Wintriss SmartPAC PRO Installation Manual
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Wintriss SmartPAC PRO Installation Manual

Press automation control
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®
Wintriss Press Automation Control
1143200
Rev. B October 2020
For complete SmartPAC PRO documentation, scan the
code below or visit www.wintriss.com/edocs/options
(case sensitive).
®
Wintriss Controls Group, LLC
100 Discovery Way
Unit 110
Acton MA 01720 USA
Phone (800) 586-8324
Fax (978)263-2048
PRINTED IN USA
Tech Support Hotline
800-586-8324
8-5 EST
www.wintriss.com
®

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Summary of Contents for Wintriss SmartPAC PRO

  • Page 1 ® ® Wintriss Press Automation Control 1143200 Rev. B October 2020 For complete SmartPAC PRO documentation, scan the code below or visit www.wintriss.com/edocs/options (case sensitive). ® Tech Support Hotline 800-586-8324 8-5 EST Wintriss Controls Group, LLC 100 Discovery Way Unit 110...
  • 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. Whenever you need assistance or service, we back all our products with excellent spare parts inventories, training programs, and prompt repair service.

  • Page 5: Table Of Contents

    Terminating Cable Shields ...................... 18 Checking the Press ......................... 18 Mounting the SmartPAC PRO Control Enclosure ................. 19 Installing SmartPAC PRO as a Panel Mount ................. 20 Installing the Resolver ........................21 Mounting the Resolver ......................23 Wiring the Resolver ......................... 24 Connecting Power Wiring –...
  • Page 6 1143200 SmartPAC PRO Installation Manual Chapter 8 – SmartPAC PRO Fault Messages ..............53 Responding to the Brake Warning LED ................. 53 Responding to Fault Messages ...................... 53 Counter Preset Reached Messages ....................54 “Good parts counter preset reached” ..................54 “Strokes counter preset reached”...
  • Page 7 Figure 2-7. Input Check Voltage Switch (S101) in the Factory Default (60-250V) Position ....28 Figure 2-8. SmartPAC PRO Main (RTS) Board showing option module boards and TB3 and TB4 .. 30 Figure 2-9. DiProPAC Boards (8-, 16-, and 32-Sensor): Location of Components ......31 Figure 2-10.
  • Page 8 Table 2-2. Stop and Input Check Circuit Wiring Connections: TB4 ........... 28 Table 2-3. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Wiring, Sensors 1-8 ......32 Table 2-4. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Wiring, Sensors 9-16 ......32 Table 2-5.
  • Page 9 Chapter 2 shows you how to install SmartPAC PRO, including the optional ProCamPAC and DiProPAC modules. Chapter 8 provides explanations of the messages that display on the SmartPAC PRO front panel when a fault condition occurs or a counter preset is reached, and shows you how to correct SmartPAC PRO faults.
  • Page 11 Important Highlighted Information Important danger, warning, caution and notice information is highlighted throughout the manual as follows: A DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. A WARNING symbol indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.
  • Page 13 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 15: Chapter 2 - Installing Smartpac Pro

    ProPAC process monitor, refer to the user manual for that option for complete details on its installation and use. This chapter describes how to install SmartPAC PRO and some of its options. It is organized in the following sections: Before You Start ..........................16 Installation Guidelines ........................

  • Page 16: Before You Start

    Before You Start NOTICE READ INSTALLATION INSTRUCTIONS BEFORE STARTING INSTALLATION If you install SmartPAC PRO yourself, read this installation chapter carefully, plan your installation, and figure out what steps you will follow before you start drilling holes, running conduit, or cutting wires.

  • Page 17: Installation Guidelines

    LEARN TO USE SMARTPAC PRO BEFORE INSTALLING ON A PRESS If you have not used SmartPAC PRO before, learn how to initialize and program it before installing it on a press. On the bench, connect your unit to a resolver (see page 24) and to AC power (see page 25) so that you can access all the menus and make settings.

  • Page 18: Terminating Cable Shields

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

  • Page 19: Mounting The Smartpac Pro Control Enclosure

    1143200 Mounting the SmartPAC PRO Control Enclosure To mount the SmartPAC PRO enclosure, follow the steps below, referring to Figure 2-1. Figure 2-1. SmartPAC PRO Mounting Dimensions Enclosure mounting – Leave enough room to open the door at least 120°. Leave clearance of approximately 18 inches (46 cm) if you wish to fully open the enclosure’s door.

  • Page 20: Installing Smartpac Pro As A Panel Mount

    Installing SmartPAC PRO as a Panel Mount Follow the steps below to install the panel mount version of the SmartPAC PRO in your enclosure. Be sure to allow at least 6 in. (152 mm) of clearance behind the panel mounting plane to leave enough room for the electronics.

  • Page 21: Installing The Resolver

    Failure to comply with these instructions will result in death or serious injury. The resolver (see Figure 2-4. Resolver Dimensions for dimensions) provides SmartPAC PRO with the exact position of the crankshaft at every angle throughout the stroke (see Resolver-based Operation, in Chapter 1 of your user manual.

  • Page 22: Figure 2-4. Resolver Dimensions

    1143200 SmartPAC PRO Installation Manual (91.9) 3.75 Figure 2-4. Resolver Dimensions Figure 2-5. Location of Terminal Blocks TB1 through TB8 Chapter 2 – Installing SmartPAC PRO...

  • Page 23: Mounting The Resolver

    Failure to comply with these instructions could result in property damage. Wintriss Controls Group stocks a spring-loaded base (part# 4194300) with a hole pattern that matches the hole pattern on the resolver.

  • Page 24: Wiring The Resolver

    3. Find the resolver connector TB-3 on the SmartPAC PRO board (see Figure 2-5, page 22). 4. Measure and cut the resolver wires so they comfortably reach SMARTPAC PRO. (If you run the position sensor cable through the same conduit, do not cut these wires until the position sensor is installed).

  • Page 25: 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 enclosure. Then, to wire the AC input terminal block, follow these steps: 1.

  • Page 26: Figure 2-6. Wiring Ac To Terminal Block, Inside Enclosure, Top Right

    • SmartPAC PRO Panel Mount: Connect the ground wire to the ground stud on the face plate below the AC input terminal block. 4. Connect AC wires to the power source only after all installation procedures have been completed and you are ready to perform final checkout tests (see page 49).

  • Page 27: Connecting Power Wiring - 24 Vdc Powered Units

    NEMA-12-protected. 2. Locate connector TB4 on the SmartPAC PRO board (see Figure 2-8, page 30) and unplug it from its socket. Connect the wires for the stop and input check circuits to TB4 pin locations, as shown in Table 2-2, below, and Figure 4 at the end of the manual.

  • Page 28: Setting The Input Check Voltage Switch

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

  • Page 29: Adding Or Upgrading Dipropac Or Procampac Option

    When the dual safety valve relay is energized by the press control to start the press, voltage is produced in the input check circuit. If SmartPAC PRO gets no signal from the resolver within the specified start time limit (resolver not turning), SmartPAC PRO opens the emergency-stop circuit and a “loss of rotation”...

  • Page 30: Figure 2-8. Smartpac Pro Main (Rts) Board Showing Option Module Boards And Tb3 And Tb4

    SmartPAC PRO Installation Manual To install a new DiProPAC or ProCamPAC board, do the following: 1. On the SmartPAC PRO board, locate the connector in which the new board should be installed (see Figure 2-8). Figure 2-8. SmartPAC PRO Main (RTS) Board showing option module boards and TB3 and...

  • Page 31: Connecting Dipro Sensor Interface To Smartpac Pro

    6. Plug the connector(s) back into their sockets on the board. 7. Verify that you have installed the board(s) properly by performing the procedure in Zeroing the Resolver, page 42. You need to complete this procedure before you can use SmartPAC PRO. Connecting DiPro Sensor Interface to SmartPAC PRO...

  • Page 32: Table 2-3. Dipro Sensor Interface (Dsi) 2 To Smartpac Pro Wiring, Sensors 1-8

    1143200 SmartPAC PRO Installation Manual Table 2-3. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Wiring, Sensors 1-8 1st DSI 2 (TB2) DiProPAC (TB554) Wire color* Pin # Pin Designation Pin # Pin Designation Brown SENSOR 1 SENSOR 1 SENSOR 2...

  • Page 33: Table 2-5. Dipro Sensor Interface (Dsi) 2 To Smartpac Pro Wiring, Sensors 17-24

    SmartPAC PRO Installation Manual 1143200 Table 2-5. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Wiring, Sensors 17-24 3rd DSI 2 (TB2) DiProPAC (TB555) Wire color* Pin # Pin Designation Pin # Pin Designation Brown SENSOR 1 SENSOR 17 SENSOR 2...

  • Page 34: Connecting Procampac Programmable Cam Channels

    The assembly contains the relays that open and close at the angles you set in SmartPAC PRO, turning your equipment on and off. Different types of relays can be used, depending on the voltages of your equipment and any special requirements.

  • Page 35: Figure 2-10. Procampac Boards (8- And 16-Channel): Location Of Components

    12-conductor cable(s) to the pin locations on the appropriate terminal blocks, as shown in Table 2-7 (for the 8-channel option) or Table 2-7 and Table 2-8 (for the 16-channel option). See also wiring diagram Figure 3 at the end of the manual. Chapter 2 – Installing SmartPAC PRO...

  • Page 36: Figure 2-11. Procampac Output Assembly

    CHAN 4 CHAN 3 CHAN 2 CHAN 1 plug in standard or solid state, but not both Clearance hole Terminals for connecting wires to equipment for #6 screw (4 places) Figure 2-11. ProCamPAC Output Assembly Chapter 2 – Installing SmartPAC PRO...

  • Page 37: Table 2-7. Procampac To Cam Output Assembly Smartpac Pro01 Wiring, Cams 1-8

    Table 2-7 (for 8-channel ProCamPAC) or Table 2-7 and Table 2-8 (for 16-channel ProCamPAC). A wire from CHAS to a lug on the ProCamPAC Output enclosure should already be connected (unless you bought the board assembly only). Chapter 2 – Installing SmartPAC PRO...

  • Page 38: Table 2-9. Connections To Relays

    (see Figure 2-12). Suppressors are supplied with each relay. Install the suppressors across the load or as close to the load as possible. Attach suppressors by connecting leads across existing terminals or junction points. DC loads: Install a diode across each DC load, (see Figure 2-13) Chapter 2 – Installing SmartPAC PRO...

  • Page 39: Wiring Setup Mode Circuit

    Typically, the Setup mode circuit is enabled when Inch mode is selected on your clutch/brake control. When you inch the press, SmartPAC PRO 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 position of the Stroke Select keyswitch of your press control, or you can use an external switch to activate the circuit.

  • Page 40: Wiring A Remote Reset Switch (Optional)

    1143200 SmartPAC PRO Installation Manual For Setup mode, you must provide contact closure when a non-Wintriss press control is in Inch mode. Connect a wire from SmartPAC PRO terminal block TB5, terminal #252 (labelled IN/SU) to one side of a normally open switch (see Table 2-10, and Figure 4 at the end of the manual). Connect the other side of the switch to GND (TB5, terminal #247).

  • Page 41: Wiring The Procampac Output With Your Mechanical Top Stop Cam Switch (Optional)

    PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE • Use SmartPAC PRO’s programmable cam switch to control auxiliary functions only. The SmartPAC PRO 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 42: Zeroing The Resolver

    Verify that the press is at top dead center (i.e., at 0°± 2°) before you zero the resolver. If the press is not at TDC, your timing settings may be wrong. You must perform this procedure the first time you power up SmartPAC PRO and whenever you install a new resolver.

  • Page 43: Verifying Installation Of Dipropac And/Or Procampac (Optional)

    Turn off power to SmartPAC PRO, and recheck all power connections. Check that the connectors are correctly seated on both ends of the cables between the SmartPAC PRO board and the display. Power up SmartPAC PRO again. If the display remains off, contact Wintriss Tech.

  • Page 44: Moving The Ram To Top Dead Center (Tdc)

    If the ram is not at TDC, you must first inch the press to 0 ± 2 before you can zero the resolver. Since SmartPAC PRO is now connected to your stop circuits, you must load a tool in order to inch the press.

  • Page 45: Installing The Position Sensor (Optional)

    If you have installed the position sensor, enable it during initialization and leave it enabled even though it is optional for SmartPAC PRO operation. If you disable the position sensor to clear an error message, misalignment between the resolver and crankshaft will go undetected.

  • Page 46: Figure 2-18. Position Sensor Dwell On Different Diameter Shafts

    SmartPAC PRO compares the timing of this signal with the angle of the resolver. If the resolver angle changes relative to this signal, SmartPAC PRO knows that the resolver drive has slipped or broken or the resolver itself has failed and issues an Emergency Stop command, simultaneously displaying an error message.

  • Page 47: Figure 2-19. Position Sensor Screen

    The crankshaft angle reading should increase as you inch the press. If it decreases (359, 358, 357, for example), swap the black and yellow wires (terminals 213 and 216) on connector TB3 on the SmartPAC PRO board (see Table 2-1, page 25 and Figure 2-5, page 22). NOTICE The press must be at top dead center (0°) before the position sensor can be installed.

  • Page 48: Figure 2-20. Position Sensor Installation

    Figure 2-20. Position Sensor Installation 15. Wire the switch to SmartPAC PRO terminal block TB5 (see Table 2-10, page 40 and Figure 4 at the end of the manual). The black wire goes to terminal 247 (GND), the white or clear wire goes to terminal 246, and the red wire goes to terminal 245.

  • Page 49: Final Checkout

    22. Inch the press while watching the Position Sensor LED, located beneath the Input Check Voltage Switch on the SmartPAC PRO board. Stop the press when the LED comes ON and make a note of the ON angle. Continue to inch the press until the LED goes OFF, and make a note of the OFF angle.

  • Page 50: Check The Top-Stop Circuit

    Test Complete 9. If you get to this step, SmartPAC PRO is working correctly. Clear any error messages by pressing RESET, then delete the test tool. You can now create a tool in SmartPAC PRO, program settings for it, load it, and begin to make parts using your new SmartPAC PRO.

  • Page 51: Wiring Tables For Other Smartpac Pro Connections

    SmartPAC PRO Installation Manual 1143200 Wiring Tables for Other SmartPAC PRO Connections Table 2-11. SFI Port (1) and Table 2-12. Special Port (3) and Module Port (2) (TB6) Wiring Comm Test Port (4) (TB7) Wiring Pin # Signal Port Pin #...
  • Page 52 1143200 SmartPAC PRO Installation Manual Chapter 2 – Installing SmartPAC PRO...

  • Page 53: Chapter 8 - Smartpac Pro Fault Messages

    Stop-time Limit, Setting Stop Time and Start Time Limits in Chapter 3, SmartPAC PRO Initialization Mode, in your user manual. 3. Power down the SmartPAC PRO, then power it back up to turn off the Brake Warning LED. When the Stopping Time exceeds the Stop-time Limit, the “Stop time exceeded” message displays (see page 58).

  • Page 54: Counter Preset Reached Messages

    Otherwise, you will get the fault message again. If the problem persists, contact Wintriss Tech. Support. Do not attempt to run the press before correcting the problem.

  • Page 55: Batch # Counter Preset Reached

    Messages for Equipment or Brake Monitor Problems The following messages cover resolver, input circuit, and position sensor faults, problems with the way the press is running, brake monitor faults, and internal problems with SmartPAC PRO. “Loss of rotation detected” Explanation: The resolver did not start rotating within the start time limit set in Initialization (see SET BRAKE MONITOR in Chapter 3, SmartPAC PRO Initialization Mode, in your user manual.) or stopped rotating while the press was running.

  • Page 56: Angle Resolver Failure

    SmartPAC PRO Installation Manual “Angle resolver failure” Explanation: The wiring input check circuit failure in the resolver circuit to SmartPAC PRO may be loose or bad, or the resolver may have failed. Another possible cause is that the press may be going faster than 800 SPM (or 1600 SPM, depending on the speed setting in SmartPAC PRO).

  • Page 57: E-Stop Errors

    Explanation: If the word “ESTOP” appears in a message, one or both of the emergency stop relay circuits are not working satisfactorily and may be defective. Remedy: Check both stop relay circuits. To reset SmartPAC PRO, turn the unit off, then on again. (You cannot use RESET to reset this error.) If the error recurs, contact Wintriss Tech.

  • Page 58: Stop Time Exceeded

    Figure 8-3. Location of JP101 “Stop time exceeded” Explanation: The stopping time of the press has exceeded the limit set in SmartPAC PRO Initialization. You should have been pre-warned of this condition by the brake warning LED, which flashes whenever the stopping time is within 10 milliseconds of the stop time limit.

  • Page 59: Messages For Programming Problems

    Explanation: The programming for the loaded tool has become corrupted. This error can occur when SmartPAC PRO has been turned off while you are in the middle of programming a setup, or when you have not properly exited (i.e., by pressing RESET) from a Program or Run menu.

  • Page 60: 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 ends, this message displays.

  • Page 61: Green Quick Check Sensor Actuated Outside Ready

    Remedy: Check for the press or equipment malfunction that the sensor was supposed to detect. If no malfunction has occurred, check for a problem Chapter 8 – SmartPAC PRO Fault Messages...

  • Page 62: Miscellaneous Fault Messages

    Remedy: Press RESET to clear. If the message reappears, call Wintriss Tech. Support “One of the sensor auto enable counters is greater than 99” Explanation: Normally, this fault will never occur since SmartPAC PRO does not let you enter a value greater than 99. However, this message could display if there is an internal problem with SmartPAC PRO.

  • Page 63: 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. For more information, see ERROR/EVENT LOG in Chapter 5, SmartPAC PRO Run Mode, in your user manual, and the Message button in the table of control buttons in Chapter 1 of your user manual.
  • Page 64 1143200 SmartPAC PRO Installation Manual Chapter 8 – SmartPAC PRO Fault Messages...
  • Page 65 SmartPAC PRO 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 67 ProCamPAC Cam Switch – SmartPAC PRO 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) angle Ch # ()
  • Page 69 ProCamPAC Cam Switch – SmartPAC PRO Setup Sheet Channels 9-16 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) angle Ch # ()
  • Page 71 DiProPAC Die Protection – SmartPAC PRO 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 Y GC E-STOP TOP STOP GS ______strokes SMART STOP...
  • Page 73 DiProPAC Die Protection – SmartPAC PRO 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 TOP STOP...

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