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SmartPAC 2 User Manual 1126700

Installation 2-9

Figure 2-5. SmartPAC 2 Mounting and Cutout Dimensions: Panel Mount

0.35

(8.9)

TYP

Dimensions:

Inches (mm)

0.35

(8.9)

TYP

4.50

(114.3)

ENTER

RESET

PROG RUN

POWER

BRAKE

WARNING

HELP

123

456

987

CLEAR

SmartPAC 2

NOTE:

SmartPAC and SmartPAC 2

both use the same size cutout:

9.5 x 11 inches. The top 9 holes

are in the same location.

If you are replacing a SmartPAC

with a SmartPAC 2, drill three

additional holes at the locations

shown for the bottom three holes.

10.65

(270.5)

11.00

(279.4)

11.30

(287.0)

12.30

(312.4)

0.35

(8.9)

TYP

8.65

(105.4)

9.00

(228.6)

10.35

(261.6)

5.50

(139.7)

0.35

(8.9)

TYP

Allow 6 inches (153 mm)

minimum clearance behind

the panel

Panel

Cutout

OFF

INCH

SINGLE

STROKE

CONT

Default Chapter4
- Table of Contents4
Chapter 1. Introduction to Smartpac 222
- Smartpac 2 Standard Features22
- Smartpac 2 Front Panel23
- Smartpac 2 Options23
- Figure 1-1. Smartpac 2 Front Panel24
- Resolver-Based Operation25
- Smartpac 2 Settings25
- Sensors Available for Dipropac26
- Procampac Programmable Cams27
- Smartpac 2'S Three Modes of Operation27
- Smartpac 2 Specifications28
Chapter 2. Installing Smartpac 230
- Before You Start31
Installing Smartpac 231
- Installation Guidelines32
- Figure 2-1. Installation Overview33
- Connecting Wires to Terminal Block Connectors34
- Figure 2-2. Attaching Wires to Connector34
- Terminating Cable Shields34
- Checking the Press35
- Figure 2-3. Connecting Shield Drain Wire to Ground Stud35
- Figure 2-4. Smartpac 2 Mounting Dimensions: Enclosure36
- Mounting the Smartpac 2 Control Enclosure36
- Installing Smartpac 2 as a Panel Mount37
  - Figure 2-5. Smartpac 2 Mounting and Cutout Dimensions: Panel Mount38
  - Figure 2-6. Resolver Dimensions ("Military-Style" Connector)39
  - Mounting the Resolver40
  - Wiring the Resolver41
  - Figure 2-7. Smartpac 2 Board: Location of Components42
- Installing the Resolver39
- Connecting AC Wiring43
- Figure 2-8. Wiring AC to Terminal Block, Inside Enclosure, Top Right43
- Connecting Stop Circuits and Input Check Circuit44
  - Figure 2-9. Schematic of Input Check Circuit for 10-130 Vac or VDC44
  - Making Wiring Connections45
  - Setting the Input Check Voltage Switch45
- Connecting to Network46
- Figure 2-10. Input Check Voltage Switch (S101)46
- Adding or Upgrading Dipropac or Procampac47
  - Replacing an Existing Board47
  - Figure 2-11. Dipropac and Procampac Boards Installed on Smartpac 2 Board48
  - Figure 2-12. Dipropac Boards (8-, 16-, and 32-Sensor): Location of Components49
  - Figure 2-13. Procampac Boards (8- and 16-Channel): Location of Components49
  - Installing a New Board50
- Connecting Dipro Sensor Interface to Smartpac 251
  - Table 2-3. Dipro Sensor Interface (DSI) 2 to Smartpac 2 Wiring, Sensors 1-852
  - Table 2-5. Dipro Sensor Interface (DSI) 2 to Smartpac 2 Wiring, Sensors 17-2453
- Connecting Programmable Cam Channels54
- Figure 2-14. Procampac Output Assembly55
- Figure 2-15. Cam Outputs Board56
- Table 2-7. Procampac to Cam Output Assembly TB301 Wiring, Cams 1-857
- Figure 2-16. Connector TB302 and TB303 for Wiring Relays to Equipment58
- Figure 2-17. Installing Suppressors Across an AC Load59
- Figure 2-18. Installing a Diode Across a DC Load59
- Wiring a Remote Reset Switch (Optional)60
- Wiring a Sensor-Disabled Output (Optional)60
- Wiring Setup Mode Circuit60
- Figure 2-19. Optional Top-Stop Wiring61
- Figure 2-20. Smartpac 2 Startup Screen62
- Turning on Power to Smartpac 262
- Figure 2-21. Main Program Menu63
- Verifying Installation of Dipropac and Procampac63
- Zeroing the Resolver64
  - Moving the Ram to Top Dead Center (TDC)65
  - Setting the Resolver Zero Position65
- Installing the Position Sensor (Optional)66
- Figure 2-25. Position Sensor Dwell on Different Diameter Shafts67
- Figure 2-26. Position Sensor Screen68
- Figure 2-27. Position Sensor Installation69
- Final Checkout70
- Set up a "Test" Tool70
  - Check and Set Direction of Rotation of Resolver71
  - Check for Position Sensor (if Installed) Error Messages71
  - Check the Top-Stop Circuit71
  - Check the Emergency-Stop Circuit71
  - Check Cam Channels (Procampac Only)71
  - Test Complete72
- Setting up High Speed Version of Smartpac 2 (Optional)70
- What Next72
- Table 2-12. Spare 1 Port (5) and WPC Port (6) (TB105) Wiring73
Chapter 3 . Smartpac 2 Keyboard, Displays and Operating74
Modes74
- Comparing Smartpac 2 with Original Smartpac75
- Smartpac 2 Keyboard76
- Smartpac 2 Display Layout in Run Mode85
- Selecting an Item on a Display86
- Smartpac 2 Operating Modes87
- Table 3-1. Initialization, Program and Run Modes: Entry and Exit Procedures88
- Initialization Mode89
- Figure 3-23. Navigation Example: Initialization Mode90
- Program Mode91
- Figure 3-25. Navigation Example: Program Mode92
- Run Mode93
- Figure 3-27. Navigation Example: Run Mode94
- Screen Capture95
  - Screen Capture in Smartpac 2 Main Versions Earlier than V 5.3.195
  - Screen Capture in Smartpac 2 Main Versions V 5.3.1 and Later97
Chapter 4. Smartpac 2 Initialization Mode98
- Entering and Exiting Initialization Mode98
- Resolver Zero99
- Position Sensor100
  - Position Sensor Mode100
  - Resolver Motion Mode (Normal Motion - Link Motion)101
  - Angle Wheel Rotation (Clockwise - Counterclockwise)101
  - Tool Number Mode101
  - Table 4-2. Numeric and Alphanumeric Tool Number Modes102
  - Counter Setup Mode103
  - Counter Increment Mode103
- Installed Options104
- Press Name105
- Set Brake Monitor105
  - Calculating the Stop Time Limit106
  - Setting Stop Time and Start Time Limits107
- SELECT CAM NAMES (Optional)107
- Figure 4-8. Cam Channel Name Menu108
- AUTO ADVANCE and Slow RPM (Optional)109
  - Figure 4-10. Auto Advance Menu110
  - Calculating the Auto Advance Constant111
  - Setting Auto Advance Constants and Slow RPM111
- SET GLOBAL CAMS (Optional)112
- Figure 4-11. Global Cams Menu113
- CUSTOM SENSOR NAMES (Optional)114
- SENSOR ENABLE MODE (Optional)115
  - Selecting Sensor Enable Mode116
  - Enabling Setup Mode117
- Tool Information117
- Figure 4-15. Tool Information Setup Screen118
- Figure 4-17. Tool Information Units Selection Screen119
- Table 4-3. Tool Information Setup Screen: Abbreviations for Units120
- Security Access121
  - Table 4-5. Security Access Settings122
  - Setting Security Access124
  - Changing Passwords125
- Backup/Restore126
  - Backing up Tools to a USB Disk127
  - Figure 4-23. Backup/Restore Control Menu128
  - Restoring Tools from a USB Disk129
- SETUP DATA COMMS (Optional)130
- Setup Network131
  - E-Mail Function131
  - Smartview Function132
  - Setup E-Mail132
  - Figure 4-27. Setup E-Mail Screen133
  - Change Network Settings134
  - Press Type135
- Diagnostics135
  - Communications136
  - Set Clock138
  - Save to Usb Disk139
  - Update Firmware139
- Using Smartpac 2 with a Link-Motion Press139
  - Setting Link Motion140
  - Using a Servofeed Interface with Link Motion140
- Using a Computer Keyboard to Enter Names142
Chapter 5. Smartpac 2 Program Mode144
- Entering and Exiting Program Mode144
- Tool Manager145
- TOOL NAME or TOOL ID151
- Tool Program Menu151
- Counters152
- DIE PROTECTION (Optional)159
- CAM SWITCH (Optional)180
- Press Speed191
- Tool Information192
- Figure 5-58. Tool Information Screen193
- SENSOR ENABLE/DISABLE & STATUS (Optional)194
Chapter 6. Smartpac 2 Run Mode198
- Entering and Exiting Run Mode199
- Loading a Tool199
- Programming Hot Keys200
- Settings Locked, or Password Required201
- Disable (Enable) Sensors202
- Displaying Multiple Faults202
- Figure 6-7. Main Run Menu with SENSORS ENABLED and SENSORS DISABLED Displays203
- Counters204
- Figure 6-10. Counters Screen with "Reload Batch Counters" Function205
- DIE PROTECTION (Optional)206
- CAM SWITCH (Optional)213
- Brake Monitor216
- Press Speed224
- Tool Information225
- Figure 6-23. Tool Number Information Screen226
- Error/Event Log227
- Load New Tool228
- Messaging229
  - Figure 6-27. Messaging Screen: List of Recipients230
  - Sending E-Mail to Wintriss Technical Support231
- Toggle Hot Keys232
Chapter 7. Smartpac 2 Fault Messages234
- Responding to Fault Messages234
- Responding to the Brake Warning LED234
- Counter Preset Reached Messages235
- Messages for Equipment or Brake Monitor Problems236
- Messages for Programming Problems239
- Messages for Sensor Faults241
- Miscellaneous Fault Messages243
- Troubleshooting Using the Error/Event Log244
- About Smartpac PM Monitor246
Appendix A. Smartpac Preventive Maintenance (PM) Monitor246
- Installing the PM Monitor248
  - For New Systems from the Factory248
  - For Existing Systems248
- Table A-1. Preventive Maintenance Items248
- Using the PM Monitor in Initialization Mode249
- Using the PM Monitor in Run Mode257
Appendix B. Updating Smartpac 2 Firmware260
- Updating Firmware Using a USB Disk260
  - Installing Updated Firmware from USB Disk to Smartpac 2261
- Table B-1. Record of Current Counts261
- Installing Firmware from a Replacement Compact Flash (CF) Card268
- Figure B-5. Firmware Load Menu with "RELOAD CURRENT FIRMWARE" Highlighted269
- Figure B-7. Smartpac 2 Display with "Loading Firmware" Message270
Appendix C. Smartview Remote Viewing and E-Mail Setup272
- Network Requirements272
- Network Setup272
- Table C-1. Smartpac 2 Board: PS 2 and Y-Cable Configuration275
- Installing Smartview277
- Smartview Operation281
- Figure C-9. Press Status Information Page284
- Remote Messaging284
- E-Mail Setup285
- Figure C-10. Smartpac 2 Remote Message285
- Figure C-11. Email Setup Page286
- Smartview Ping Utility286
- Figure C-12. Mabry Internet Ping Window287
- Figure C-14. Ping Utility Window with Example of a Successful Ping288
Appendix D. Upgrading from Original Smartpac to Smartpac 2290
- Backing up Tools on Original Smartpac290
- Figure D-1. Backup/Restore Control Menu291
- Removing Smartpac 1 and Mounting Smartpac 2292
- Wiring the Smartpac 2293
- Table D-1. Smartpac 1 to Smartpac 2 Wiring Changes: Main Power295
- Table D-4. Smartpac 1 to Smartpac 2 Wiring Changes: Resolver Port296
- Table D-7. Smartpac 1 to Smartpac 2 Wiring Changes: Dipropac, 16-Channel297
- Table D-9. Smartpac 1 to Smartpac 2 Wiring Changes: Procampac, 16-Channel298
- Table D-13. Smartpac 1 to Smartpac 2 Wiring Changes: Remote Reset (Optional)299
- Table D-15. Smartpac 1 to Smartpac 2 Wiring Changes: SFI (Optional)300
  - AC Wiring on Smartpac 2301
- Figure D-2. Smartpac 2 AC Wiring (Inside Enclosure, Top Right)301
- Restoring Tools to Smartpac 2301
- Figure D-3. Backup/Restore Control Menu with Restore Confirmation Message Displayed302
- System Checkout303
Appendix E. Replacing Smartpac 2 PC Board304
- Unpacking the Replacement Board304
- Installing the Replacement Board305
- Figure E-1. Smartpac 2 PC Board306
- Figure E-2. Firmware Load Menu with "RELOAD CURRENT FIRMWARE" Highlighted308
Appendix F. Reporting Downtime and Scrap to SFC310
- Machine States to Which SFC Logs Press Time310
- Smartpac 2 Downtime Reporting Features311
- Setting up Smartpac 2 to Report Downtime316
  - Making Downtime Reporting Settings316
    - Figure F-4. Smartpac 2 Main Initialization Menu317
    - Table F-1. Set Communications Menu Settings318
  - Programming Downtime Reasons321
    - Figure F-6. Dialog Fixed Name Choice Menu322
    - Figure F-7. Dialog Special Choice Name Menu324
- Documenting Downtime on the Dialog Menu325
- Reporting Scrap and Good Parts to SFC331
Appendix G. Reporting Downtime and Scrap to LETS336
- Machine States to Which LETS Logs Press Time336
- Smartpac 2 Downtime Reporting Features337
- Setting up Smartpac 2 to Report Downtime341
  - Making Downtime Reporting Settings342
- Table G-1. Set Communications Menu Settings343
  - Programming Downtime Reasons346
  - Figure G-7. Dialog Special Choice Name Menu348
- Documenting Downtime on the Dialog Menu349
- Reporting Scrap and Good Parts to LETS354
Glossary360
Index364
Wintriss Manuals370
Smartpac 2 Setup Sheets371

Brand	Wintriss
Model	SmartPAC2
Category	Controller
Language	English

Wintriss SmartPAC2 User Manual

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