programmable cam switch to control auxiliary functions only. The SmartPAC PRO Servo programmable cam capability should never be used to provide timing signals for any safety use including muting of light curtains.

  • Page 50: Figure 2-14. Procampac Output Assembly

    1147100 SmartPAC PRO Servo User Manual enclosure. If you are wiring an 8-channel ProCamPAC Linear, one cable is supplied (for channels 1-8). If you are wiring a 15-channel board, two cables are supplied, one for channels 1 through 8, the other for channels 9 through 15.

  • Page 51: Figure 2-15. Cam Outputs Board

    SmartPAC PRO Servo User Manual 1147100 Figure 2-15. Cam Outputs Board Chapter 2 – Installation...

  • Page 52: Table 2-7. Procampac Linear To Cam Output Assembly Tb301 Wiring, Cams 1-8

    1147100 SmartPAC PRO Servo User Manual Table 2-7. ProCamPAC Linear to Cam Output Assembly TB301 Wiring, Cams 1-8 Wire ProCamPAC Linear 1st Cam Output Board TB451 (Pin #) TB301 (Pin #) CHAS (1) White Relay Pwr (270) A (3)* Black...

  • Page 53: Figure 2-16. Tb302 And Tb 303 For Wiring Relays To Equipment

    “C” and either the N/O or N/C side of the relay. If you connect to N/O, the equipment will be on for the number of degrees set in SmartPAC PRO Servo. 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 PRO Servo to turn it on.

  • Page 54: Figure 2-17. Install Suppressors Across Ac Loads

    1147100 SmartPAC PRO Servo User Manual Table 2-9. Connections to Relays Module How to Connect Type Electro-mechanical Relay One wire to C, one wire to N/O or SPDT N/C, polarity does not matter – to C, + to N/O DC Solid State...

  • Page 55: Wiring Setup Mode Circuit

    Typically, the Setup mode circuit is enabled when Inch mode is selected on your main control. When you inch the press, SmartPAC PRO Servo will not stop the press when a fault condition is detected. The Setup mode terminal can be wired to an extra contact on the Inch switch of your main control, or you can use an external switch to activate the circuit.

  • Page 56: Turning On Power To Smartpac Pro Servo

    SmartPAC PRO Servo changes modes. Before turning the Program/Run key, make sure SmartPAC PRO Servo is in the Main menu for the mode it is in. If it is not, press EXIT or BACK repeatedly until the Main menu appears. Then turn the Program/Run key.

  • Page 57: Verifying Installation Of Dipropac And Procampac

    Power down SmartPAC PRO Servo, and check that the connectors are correctly seated on both ends of the cables between the SmartPAC PRO Servo board and the display. Power up SmartPAC PRO Servo again. If the display remains off, contact Wintriss Tech. Support.

  • Page 58: Final Checkout

    Figure 2-22. Installed Options Screen Final Checkout Before using SmartPAC PRO Servo, you need to make a few test press runs to ensure that your unit is working properly. To perform final checkout, follow these instructions. Do not proceed to the next step or group of steps until the item you are testing checks out.

  • Page 59: Check Stroke Limits

    Test Complete 11. If you get to this step, SmartPAC PRO Servo is working correctly. Clear any error messages by pressing RESET, then delete the test tool. You can now create a tool in SmartPAC PRO Servo, program settings for it, load it, and begin to make parts using your new SmartPAC PRO Servo.

  • Page 60: What Next

    SmartPAC PRO Servo User Manual What Next? To program and use your SmartPAC PRO Servo, follow the instructions in the remaining chapters of this manual. Go to Chapter 4 to make Initialization settings for your SmartPAC PRO Servo. Wiring Tables for SmartPAC PRO Servo Options Table 2-10.

  • Page 61: Table 2-12. Special Port And Aux (Tb7) Wiring

    SmartPAC PRO Servo User Manual 1147100 Table 2-12. Special Port and AUX (TB7) Wiring Function Pin # Signal +RXD3 –RXD3 TXD3 SPECIAL PORT +TXD3 –TXD3 +RXD4 –RXD4 TXD4 +TXD4 –TXD4 Table 2-13. WPC Port and Spare 1 Port (TB8) Wiring...

  • Page 62: Table 2-14. Stop And Input Check Circuit (Tb4) Wiring

    1147100 SmartPAC PRO Servo User Manual Table 2-14. Stop and Input Check Circuit (TB4) Wiring Pin # Signal Input check A Input check B E-stop E-stop Top-stop Top-stop Chapter 2 – Installation...

  • Page 63: Chapter 3 - Displays And Operating Modes

    PRO Servo front panel, Figure 3-1. It is a good idea to learn how to use SmartPAC PRO Servo before you install it. Set up the unit on a bench and wire a power cord and a position transducer to it. Then, try making settings on the displays.

  • Page 64: Smartpac Pro Operating Modes

    Initialization Mode (Chapter 4) Program Mode (Chapter 5) Run Mode (Chapter 6) Figure 3-2. SmartPAC PRO Servo Operating Modes, Showing Main Menus Chapter 3 – Displays and Operating Modes...

  • Page 65: Table 3-1. Initialization, Program And Run Modes: Entry And Exit Procedures

    SmartPAC PRO Servo User Manual 1147100 Table 3-1. Initialization, Program and Run Modes: Entry and Exit Procedures Mode How to Enter This Mode How to Exit This Mode Initialization Turn the key switch to To switch to Program mode: Make settings that control “PROG”...

  • Page 66: Initialization Mode

    (Settings for individual tools are made in Program mode–see Chapter 5.) Initialization mode is used extensively when you install a new SmartPAC PRO Servo, but you will likely use it only occasionally after SmartPAC PRO Servo is set up and the press is running.

  • Page 67: On-Screen Keyboard

    Whenever you select a field that requires the input of a combination of letters, symbols, and/or numbers, SmartPAC PRO Servo displays its on-screen keyboard, Figure 3-4. The backspace key clears the value. The Cancel key closes the numeric keypad without making any changes, and the Enter key accepts the value entered into the field.

  • Page 68: The "Alt" Menu

    1147100 SmartPAC PRO Servo User Manual Please note that when the on-screen keyboard is displayed, the “EXIT” key and any other buttons on the screen behind the keyboard are disabled. You must enter or cancel the value before you can access any other buttons on the screen.

  • Page 69: Figure 3-5. Save To Usb Disk

    Figure 3-6. USB Disk Error Message The SmartPAC PRO creates a directory on the drive labelled “UploadXXXXXXX” - with the XXXXXXX replaced by the SmartPAC PRO Servo’s serial number. The screen caps are saved in this directory. Chapter 3 – Displays and Operating Modes...
  • Page 70 1147100 SmartPAC PRO Servo User Manual Chapter 3 – Displays and Operating Modes...

  • Page 71: Chapter 4 - Smartpac Pro Servo Initialization Mode

    This chapter shows you how to make settings in SmartPAC PRO Servo Initialization mode. Initialization settings entered via the Main Initialization Menu (Figure 4-1) control operation of SmartPAC PRO Servo for all tools. (You make settings for individual tools in Program mode–see Chapter 5).

  • Page 72: Figure 4-2. Main Initialization Menu, Next Items

    NOTICE SET THE INTERNAL CLOCK IN SMARTPAC PRO SERVO When you initialize your SmartPAC PRO Servo, be sure to set the clock to the correct date and to your local time according to the instructions in SET CLOCK, page 102.

  • Page 73: Position Sensor

    Position Sensor Mode (INITIALIZATION – POSITION SENSOR) SmartPAC PRO Servo does not use a position sensor, and this item is set to “DISABLED” by default. If POSITION SENSOR MODE has been inadvertently set to “ENABLED,” the “Position sensor incorrect” message displays (see page 188 for details). To correct this problem, do the following: 1.

  • Page 74: Counter Setup Mode

    This item allows you to enable or disable counter setup mode if you have made the appropriate wiring connections to make SmartPAC PRO Servo “setup mode ready” (see Wiring Setup Mode Circuit, page 55.) To set this parameter, do the following: 1.

  • Page 75: Installed Options

    1147100 INSTALLED OPTIONS (INITIALIZATION – INSTALLED OPTIONS) This item enables you to view the options that are installed on your SmartPAC PRO Servo (see Figure 4-4), including the number of cam channels and sensors. Figure 4-4. Installed Options Screen (Your screen will look different.) OPTIONS MANAGER (INITIALIZATION –...

  • Page 76: Preferences

    1147100 SmartPAC PRO Servo User Manual To access the Options Manager: in the Initialization menu screen press INSTALLED OPTIONS and on the screen that opens press OPTIONS MANAGER. In the Options Manager you can enable or disable installed options. PREFERENCES (INITIALIZATION –...

  • Page 77: Select Language (Optional)

    If you have ordered the alternate language option, the Installed Options screen provides a Select Language button that allows you to select the language in which you want SmartPAC PRO Servo screens displayed. When you press the Select Language button, the screen shows the available languages.

  • Page 78: Press Name

    PRESS NAME (INITIALIZATION – PRESS NAME) This item enables you to name the press on which SmartPAC PRO Servo is installed. When you select PRESS NAME, the on-screen keyboard appears, allowing you to enter the press name. Figure 4-9.Press Name Entry Window SELECT CAM NAMES (Optional) (INITIALIZATION –...
  • Page 79 SmartPAC PRO Servo User Manual 1147100 Figure 4-10. Cam Channel Name Menu (Your display may look different) 2. Select a channel. The screen shown in Figure 4-11 displays. Figure 4-11. Select Name for Cam Channel Screen 3. Select from the list of names the name that best describes the function of the selected cam channel.

  • Page 80: Set Global Cams (Optional)

    (INITIALIZATION – SET CAM NAMES) PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE Use SmartPAC PRO Servo’s programmable cam switch to control auxiliary functions only. The SmartPAC PRO Servo 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 81 SmartPAC PRO Servo User Manual 1147100 Figure 4-12. Global Cams Menu Asterisk (*) indicates Global Cams. 2. Select the cam you want to program. The Global Cam Timing Type screen displays, Figure 4-13. Figure 4-13. Global Cam Timing Type Screen 3.

  • Page 82: Custom Sensor Names (Optional)

    1147100 SmartPAC PRO Servo User Manual 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 83: Sensor Enable Mode (Optional)

    SmartPAC PRO Servo User Manual 1147100 SENSOR ENABLE MODE (Optional) The SENSOR ENABLE MODE item, which appears on the Main Initialization Menu only when DiProPAC is installed, allows you to select the way in which your die protection sensors are enabled.

  • Page 84: Enabling Setup Mode

    1147100 SmartPAC PRO Servo User Manual Enabling Setup Mode Setup mode allows you to run the press in Inch without incrementing the good parts and batch counters or triggering a fault condition in the green sensors. This mode, as its name indicates, is used during setup.
  • Page 85 SmartPAC PRO Servo User Manual 1147100 Figure 4-16. Linear Sensor Setup Screen Table 4-2 explains the settings displayed on the Linear Sensor Setup screen and, where applicable, provides available options. Chapter 4 – Initialization Mode...

  • Page 86: Table 4-2. Linear Sensor Setup Screen Field Definitions

    1147100 SmartPAC PRO Servo User Manual Table 4-2. Linear Sensor Setup Screen Field Definitions Field Settings SENSOR The smallest change the sensor can detect in its measurement RESOLUTION range. There are three linear sensor resolution options (displayed in micrometers, μm), which are dependent on the length of the sensor: 5 μm...

  • Page 87: Tool Information

    SmartPAC PRO Servo User Manual 1147100 4. Highlight the SENSOR RESOLUTION item. Press ENTER until the setting you want is displayed, referring to Table 4-2 for available options. NOTICE DO NOT enter the OFFSET VALUE field until you have set the Zero Value and Upper Limit.
  • Page 88 1147100 SmartPAC PRO Servo User Manual Program and Run modes (see TOOL INFORMATION, page 5-48 and TOOL INFORMATION, page 6-20). NOTICE Tool Information screens maintain only information about the tool. They do not control any aspect of press operation. NOTICE This feature is not available if you have the optional PLC interface installed.
  • Page 89 SmartPAC PRO Servo User Manual 1147100 Figure 4-18. Tool Information Name Screen 3. Highlight the name you want, using the cursor keys, and press ENTER. You are returned to the Tool Information Setup screen with the name you selected displayed.

  • Page 90: Table 4-3. Tool Information Setup Screen: Abbreviations For Units

    1147100 SmartPAC PRO Servo User Manual Figure 4-19. Tool Information Units Selection Screen 7. Highlight the abbreviation for the unit you want, using the cursor keys, and press ENTER. (See the table below for an explanation of abbreviations.) You are returned to the Tool Information Setup screen with your units selection displayed.

  • Page 91: Table 4-4. Tool Information Setup Screen: Decimal Places And Formats

    SmartPAC PRO Servo User Manual 1147100 8. If you want to specify a unit that is not in the list, select “CUSTOM.” When the on-screen keyboard displays, key in a unit of up to 6 characters and press Enter. You are returned to the Tool Information Setup screen with the unit you created displayed.

  • Page 92: Security Access

    Figure 4-21. Security Access Menu The SECURITY ACCESS item on the Main Initialization Menu allows you to control user access to SmartPAC PRO Servo operating modes and settings. You set user access on the Security Access Menu, which is shown in Figure 4-21.
  • Page 93 NOTICE 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 in the “Enter General Password” box. Information about accessing menus in Program and Run modes is provided in chapters 5 and 6.

  • Page 94: Table 4-5. Security Access Settings

    1147100 SmartPAC PRO Servo User Manual Table 4-5. 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 DELETE TOOL #...

  • Page 95: Setting 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 PRO Servo in Run mode when the press stops as the result of a malfunction.

  • Page 96: Changing Passwords

    Passwords must be numeric and can be from one to four digits in length. NOTICE DEFAULT PASSWORDS Your SmartPAC PRO Servo comes from the factory with all passwords set to the default password “1234.” If you have upgraded your SmartPAC PRO Servo in the field, your passwords may be different.

  • Page 97: Backup/Restore

    Tools may be backed up to a network drive, or, if you have ordered the USB Backup/Restore option to a USB disk inserted in the SmartPAC PRO Servo USB connector on the front of the unit. This feature also backs up the SmartPAC PRO Servo Initialization parameters. Instructions for backing up tools to a network drive are provided on the Wintriss Web site (http://www.wintriss.com/wcg/automation/smartview/smartview_setup.html).

  • Page 98: Backing Up Tools To A Usb Disk

    (INITIALIZATION – BACKUP/RESTORE) NOTICE You should need to perform a restore only if the SmartPAC PRO Servo tool and Initialization programming has been corrupted or if the SmartPAC PRO Servo board has been replaced. The restore process overwrites programming for all your tools and Initialization setups with the tool and Initialization settings saved during the most recent backup.

  • Page 99: Setup Network

    SmartPAC PRO Servo’s E-mail function allows you to send e-mails to individuals in your SmartPAC PRO Servo network and to other recipients, such as Wintriss Tech. Support, via the Internet. If you plan to use E-mail, do the following to enable this function: 1.

  • Page 100: Smartview Function

    Your entry for the PRESS TYPE item is used by SmartView remote viewing to select the graphic it uses to illustrate the type of press (i.e., straight side or gap frame) on which SmartPAC PRO Servo is installed. This graphic appears in the press information summary on the SmartView Main Page.

  • Page 101: Diagnostics

    (INITIALIZATION – DIAGNOSTICS) The DIAGNOSTICS item on the Main Initialization Menu gives you access to the Diagnostics Menu (see Figure 4-26), which you use primarily when you are working with Wintriss Tech. Support for initial setup or troubleshooting. Figure 4-26. Diagnostics Menu This section documents only the following items: •...

  • Page 102: Communications

    Data Viewer screen, Figure 4-27, displays. Figure 4-27. Communications Data Viewer Screen This screen allows you to verify communications between SmartPAC PRO Servo and its installed modules, including SFI’ In the “combined” view, Transmit and Receive data are shown together, Transmit data being displayed as blue on a white background, Receive data displayed as white on blue.

  • Page 103: Save To Usb Disk

    This item enables you to save the error/event log, screen captures, and other data maintained in a special SmartPAC PRO Servo 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. Support or to another recipient (see MESSAGING in Chapter 6).

  • Page 104: Update Firmware

    3. When the second message appears, press EXIT to return to the Diagnostics Menu and remove the USB disk. UPDATE FIRMWARE (INITIALIZATION – DIAGNOSTICS – UPDATE FIRMWARE) To update the firmware in your SmartPAC PRO Servo, contact Wintriss Tech Support. Chapter 4 – Initialization Mode...

  • Page 105: Chapter 5 - Program Mode

    Once you have programmed and loaded a tool, you can switch to Run mode to run that tool on your press (refer to Chapter 6). In Run mode, you can also make some adjustments to tool settings. If you need help using the SmartPAC PRO Servo keyboard to input information on Program mode displays, refer to Chapter 3.

  • Page 106: Entering And Exiting Program Mode

    Servo changes modes. Make sure SmartPAC PRO Servo is in the Main (or top) menu for the mode it is in before you turn the Program/Run key. If SmartPAC PRO Servo is not in a top-level menu, press RESET repeatedly until the Main menu appears.

  • Page 107: Creating A New Tool

    SmartPAC PRO Servo User Manual 1147100 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 76). • If the setting is NUMERIC, tools are sorted by tool number •...

  • Page 108: Copying An Existing Tool

    Initialization. NOTICE If there are more tools in SmartPAC PRO Servo’s memory than can be displayed in two columns, press the Left () or Right () cursor key to display the additional hidden column(s). 2. Key in the desired tool number, following the directions displayed in the applicable window.

  • Page 109: Copying Tool Template To A New Tool

    SmartPAC PRO Servo User Manual 1147100 5. Change settings for the new tool, as necessary, following the directions in Tool Program Menu, page 112. Then load the tool, referring to Loading a Tool, page 110, for instructions. Copying Tool Template to a New Tool (PROGRAM –TOOL MANAGER –...

  • Page 110: Loading A Tool

    1147100 SmartPAC PRO Servo User Manual Loading a Tool (PROGRAM –TOOL MANAGER – SELECT TOOL – LOAD TOOL) ANCILLARY EQUIPMENT MAY OPERATE WHEN TOOL IS LOADED Ensure that all personnel stand clear when you load a tool. Failure to comply with these instructions will result in death or serious injury.

  • Page 111: Changing Settings For A Loaded Tool

    NOTICE If an error message displays, go to Chapter 7, page 185 and follow the instructions for correcting the problem. If the error is not covered in Chapter 7, or you cannot fix the problem, call Wintriss Tech. Support. Changing Settings for a Loaded Tool (PROGRAM –TOOL MANAGER –...

  • Page 112: Deleting A Tool

    1147100 SmartPAC PRO Servo User Manual Deleting a Tool (PROGRAM –TOOL MANAGER – select tool – DELETE TOOL) To delete a tool, perform the following steps: 1. On the Tool Manager screen, highlight the tool you want to delete, and press Delete Tool. The window shown in Figure 5-9 appears, asking you to confirm that you want to delete the tool.

  • Page 113: Tool Name

    SmartPAC PRO Servo User Manual 1147100 Figure 5-10. Tool Program Menu (Includes some options. Your display may look different.) The following sections show you how to make settings for each of the items on the menu. NOTICE For help with screens accessible from the Tool Program Menu, press ? with that screen displayed.

  • Page 114: Counters

    Settings are made via the Counters screen, Figure 5-12. Figure 5-12. Counters Screen SmartPAC PRO Servo uses the following counters: Chapter 5 – Program Mode...

  • Page 115: Setting Preset Values

    Top Stop, Toggle, and Pulse. When a Batch counter is set to TOP STOP, SmartPAC PRO Servo top-stops the press and displays a message (page 187), 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 116: Changing Count Values

    1147100 SmartPAC PRO Servo User Manual Figure 5-13. Enter Password Window If this window appears, enter your general password to loading the tool. See SECURITY ACCESS, page 92, in Initialization to set password access. 2. Select the setting displayed in the PRESET VALUE column of the counter you want to program.

  • Page 117: Clearing The Total Hits Counter

    SmartPAC PRO Servo User Manual 1147100 Figure 5-14. Change Count Confirmation Window 3. Press the Up () cursor key to proceed with the Change Count process. The value you entered in step 2 displays in the COUNT field for the counter you selected in step 1.

  • Page 118: Setting Counter Increment Angle

    1147100 SmartPAC PRO Servo User Manual Figure 5-15. Counter Mode Selections Screen 2. Move the highlight bar to the setting in the OUTPUT MODE column for the Batch counter you want to program, then press ENTER to scroll through the three options (i.e., TOP STOP, TOGGLE, and PULSE) until the setting you want is displayed.

  • Page 119: Setting Parts Per Stroke Or Strokes Per Part

    Setting Parts per Stroke or Strokes per Part SmartPAC PRO Servo 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 increment of the...

  • Page 120: Setting Batch Pre-Load Counts

    Any cams programmed within these ranges will actuate once for each hit. Die protection ready signals programmed within these ranges will expect sensor actuation once for each hit. If this is not feasible, please contact Wintriss Tech. Support to learn about new advanced features.

  • Page 121: Understanding Sensor Terminology

    (DiProPAC 16-sensor option shown. Your display may look different.) Understanding Sensor Terminology In order to make proper sensor settings on the SmartPAC PRO Servo display, you need to be familiar with basic sensor terminology. Terms that appear on sensor displays are explained in the following sections.
  • Page 122 Yellow sensors, which are normally open to ground, are ideally suited to monitor events like stock buckling, end of stock, or die overload. When a yellow sensor closes, SmartPAC PRO Servo sends a Stop command to the press. Because yellow sensors work independently of the ram angle and do not actuate on every stroke, you do not set a Ready signal for them.
  • Page 123 SmartPAC PRO Servo User Manual 1147100 Green Sensors A sensor input set to “green” must turn on, at least momentarily, within the Ready signal and be off, at least momentarily, at some point outside the Ready signal, Figure 5-18. Figure 5-18. Ready Signal Programming for a “Green” Sensor Green Quick Check Sensors A sensor input set to “green quick check”...
  • Page 124 Green Special sensor input for a six-stroke window. If no slugs are ejected after six strokes, SmartPAC PRO Servo 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 125: Programming Sensor Settings

    SmartPAC PRO Servo User Manual 1147100 satisfied and the press continues to run. However, there are still five slugs in the ejection hole. If the press makes five more strokes without ejecting a slug, ten slugs are now stuck in the hole.
  • Page 126 1147100 SmartPAC PRO Servo User Manual Figure 5-21. “Enter General Password” Screen Figure 5-22. Die Protection Sensor Menu with Auto Enable by Tool Counter 2. Select the AUTO ENABLE COUNTER field. The Numeric Entry window displays. 3. Key in the value you want (maximum is 99), following the directions in the window, and press ENTER.
  • Page 127 SmartPAC PRO Servo User Manual 1147100 Figure 5-23. Sensor Names Screen On this screen you can select one of the names displayed, or you can select one of the “custom” names set in Initialization (see CUSTOM SENSOR NAMES (Optional), page 82).
  • Page 128 1147100 SmartPAC PRO Servo User Manual Figure 5-24. Custom Sensor Names Screen 4. 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 (page 83), you are taken to the Auto Enable by Sensor Counter screen (see next section).
  • Page 129 SmartPAC PRO Servo User Manual 1147100 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 156, and DISABLE (ENABLE) SENSORS, page 163) To set the Auto Enable by Sensor counter, do the following: 1.
  • Page 130 • Top Stop. SmartPAC PRO Servo stops the press at the top of its stroke after a sensor fault is detected. You should use this setting for events that do not threaten the die or that occur between the critical angle and bottom dead center (BDC).
  • Page 131 Figure 5-28. Critical Angle Programming Screen 2. Decrement the CRITICAL ANGLE default value of 185°, using the Down () cursor key, until the value you want is displayed. SmartPAC PRO Servo accepts Critical Angle values between 0° and 184°. Chapter 5 – Program Mode...
  • Page 132 The Ready signal is the timing window during which the sensor must actuate to prevent SmartPAC PRO Servo from sending a stop signal to the press. In the example shown in Figure 5-29, the Ready On signal is set to 166°, the Ready Off signal to 194°.
  • Page 133 SmartPAC PRO Servo User Manual 1147100 Figure 5-29. Ready Signal Programming Screen NOTICE The Ready signal you set in Program mode can be fine-tuned in Run mode after you have run the press. See Adjusting the Ready Signal for Green Sensors, page 168, for details.
  • Page 134 1147100 SmartPAC PRO Servo User Manual Otherwise, press RESET to return to the Die Protection Sensor Menu. The highlight bar automatically scrolls down to the next sensor displayed on the menu. Setting the Counter Value for a Green Special Sensor When you select GREEN SPECIAL as the sensor type on the Sensor Type screen, the Green Special Sensor Stroke Count screen displays, Figure 5-30.
  • Page 135 SmartPAC PRO Servo User Manual 1147100 Viewing and Changing Sensor Settings When you finish making settings for a sensor, you are taken to a screen that displays all your sensor settings, similar to Figure 5-31. Figure 5-31. Sensor Settings Screen This screen also displays whenever you select a programmed sensor on the Die Protection Sensor Menu.

  • Page 136: Programming Dipropac 32 Sensors

    1147100 SmartPAC PRO Servo User Manual Figure 5-32. Sensor Summary Screen Deleting a Sensor To delete a Die Protection sensor, do the following: 1. On the Die Protection Sensor Menu, select the sensor you want to delete. The Sensor Settings screen displays.
  • Page 137 SmartPAC PRO Servo User Manual 1147100 Figure 5-33. Tool Program Menu with DIPROPAC 1-16 and DIPROPAC 17-32 Items When planning the sensors to be assigned to each DiProPAC 32 input, reserve sensor positions 1-16 for green sensors only. Also, if you are using multiple green sensors for the same function (e.g., transfer, stripper, slug detection, etc.), program only one of the sensor positions 1-16 for this...
  • Page 138 1147100 SmartPAC PRO Servo User Manual 2. Select the sensor number that you want to program. The Sensor Names screen displays, Figure 5-35. Figure 5-35. Sensor Names Screen with Stripper Function Highlighted 3. Select a function for the sensor. (“Stripper” is used as an example in Figure 5-35.) The Sensor Type screen displays, Figure 5-36.
  • Page 139 SmartPAC PRO Servo User Manual 1147100 Figure 5-37. Sensor Stop Type Screen 5. Select the stop type you want. The Sensor Summary screen displays, Figure 5-38, with the Ready signal On and Off angles shown for each green sensor programmed in the group of sensors 1-16.
  • Page 140 1147100 SmartPAC PRO Servo User Manual Figure 5-39. Sensor Settings Screen 7. Press RESET to return to the Die Protection Sensor 17-32 Menu. 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...
  • Page 141 SmartPAC PRO Servo User Manual 1147100 2. Select a function for the sensor. (“Slug Detection” is used as an example in Figure 5-40.). The Sensor Type screen displays, Figure 5-41. Figure 5-41. Sensor Type Screen with “GREEN SPECIAL” Highlighted 3. Select GREEN SPECIAL from the Sensor Type items.

  • Page 142: Cam Switch

    Any cams programmed within these ranges will actuate once for each hit. Die protection ready signals programmed within these ranges will expect sensor actuation once for each hit. If this is not feasible, please contact Wintriss Tech. Support to learn about new advanced features.
  • Page 143 SmartPAC PRO Servo User Manual 1147100 NOTICE For help with the Cam Channel Menu and screens accessible from it, press the HELP key when the applicable screen is displayed. This item enables you to program up to 8 (for standard 8-channel ProCamPAC) or 15 (for optional 15-channel ProCamPAC) cam channels.

  • Page 144: Selecting A Cam Channel

    Instructions for programming cam channels using each of the program types shown on the Cam Channel Program Type Menu except Auto Advance are provided in the following sections. Auto Advance is not available as a cam timing option for SmartPAC PRO Servo. Chapter 5 – Program Mode...

  • Page 145: Making An On/Off Setting

    4. Press RESET when you are finished to return to the Cam Channel Program Type Menu. Setting Multiple ON/OFF Cycles SmartPAC PRO Servo 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.

  • Page 146: Table 5-2. Additional On/Off Settings, 8-Channel Procampac: Examples

    1147100 SmartPAC PRO Servo User Manual ProCamPAC. Additional On/Offs you set for global cam channels (see SET GLOBAL CAMS (Optional), page 80) count toward the six-cycle maximum. Table 5-2 gives examples of how you might use the extra ON/OFFs on an 8-channel ProCamPAC.
  • Page 147 SmartPAC PRO Servo User Manual 1147100 NOTICE A new arc always starts at 0°. If one of the arcs you want to program is located near 0°, program it last. If you find that you have too many arcs at 0°, delete channel settings (see page 150) and start over again.

  • Page 148: Making A Timed Output Setting

    1147100 SmartPAC PRO Servo User Manual 5. If you want to adjust On/Off settings for a previously programmed arc, press SELECT ARC one or more times until the highlighting for that arc turns green, then use the cursor keys to change the On and/or Off angles.

  • Page 149: Setting Dsv On Channel Timing

    The DSV ON output type setting is available only if you have wired the input check circuit inputs #205 and #206 on TB4 on the SmartPAC PRO Servo board. To activate this circuit, you must apply 12 to 250 V to these inputs when the press is in motion.

  • Page 150: Deleting Channel Settings

    1147100 SmartPAC PRO Servo User Manual Figure 5-52. Cam Channel DSV ON Program Screen DSV On cam channel programming is useful for controlling conveyors and other accessories that must operate for a short time after the press stops. To set the DSV delay time, do the following: 1.

  • Page 151: Viewing The Cam Summary

    Global cams, which are programmed in Initialization mode (see SET GLOBAL CAMS (Optional), page 80), are cam channels that can be used with any tool set up on your SmartPAC PRO Servo. Global cams can be programmed for any channel except channels 6, 7 and 8 and, once set, cannot be programmed for individual tools.

  • Page 152: Tool Information

    1147100 SmartPAC PRO Servo User Manual Figure 5-55. Global Cam Summary Screen TOOL INFORMATION (PROGRAM – GO TO THE TOOL MANAGER – SELECT TOOL – EDIT TOOL – TOOL INFORMATION) NOTICE • The Tool Information screen provides a convenient place to record information about the tool.
  • Page 153 SmartPAC PRO Servo User Manual 1147100 Figure 5-56. Tool Information Screen To enter tool information, do the following: 1. Select TOOL INFORMATION on the Tool Program Menu. The Tool Information screen displays. Figure 5-57. “Enter General Password” Screen 2. Select a desired parameter. The Numeric Entry window displays.

  • Page 154: Ram Position

    Lower Limit. Similarly, if the ram passes the Upper Limit on the upstroke, SmartPAC PRO Servo holds the angle at 0° until the ram moves past the Upper Limit on its downstroke.
  • Page 155 SmartPAC PRO Servo User Manual 1147100 In a pendulum motion, the ram position at the top during clockwise movement is often not the same as the top position during counter-clockwise movement. In such a situation, it is very important to set the Upper Limit just below the lower of these two positions.

  • Page 156: Sensor Enable/Disable & Status (Optional)

    5. Leave the STAGE TYPE field set to “SINGLE STAGE.” Advanced users who wish to change the setting to “MULTI STAGE” should contact Wintriss Tech. Support. 6. Leave the CURVE TYPE field set to “SINE.” Advanced users who wish to change the setting to one of the other options (i.e., “PROPORT,”...

  • Page 157: Viewing Sensor Status

    3. Press RESET to return to the Main Program Menu. NOTICE When a tool is loaded, or when SmartPAC PRO Servo is powered up, all sensors are turned on and enabled. Enabling or Disabling All Sensors When you access the Sensor On/Off Status screen, The enable status is displayed at upper left of the screen., either SENSORS ENABLED or SENSORS DISABLED.
  • Page 158 1147100 SmartPAC PRO Servo User Manual Chapter 5 – Program Mode...

  • Page 159: Chapter 6 - Run Mode

    Make sure that Ram Position settings have been programmed (see page 154) for each tool you load. If you do not set ram upper and lower limits, SmartPAC PRO Servo will use the default setting of 0.000 in., and the ram angle clock will display 0° irrespective of the vertical position of the ram.

  • Page 160: Entering And Exiting Run Mode

    The chapter also covers displaying multiple faults, and sending e-mail messages. If you need help using the SmartPAC PRO Servo touch display to input information on Run mode displays, refer to Chapter 3.

  • Page 161: Loading A Tool

    For help with a Run mode screen, press the ? key when that screen is displayed. Loading a Tool A tool must be loaded before SmartPAC PRO Servo 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 shown in Figure 6-2 displays.

  • Page 162: Displaying Multiple Faults

    1147100 SmartPAC PRO Servo User Manual Figure 6-3. “Enter General Password” Screen When you enter the password, you are given access to the item. When a Run mode item is set to PROGRAM MODE ONLY, NO CHANGES ALLOWED, ALLOW RECALC ONLY, or NO RECALC/ADJUST, you are prevented from gaining access to that item. No message displays to indicate that the setting is locked, but when you press ENTER to access the item or press the cursor buttons to make an adjustment, nothing happens.

  • Page 163: Disable (Enable) Sensors

    SmartPAC PRO Servo User Manual 1147100 display is useful such as angle adjustment screens for cams and die protection sensors. Simply press the decimal point (.) key when you are on the Main Run Menu. The ram angle window opens in the upper right corner of the screen, as shown in Figure 6-5.
  • Page 164 1147100 SmartPAC PRO Servo User Manual Figure 6-6. Main Run Menu with SENSORS ENABLED When sensors are disabled, the message SENSORS DISABLED shows at the left of the Status Box, and the item button says ENABLE SENSORS. To disable or enable sensors, do the following: 1.

  • Page 165: Counters

    SmartPAC PRO Servo User Manual 1147100 You can manually enable or disable sensors no matter which setting (i.e., Manual, Auto by Tool, or Auto by Sensor) is selected for Sensor Enable Mode in Initialization (see Selecting Sensor Enable Mode, page 83). If either of the Auto Enable options is selected, refer to Setting the “Auto Enable by Tool”...
  • Page 166 1147100 SmartPAC PRO Servo User Manual Figure 6-8. Counters Screen If you have set the CHANGE COUNTS parameter on the Security Access Menu in Initialization to PROGRAM AND RUN MODES (see page 95), you can reset batch counts to the values you have programmed for batch pre-loads (see Setting Batch Pre-Load Counts, page 120).

  • Page 167: Die Protection (Optional)

    Any cams programmed within these ranges will actuate once for each hit. Die protection ready signals programmed within these ranges will expect sensor actuation once for each hit. If this is not feasible, please contact Wintriss Tech. Support to learn about new advanced features.

  • Page 168: Adjusting The Ready Signal For Green Sensors

    NOTICE FOR MORE INFORMATION For a detailed description of the different types of sensors available in SmartPAC PRO Servo with die protection, refer to Understanding Sensor Terminology, page 121. Refer to Programming Sensor Settings, page 125, for detailed instructions on modifying sensors..
  • Page 169 If the On angle for a green quick check sensor fluctuates between 190° and 195° from stroke to stroke, SmartPAC PRO Servo continuously displays 190° as the sensor’s On value. However, if the On angle changes to 189°, SmartPAC PRO Servo displays the On angle as 189° on the next stroke.

  • Page 170: Adjusting The Stroke Preset For Green Special Sensors

    1147100 SmartPAC PRO Servo User Manual NOTICE If you have turned off the sensor in Program mode (see NOTICE above), a message displays indicating that the sensor is turned off. Press ENTER to clear the message. 2. Run the press.

  • Page 171: Viewing Sensor Status

    SmartPAC PRO Servo User Manual 1147100 Viewing Sensor Status (RUN – DIE PROTECTION –SHOW SENSOR STATUS) You can view the status of your sensors by pressing SHOW SENSOR STATUS. When you do so, the Sensor Status screen, shown in Figure 6-12, page 172, displays.

  • Page 172: Adjusting Dipropac 32 Sensors

    SmartPAC PRO Servo User Manual Figure 6-12. Sensor Status Screen Adjusting DiProPAC 32 Sensors You access DiProPAC 32 sensors on the SmartPAC PRO Servo Main Run Menu via the Die Protection item, Figure 6-13. Figure 6-13. Main Run Menu with DiProPAC When you select the DIPROPAC 1-16 item, the Die Protection Sensor menu for sensors 1-16 displays.
  • Page 173 SmartPAC PRO Servo User Manual 1147100 When you select DIPROPAC 17-32, the Die Protection Sensor menu for sensors 17-32 displays (see Figure 6-16, which shows the sensors that are used as examples in Chapter 5). Figure 6-14. 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.
  • Page 174 1147100 SmartPAC PRO Servo User Manual Figure 6-15. Ready Signal Programming Screen, Run Mode 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 beneath the stroke preset, indicating that you cannot change the green special stroke count for this sensor (see Figure 6-16).

  • Page 175: Cam Switch

    Any cams programmed within these ranges will actuate once for each hit. Die protection ready signals programmed within these ranges will expect sensor actuation once for each hit. If this is not feasible, please contact Wintriss Tech. Support to learn about new advanced features.

  • Page 176: Viewing Cam Timing

    1147100 SmartPAC PRO Servo User Manual installed the ProCamPAC 15 option. If you have assigned names to your cam channels in Initialization mode, those names will be displayed. Channels programmed as Global cams are not shown (see SET GLOBAL CAMS (Optional), page 80).

  • Page 177: Viewing The Global Cam Summary

    SmartPAC PRO Servo User Manual 1147100 Figure 6-18. Cam Timing Screen Viewing the Global Cam Summary (RUN – CAM SWITCH – VIEW GLOBAL CAM SUMMARY) You can view a summary of the Global cams by pressing VIEW GLOBAL CAM SUMMARY. The screen that displays is identical to the Global Cam Summary screen accessible in Program mode (see Viewing Global Cams, page 151) except that it displays additional information in the Status box.
  • Page 178 1147100 SmartPAC PRO Servo User Manual Figure 6-19. Tool Number Information Screen To change tool information, do the following: 1. Select TOOL INFORMATION on the Main Run Menu. The Tool Number Information screen displays. 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 179: Ram Position

    SmartPAC PRO Servo User Manual 1147100 RAM POSITION (RUN–RAM POSITION) NOTICE SET INITIALIZATION PARAMETERS BEFORE SETTING UPPER/LOWER LIMITS Before you create or adjust settings for upper and lower limits in Run mode, be sure to set the maximum Upper Limit and Offset Value on the Linear Sensor screen in Initialization mode (see page 84).

  • Page 180: Error/Event Log

    When a new tool is loaded, the log displays the tool number. If SmartPAC PRO Servo is connected to a computer network and e-mail is enabled, the log also shows messages sent by SmartPAC PRO Servo. When SmartPAC PRO Servo is networked, you can send the Error/Event Log to Wintriss Tech.

  • Page 181: Load New Tool

    SmartPAC PRO Servo User Manual 1147100 To view the Error/Event Log, do the following: 1. Select ERROR/EVENT LOG on the Main Run Menu to display the Error/Event Log. 2. Use the cursor keys to scroll through the errors and events. When an error is selected, the full text of the error message is displayed in the blue window at the bottom of the screen.

  • Page 182: Messaging

    NOTICE If an error message displays, go to Chapter 7 and follow the instructions for correcting the problem. If the error is not covered in Chapter 7, or you cannot fix the problem, call Wintriss Tech. Support. MESSAGING (RUN – MESSAGING) NOTICE For help with the MESSAGING item, press ? when the Messaging screen is displayed.
  • Page 183 SmartPAC PRO Servo User Manual 1147100 Figure 6-24. Messaging Screen: List of Recipients 2. Highlight the message recipient, using the cursor keys, then press SELECT RECIPIENT. The recipient’s name displays in the “To:” field at the top of the screen.

  • Page 184: 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 6-27.

  • Page 185: Chapter 7 - Fault Messages

    Make sure that Ram Position settings have been programmed (see page 154) for each tool you load. If you do not set ram upper and lower limits, SmartPAC PRO Servo will use the default setting of 0.000 in., and the ram angle clock will display 0° irrespective of the vertical position of the ram.

  • Page 186: Responding To Fault Messages

    1147100 SmartPAC PRO Servo User Manual This chapter documents the fault messages that display on the SmartPAC PRO Servo LCD or in the Error/Event Log, providing a brief explanation of each message and a remedy for correcting the problem. Responding to Fault Messages When an error occurs, a red message window like the one shown in Figure 7-1 displays, indicating the type of error and providing a brief explanation.

  • Page 187: Counter Preset Reached Messages

    SmartPAC PRO Servo User Manual 1147100 Counter Preset Reached Messages “Good parts counter preset reached” Explanation: The value set for the parts counter has been reached. The press should stop at top dead center. Remedy: Press Exit to clear the message. If your part run is complete, you need to change tooling, material, etc.

  • Page 188: Messages For Programming Problems

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

  • Page 189: Messages For Sensor Faults

    If a green or green quick check sensor does not come on during its Ready signal, SmartPAC PRO Servo continues to look for the sensor signal. If it sees the sensor come on within 50 milliseconds after the Ready signal ends, this message displays.

  • Page 190: Green Sensor Failure

    1147100 SmartPAC PRO Servo User Manual “Green sensor failure” Explanation: 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 191: Miscellaneous Fault Messages

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

  • Page 192: Troubleshooting Using The Error/Event Log

    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, page 180, and Sending E-mail to Wintriss Technical Support, page 184, for more information.

  • Page 193: Appendix A - Installing The Balluff Linear Transducer

    30 - 36 in. 42 - 48 in. 3. Make a second bracket to hold the magnet connecting rod. 4. Mount the bracket for the transducer on the press. 1147100 SmartPAC PRO Servo User Manual Appendix A – Installing the Balluff Linear Transducer...

  • Page 194: Wiring The Transducer

    8. Once the magnet is secure, tighten down the transducer. Wiring the Transducer To wire the transducer to the SmartPAC PRO Servo board, perform the following steps: 1. Plug the connector on the transducer cable into the transducer if it is not already connected, twisting the locknut so the connection is tight.
  • Page 195 2. Run the transducer cable through 1/2-in. conduit from the transducer to one of the knockouts on the bottom left of the SmartPAC PRO Servo enclosure. 3. Measure and cut the transducer wires so they comfortably reach TB402 on the ProCamPAC board.
  • Page 196 1147100 SmartPAC PRO Servo User Manual Table A- 2. Balluff Linear Transducer Wiring Pin # on TB402 Wire Color * ProCamPAC Linear Board Shield Terminate shield drain wire at the ProCamPAC board under a screw in one of the standoffs.

  • Page 197: Glossary

    A numeric value calculated when a tool is stored in memory and when it is loaded. The two values must match or SmartPAC PRO Servo displays a fault message. communications Data sent by SmartPAC PRO Servo to one of its installed options (e.g., SFI) or received from an installed option. counter...
  • Page 198 1147100 SmartPAC PRO Servo User Manual error message A message appearing on the SmartPAC PRO Servo LCD that indicates a fault condition, identifies the problem, and may suggest how to correct it. manual enable A die protection mode in which sensors are manually enabled or disabled by the operator.

  • Page 199: Index

    109 yellow sensors, description, 122 counters, 114 DiPro Sensor Interface 2 (DSI 2) batch, 115 connecting to SmartPAC PRO Servo, 45 batch output, 117 DiProPAC. See also die protection batch pre-load count, 120 adding or upgrading, 44...
  • Page 200 192 E-Stop errors, 188 messaging, 182 responding to, 186 email, sending, 182 fault messages, 186 e-mail, sending to Wintriss Technical Support, 184 Favorite button, 68 features optional, 21, 25 standard, 20 network firmware, updating, 104...
  • Page 201 SmartPAC PRO Servo User Manual 1147100 panel mount screen capture button, 68 cutout dimensions, 33 security access, 92 dimensions, SmartPAC PRO Servo, 34 factory settings, 95 installation, 33 forgotten password recovery, 93 parts counter, 115 password, 93 parts per stroke, counter, 119 password protection, Initialization mode, 65 password.
  • Page 202 130 Wintriss Technical Support total hits counter, 115 e-mail, sending to, 184 clearing, 117 Wintriss Technical Support, sending error/event log to, troubleshooting. See fault messages wiring AC, 40 wiring tables SmartPAC PRO Servo options, 60 USB drive...
  • Page 203 SmartPAC PRO Servo Setup Sheet Tool Name and Number: _____________________________________________________ Counter Presets Batch 1 (Ch. 6) Batch 2 (Ch. 7) Batch 3 (Ch. 8) Preset Value Output mode Top Stop Top Stop Top Stop (circle one) Toggle Toggle Toggle Pulse for...
  • Page 205 ProCamPAC Cam Switch – SmartPAC PRO Servo Setup Sheet Channels 1 – 8 Tool Name and Number: _______________________________ ON/OFF Multiple arcs for ON/OFF only TIMED DSV-ON 6 extras, total 4 max. Global Time to cam? shut-off Arc # Cam Name (function)
  • Page 207 ProCamPAC Cam Switch – SmartPAC PRO Servo Setup Sheet Channels 9 – 15 Tool Name and Number: _______________________________ ON/OFF Multiple arcs for ON/OFF only TIMED DSV-ON 6 extras, total 4 max. Global Time to cam? shut-off Arc # Cam Name (function)
  • Page 209 DiProPAC Die Protection – SmartPAC PRO Servo 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...
  • Page 211 DiProPAC Die Protection – SmartPAC PRO Servo 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 TOP STOP GS ______strokes SMART STOP E-STOP...

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