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SmartPAC 2
Honeywell SmartPAC 2 User Manual
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SmartP
AC 2 Pres
s
Automation Control
T
ech S
upport Ho
tlin
e
80
0-586-83
24
8-5
EST
www
.wintriss.co
m
®
includes optional DiPro P
AC and
ProCam P
AC
1
126800 Rev
. 1 September
2003
®®
with Wintr
iss WPC Clutch/Brake Cont
rol
®
Wintri
s
s
Wintri
ss Controls Group
100 Discovery W
ay
Acton MA
01720-3648
USA
Phone (978)
264-9550
(800) 586-8324
Fax (978) 263-2491
PRINTED I
N USA
DA70194
3
2
Table of Contents
Default Chapter
5
Table of Contents
5
Chapter 1 - Introduction to Smartpac 2 with WPC
23
Smartpac 2
23
WPC and Control Reliability
23
Smartpac with WPC
24
How Smartpac 2 with WPC will Benefit Your Operation
24
Standard Features
24
Optional die Protection and Programmable Cam Switch Features
25
Smartpac 2 Front Panel
26
System Components
27
Figure 1 - 2. Illustration of Operator Station
28
WPC Options
29
How Smartpac 2 Works
30
Settings You Can Make on Smartpac 2
31
Sensors Available for Optional Dipropac
33
Understanding Sensor Terminology
34
Normally Open, Normally Closed
34
Ready Signal
34
Impedance
35
Sensor Types
35
Figure 1 - 3. How Smartpac 2 Interprets Signals from a "Green" Sensor
36
Considerations for Setting Sensor Stop Type
40
Procampac Programmable Cams (Optional)
40
Smartpac 2'S Three Modes of Operation
41
Specifications: Smartpac 2 with WPC
42
Chapter 2 - Installing WPC and Smartpac 2
45
Part 1 - Installation Overview
48
Before You Start
48
The First Step - Checking the Press
49
Installation Guidelines
49
Figure 2 - 1. Installation Overview
51
Overview of the Installation
52
How to Connect Wires to Terminal Block Connectors
52
How to Terminate Cable Shields
53
Part 2 - Install and Wire WPC
54
Mounting the WPC Control Enclosure
55
Install WPC Without Enclosure
56
Wiring the WPC
57
Slide Adjust Considerations
57
Connecting AC Wiring to WPC
57
Figure 2 - 6. Setting Voltage Selector Switch
58
Installing and Wiring Dual Safety Valve and Sensors for Clutch and Counterbalance Air Pressure
59
Dual Safety Valve
59
Air Pressure Sensors or Switches
60
Install the Resolver
63
Mounting and Wiring the Resolver
64
If You Replace Your Resolver
65
Install the Overrun Limit Sensor Magnetic Switch
66
Planning Your Overrun Sensor Installation
67
Mounting the Overrun Sensor Magnetic Switch
67
Wiring the Overrun Sensor Magnetic Switch
68
Mounting and Wiring the Operator Station and Light Curtain(S)
69
Figure 2 - 9. Operator Station, Side Buttons
70
Using a Light Curtain on Your Press
71
Mounting the Operator Station if You Do Not Use Light Curtains
72
Using Two Light Curtains on Your Press
72
Connecting Other Wintriss Products to WPC
72
Wiring WPC User Inputs
74
Part 3 - Install and Wire WPC Options
77
Wiring Lockout Relay (Optional)
77
Wiring a Remote Reset Switch (Optional)
78
Wiring Operator Mode Outputs (Optional)
78
Wiring Foot Switch (Optional)
79
Installing One-Hand Control (Optional)
80
Mounting One-Hand Control Switch
80
Figure 2 - 12. One-Hand Control Switch Dimensions
81
Light Curtain Break" Mode
82
Wiring One-Hand Control to WPC
83
Wiring Automatic Single Stroke/External Trip
84
Wiring Continuous on Demand
84
Installing Multiple Operator Stations
85
Auxiliary Outputs (Optional)
86
Wiring Auxiliary 1 Output (Optional)
86
Wiring Auxiliary 2 Output (Optional)
87
Wiring Auxiliary 3 Output (Optional)
88
Wire a Keylock Switch to Prevent Changes to WPC Settings in Program and Run (Optional)
88
Installing Flywheel Speed Sensor (Optional Hardware Required)
89
Mounting and Wiring the Bar Control Enclosure (Optional)
90
Part 4 - Install and Wire Smartpac
91
Smartpac 2 the First Step-Checking the Press
91
Installing Smartpac 2 Enclosure
92
Figure 2 - 18. Smartpac 2 Mounting Dimensions, Enclosure
93
Installing Smartpac 2 as a Panel Mount
94
Standard Enclosure Versus Optional Panel Mount
94
Preparation for Mounting Smartpac 2 Using Your Enclosure
94
Figure 2 - 19. Smartpac 2 Mounting and Cutout Dimensions, Panel Mount
95
Wiring between WPC and Smartpac
96
Connecting Wpc's Resolver to Smartpac
96
Connecting Communications between Smartpac 2 and WPC
97
Connecting AC Wiring between WPC and Smartpac 2
98
Connect Stop Circuits and Input Check Circuit to Smartpac 2
99
Setting Input Check Voltage Switch
99
Connecting Smartpac 2 to a Network
101
Part 5 - Install Smartpac Options
102
Adding or Upgrading Procampac or Dipropac
102
Connecting Programmable Cam Channels
105
Making the Connections
105
Connecting Dipro Sensor Interface to Smartpac 2
112
Installing the Dipro Remote Connection Box
114
Set up High Speed Version of Smartpac 2 with WPC (Optional)
116
Wiring Setup Mode Circuit
116
Wiring a Sensor-Disabled Output (Optional)
116
Part 6 - Set up Smartpac2 with WPC
117
Turn on Power to Smartpac 2 and WPC
118
Problems at Startup
120
Verify Proper Installation of Procampac And/Or Dipropac Options
122
Initialize Press Parameters
123
Create and Load a Test Tool Number
125
Check and Set Direction of Resolver Rotation
126
Zero the Resolver
127
Set Top Stop Angle and Install Overrun Magnet
129
Check Top Stop after You Change Top Stop Angle
137
Prepare to Install Magnet for Overrun Limit Sensor
138
Install Magnet for Overrun Sensor
147
Check the on and off Time of the Overrun Sensor
148
Part 7 - Perform Checkout Tests
149
WPC Power Supply Test
151
Check Safeguarding Devices
152
Check Dual Safety Valve (DSV) Wiring
154
Check the Emergency-Stop Circuit
156
Check the Top Stop Circuit
157
System Static Test
158
Anti-Tiedown Test
160
Anti-Repeat Test
161
Shadow Light Curtain Test
162
Single Stroke Mode Test with Light Curtain
164
Single Stroke Mode Test Without Light Curtain(S)
167
Continuous Mode Test with Light Curtain
169
Continuous Mode Test Without Light Curtain(S)
171
Foot Switch Test (with Optional Foot Switch)
173
One-Hand Control Switchtests (with Optional One-Hand Control)
175
Test for One-Hand Control with "Light Curtain Break" Mode
176
Test for One-Hand Control Without "Light Curtain Break" Mode
177
Bar Mode Control Test - Optional
178
User Inputs Test
179
Cam Channels Test (Optional - with Procampac)
179
Checkout Tests Complete
179
Part 8 - PC Board Illustrations and Wiring Tables
180
Chapter 3 - Smartpac 2 Keyboard, Displays and Operating Modes
193
Comparing Smartpac 2 with Original Smartpac
195
Smartpac 2 Keyboard
196
Figure 3 - 4. Stroke Select Key Switch
197
Number Keys
198
Clear Key
199
Help Key
200
Cursor Keys
201
ENTER and RESET Keys
203
Figure 3 - 12. RESET Key
204
Program/Run Key Switch
205
Function Keys
206
Hot Keys
207
Smartpac 2 Display
208
Selecting an Item on a Display
209
The Three Operating Modes of Smartpac 2
210
Table 3 - 1. Initialization, Program and Run Modes
211
Initialization Mode
212
Figure 3 - 19. Navigation Example: Initialization Mode
213
Program Mode
214
Figure 3 - 21. Navigation Example: Program Mode
215
Run Mode
216
Using Cursor Keys to Set Timing
217
Figure 3 - 24. Setting Cam Timing
218
Figure 3 - 26. Setting on Angle
219
Figure 3 - 27. Setting off Angle
220
Screen Capture
221
Chapter 4 - Smartpac 2 with WPC Initialization Mode
223
Smartpac 2 and Original Smartpac
224
How to Enter and Exit Initialization Mode
225
Initialize Press Parameters
226
Resolver Zero
226
Position Sensor
227
Position Sensor Mode
227
Resolver Motion Mode (Normal Motion - Link Motion)
228
Tool Number Mode
228
Table 4 - 1. Numeric and Alpha-Numeric Tool Number Modes
229
Counter Setup Mode
230
Installed Options
231
Press Name
232
SELECT CAM NAMES (Optional)
233
Figure 4 - 8. Custom Name Entry Box
234
AUTO ADVANCE and Slow RPM
235
Setting Auto Advance Constant and Slow RPM
236
SET GLOBAL CAMS (Optional)
238
Figure 4 - 11. Global Cams, Select Cam Channel
239
CUSTOM SENSOR NAMES (Optional)
240
SENSOR ENABLE MODE (Optional)
241
Enabling Sensors
241
Enabling or Disabling Setup Mode
242
TOOL INFORMATION (Optional)
243
Figure 4 - 18. Tool Information Names
244
Figure 4 - 20. Units Selection Menu
245
Figure 4 - 21. Completed Tool Number Information Screen
246
Press Control
247
User Interlocks
247
Figure 4 - 23. "User Interlock" Display
249
Figure 4 - 24. "Select Name" Display
250
Press Parameters
251
Stop Limit
252
Stopping Time and Stop Time Limit
252
Figure 4 - 26. Selecting "Brake Monitor" from Smartpac's Run Menu
253
Setting Stop Time Limit at Press Parameters
254
Setting the Start Time Limit at Press Parameters
256
Using Auto Carry-Up
257
Setting Auto Carry-Up Angle
258
Setting Micro-Inch Time and Angle (Optional)
258
Figure 4 - 31. "Micro-Inch" Display
259
Setting Clutch and Counterbalance Air Pressure Limits
260
Setting Shutdown and Flywheel Timer Limits (Optional)
261
Setting the ACTS Angle (Optional)
262
Initialize Parameters
263
Press Options
263
Setting Switches
264
Table 4 - 6. Switch 3 Settings for One-Hand Control or Foot Switch Mode
265
Table 4 - 7. Switch 4 Settings for Auto Compensated Top Stop
266
Table 4 - 8. Switch 5 Setting for Prior Act Timing
267
Table 4 - 9. Switch 6 Setting for Single or Dual Light Curtains
268
Table 4 - 11. Switch 8 Settings for Top Stop with F and H Errors
270
Operator Mode Settings on Press Control Option Switch Screen
271
Input Status
272
Security Access
273
Figure 4 - 34. "Enter Your Password" Screen
274
Table 4 - 13. Security Access Settings
275
Selecting Security Access Options
276
Changing Passwords
277
Reset Mode
277
Figure 4 - 36. Set Passwords Menu
278
Additional Security
279
Pacnet
280
Setup Network
281
E-Mail Function
281
Smartview Function
282
Setup E-Mail
282
Change Network Settings
284
Press Type
285
Diagnostics
285
Communications
286
Figure 4 - 44. Communications Data Combined (Left), Split (Right)
287
Set Clock
288
Update Firmware
288
Save to Usb Disk
289
Using Smartpac 2 with a Link-Motion Press
290
Setting Link Motion
290
Using a Servofeed Interface with Link Motion
291
Using a Computer Keyboard to Enter Names
292
Figure 4 - 46. Alphabetic Entry Window
293
Chapter 5 - Smartpac 2 with WPC Program Mode
295
Smartpac 2 and Original Smartpac
296
Entering and Exiting Program Mode
297
Tool Manager
298
Figure 5 - 4. Tool Manager
299
Load an Existing Tool
300
Delete a Tool
301
Tool Template
302
Create a New Tool
303
Change Settings for an Existing Tool
304
Copy an Existing Tool
304
Figure 5 - 10. Load Tool Warning Box
306
Tool Program Menu
307
TOOL NAME or TOOL ID
308
Counters
308
Setting or Clearing the Counter Presets
309
Setting or Clearing the Counter Values
310
Clearing the Total Hits Preset Message
310
Setting Counter Mode
310
Figure 5 - 14. Counter Setup Mode Menu
311
Setting Parts/Stroke or Strokes/Part
312
Figure 5 - 15. Advanced Counter Mode
313
Die Protection
314
Setting "Auto Enable by Tool" Counter Value
314
Figure 5 - 17. Setting "Auto Enable by Tool" Counter
315
Naming the Sensor
316
Setting the "Auto Enable by Sensor and Tool" Counter Value
316
Setting Sensor Type
317
Setting Stop Type
318
Setting the Ready Signal for a Green Sensor
319
Figure 5 - 24. Example of a Programmed Ready Signal for Part Ejection
320
Setting the Other Sensors for the Tool
321
Going Back to the Main Programming Menu
321
Figure 5 - 26. Load Tool Warning Box
322
Cam Switch
324
Figure 5 - 27. Cam Program Menu
325
View Global Cams
326
Make an ON/OFF Setting for a Channel
327
View Cam Summary
327
Figure 5 - 30. Select Type of Cam Timing
328
Multiple On/Offs for Cam Channels
329
Figure 5 - 32. One ON/OFF Arc
330
Selecting a Channel and Making a Timed Output Setting
331
Figure 5 - 35. a Timed Output Channel
332
Selecting a Channel and Making an Auto Advance Setting
333
Setting DSV on Channel Timing
334
Delete Channel Settings
335
Set Other Channels for the Tool
335
Press Control
336
Tool Information
337
Figure 5 - 40. Text Entry Box
338
Sensor Enable/Disable & Status
339
Controlling Which Sensors Smartpac 2 Monitors
339
Enable or Disable All Sensors
340
Turn a Sensor off or on
340
RECALCULATE SETPOINTS (Optional)
341
Chapter 6 - Smartpac 2 with WPC Run Mode
343
About Run Mode
344
What You Can and Cannot Do in Run Mode
344
Why some Tasks Are Duplicated in each Mode
344
Locking Run Mode
344
Interrupted Stroke
344
Hot Keys
345
Smartpac 2 and Original Smartpac
346
Part 1 - Using Smartpac 2 in Run Mode
347
How to Enter and Exit Run Mode
347
Load a Tool Number before Switching to Run Mode
347
Settings Locked in Run Mode, or Password Required
348
How to Use Hot Keys
349
Toggle Hot Keys
349
How to Program a Hot Key
350
How to Delete a Hot Key
350
Main Run Menu
351
DISABLE (ENABLE) SENSORS (Optional)
352
Setup Mode Message
353
Counters
354
DIE PROTECTION (Optional)
355
Adjusting the Ready Signal for Green Sensors
356
Figure 6 - 11. Adjust Ready Signal
357
View Sensor Summary
359
Show Sensor Status
360
CAM SWITCH (Optional)
362
View Cam Timing
363
Figure 6 - 15. Viewing Cam Timing
364
View Global Cam Summary
365
View Cam Summary
366
Brake Monitor
367
Setting Stop Time, Stop Angle, and Start Time
367
Start Time
367
Stopping Angle
368
Brake Warning
368
Performing the 90° Stop-Time Test
368
Figure 6 - 18. Using "Brake Monitor" Display for 90° Test
369
Calculating the Safety Distance
370
Press Control
375
Adjusting Top Stop Angle, Press Speed Limits, Counterbalance Setpoint, Main System Air Limit.353
375
Show Overrun Angles
376
Viewing Actual Counterbalance and Main Air Pressure Limits (Optional)
376
TOOL INFORMATION (Optional)
377
Error Log
378
Load New Tool
379
Load Next Tool Number (Available Only with Pacnet Software)
379
Figure 6 - 24. Next Tool Number Display
380
Select a Tool to Load
381
Figure 6 - 28. Load Tool Warning Box
382
Messaging
383
Send E-Mail to Wintriss Tech Support
384
Toggle Hot Keys
385
Part 2 - Operating the Press
386
Interrupted Stroke
386
Mode Select Menu
387
Operating the Press in INCH Mode
388
Three Ways You Can Operate the Press in INCH Mode
388
Operating the Press in Single Stroke Mode
390
One-Hand Operation, Single Stroke Mode
391
Two-Hand Operation, Single Stroke Mode
392
Foot Operation, Single Stroke Mode
394
Operating the Press in Automatic Single Stroke Mode
395
Setting Prior Act Timing for Automatic Single Stroke
396
Automatic Single Stroke Operating Instructions
396
Operating the Press in Continuous Mode
397
Two-Hand Operation, Continuous Mode
397
Foot Operation, Continuous Mode
398
Operating the Press in Continuous on Demand Mode
399
Using One-Hand Control
400
Light Curtain Break" Mode
400
Operating the Press Using One-Hand Control
401
Operating the Press in BAR Mode
402
Multiple Operator Stations
402
Chapter 7 - Smartpac 2 with WPC Fault Messages and Troubleshooting383
405
Smartpac 2 and Original Smartpac
406
What Happens When You Get a Fault Message
407
How to Clear the Fault Message from the Display
407
Status Code #10
408
Interrupted Stroke
408
Lockout
409
Brake Monitor Brake Warning
410
Brake Monitor - Stop Time Exceeded
410
Customized Status Codes
412
Description of Status Codes and How to Correct
412
Messages Displayed Due to Press Control Problems
413
Resolver Faults
414
Operational Faults
415
Inter-Processor Failures
419
Input Buffer Test Failures
419
Air Pressure Limits Exceeded
420
Component Failures
421
Customized Status Codes
422
Table 7 - 1. User Inputs (Interlocks), Smartpac with WPC
423
Light Curtain Faults
424
Emergency Stop Circuit Driver Failure
426
Top Stop Circuit Driver Failure
426
DSV Interface and Lockout Relay Failures
427
Loss of Rotation
428
Internal Timing Input Failures
428
Top Stop and Overrun Setting Faults
429
Overrun Limit Switch Fault
429
Overrun Limit Switch Test Angle Fault
430
Overrun Limit Switch Setting Fault
430
Internal Memory Failures
431
Messages Displayed for Equipment or Brake Monitor Problems
431
Messages Displayed for Programming Problems
434
Messages Displayed When a Sensor Signals a Fault
436
Miscellaneous Fault Messages
438
Error Log
440
E-Mail Error Log and Other Information to Wintriss Tech Support
441
Using the WPC Input Status Display
442
Figure 7 - 11. Display WPC Input Status Menu
443
Figure 7 - 13. Display of Estops/Top Stops Input Status
444
Install Revised Firmware into WPC
445
Appendix A - OSHA Regulations and ANSI Standards
449
Section 1 OSHA Regulation 1910.217
449
Section 2 ANSI Standards for Presence-Sensing Devices
453
Appendix B - Smartpac Preventive Maintenance (PM) Monitor (Optional)437
459
Comparison with Traditional Preventive Maintenance
459
How the PM Monitor Works
460
Examples of How to Use the PM Monitor
460
Table B - 1. Preventive Maintenance Items
461
Smartpac 2 and Original Smartpac
462
Installing the PM Monitor
463
For New Systems from the Factory
463
For Existing Systems
463
Using the PM Monitor in Initialization Mode
463
How to Get into Smartpac Initialization and PM Monitor
463
Figure B - 2. "PM Monitor" Highlighted at Smartpac Initialization Menu
464
Initializing the PM Monitor
465
Figure B - 4. PM Password Screen
466
Assigning a New PM Password Number
467
Select PM Item Names
468
Figure B - 9. Displaying Available List of PM Names
469
Figure B - 11. Selecting Tracking Unit of Measure
470
Figure B - 13. Example
471
Using the PM Monitor in Run Mode
472
How to Get into Smartpac Run Mode
472
A Tool Number Must be Loaded before Switching to Run Mode
472
Viewing and Modifying PM Alerts
473
Figure B - 16. Shows "Slide Adjust Motor" in "Alert" Mode
474
Appendix C - Update Smartpac 2 Firmware
475
Appendix D - Smartview Remote Viewing and E-Mail Setup
477
Appendix E - Upgrade from Original Smartpac to Smartpac 2
479
Appendix F - Replacing Smartpac 2 PC Board
481
Glossary of Terms
483
Index
493
Procampac Cam Switch Setup Sheet Channels
501
Procampac Cam Switch Setup Sheet Channels
502
4
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Honeywell SmartPAC 2 Specifications
General
Brand
Honeywell
Model
SmartPAC 2
Category
Control Unit
Language
English
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