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SmartPAC 2 User Manual 1126700

Installation 2-13

Table 2-1. Resolver Wiring

PIN # on TB101 Wire Color

Shield

(terminate to ground stud

nearest entry to enclosure)

212 (GND) No connection

213 (S1) Black*

214 (S2) Green

215 (R1) Red

216 (S3) Yellow*

217 (R2) Orange

218 (S4) Brown

* Shown for clockwise rotation, facing shaft.

For counterclockwise rotation, swap black and yellow wires.

Figure 2-7. SmartPAC 2 Board: Location of Components

TB101

RESOLVER

S101

TB105

TB106

TB102

TB107

TB104 TB103

AUX I/O

JP101

MASTER

SLAVE

JP102

SPEED

LOW

HIGH

INPUT

CHECK

SWITCH

ProCam DiPro

PACNET

SPECIAL MODULE

SFI

E-STOP

RELAYS

POSITION

SENSOR

LED

USB PORT

LEDS

TOP

STOP

LED

POWER

LEDS

ETHERNET

ETHERNET LEDS

LINK

ACTIVITY

USB

INPUT

CHECK

LED

E-STOP

LEDS

COMPACT

FLASH

ACCESS LED

K101 K102

F101

F102 F103

INPUT CHECK

FUSE

E-STOP

FUSE

TOP STOP

FUSE

TOP

STOP

RELAY

PS/2

ZERO

CAM

LED

BATTERY

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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