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Wintriss SmartPAC2 User Manual
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SmartP
A
C 2 User Manual
1
126700
Installation
2-35
Zeroi
ng the Resolver
You must perform t
his procedur
e the first time you
power up SmartPAC 2 and whenever you
instal
l a new resol
ver.
Figure 2-22. Main
Initi
alization Menu
Figure 2-2
3. Installed Opti
ons Screen
PRESS MUST B
E A
T TDC WHE
N ZEROING RE
SOLVER
V
erify that the p
ress is at top
dead cen
ter (i.e., at 0
°
± 2
°
)
before you z
ero the resolv
er
. If the
press
is not at
TDC, your ti
ming set
tings may
be wrong
.
F1
F2
F3
F4
F5
F6
F7
F8
NOTICE
63
65
Table of Contents
Default Chapter
4
Table of Contents
4
Chapter 1. Introduction to Smartpac 2
22
Smartpac 2 Standard Features
22
Smartpac 2 Front Panel
23
Smartpac 2 Options
23
Figure 1-1. Smartpac 2 Front Panel
24
Resolver-Based Operation
25
Smartpac 2 Settings
25
Sensors Available for Dipropac
26
Procampac Programmable Cams
27
Smartpac 2'S Three Modes of Operation
27
Smartpac 2 Specifications
28
Chapter 2. Installing Smartpac 2
30
Before You Start
31
Installing Smartpac 2
31
Installation Guidelines
32
Figure 2-1. Installation Overview
33
Connecting Wires to Terminal Block Connectors
34
Figure 2-2. Attaching Wires to Connector
34
Terminating Cable Shields
34
Checking the Press
35
Figure 2-3. Connecting Shield Drain Wire to Ground Stud
35
Figure 2-4. Smartpac 2 Mounting Dimensions: Enclosure
36
Mounting the Smartpac 2 Control Enclosure
36
Installing Smartpac 2 as a Panel Mount
37
Figure 2-5. Smartpac 2 Mounting and Cutout Dimensions: Panel Mount
38
Figure 2-6. Resolver Dimensions ("Military-Style" Connector)
39
Mounting the Resolver
40
Wiring the Resolver
41
Figure 2-7. Smartpac 2 Board: Location of Components
42
Installing the Resolver
39
Connecting AC Wiring
43
Figure 2-8. Wiring AC to Terminal Block, Inside Enclosure, Top Right
43
Connecting Stop Circuits and Input Check Circuit
44
Figure 2-9. Schematic of Input Check Circuit for 10-130 Vac or VDC
44
Making Wiring Connections
45
Setting the Input Check Voltage Switch
45
Connecting to Network
46
Figure 2-10. Input Check Voltage Switch (S101)
46
Adding or Upgrading Dipropac or Procampac
47
Replacing an Existing Board
47
Figure 2-11. Dipropac and Procampac Boards Installed on Smartpac 2 Board
48
Figure 2-12. Dipropac Boards (8-, 16-, and 32-Sensor): Location of Components
49
Figure 2-13. Procampac Boards (8- and 16-Channel): Location of Components
49
Installing a New Board
50
Connecting Dipro Sensor Interface to Smartpac 2
51
Table 2-3. Dipro Sensor Interface (DSI) 2 to Smartpac 2 Wiring, Sensors 1-8
52
Table 2-5. Dipro Sensor Interface (DSI) 2 to Smartpac 2 Wiring, Sensors 17-24
53
Connecting Programmable Cam Channels
54
Figure 2-14. Procampac Output Assembly
55
Figure 2-15. Cam Outputs Board
56
Table 2-7. Procampac to Cam Output Assembly TB301 Wiring, Cams 1-8
57
Figure 2-16. Connector TB302 and TB303 for Wiring Relays to Equipment
58
Figure 2-17. Installing Suppressors Across an AC Load
59
Figure 2-18. Installing a Diode Across a DC Load
59
Wiring a Remote Reset Switch (Optional)
60
Wiring a Sensor-Disabled Output (Optional)
60
Wiring Setup Mode Circuit
60
Figure 2-19. Optional Top-Stop Wiring
61
Figure 2-20. Smartpac 2 Startup Screen
62
Turning on Power to Smartpac 2
62
Figure 2-21. Main Program Menu
63
Verifying Installation of Dipropac and Procampac
63
Zeroing the Resolver
64
Moving the Ram to Top Dead Center (TDC)
65
Setting the Resolver Zero Position
65
Installing the Position Sensor (Optional)
66
Figure 2-25. Position Sensor Dwell on Different Diameter Shafts
67
Figure 2-26. Position Sensor Screen
68
Figure 2-27. Position Sensor Installation
69
Final Checkout
70
Set up a "Test" Tool
70
Check and Set Direction of Rotation of Resolver
71
Check for Position Sensor (if Installed) Error Messages
71
Check the Top-Stop Circuit
71
Check the Emergency-Stop Circuit
71
Check Cam Channels (Procampac Only)
71
Test Complete
72
Setting up High Speed Version of Smartpac 2 (Optional)
70
What Next
72
Table 2-12. Spare 1 Port (5) and WPC Port (6) (TB105) Wiring
73
Chapter 3 . Smartpac 2 Keyboard, Displays and Operating
74
Modes
74
Comparing Smartpac 2 with Original Smartpac
75
Smartpac 2 Keyboard
76
Number Keys
76
CLEAR Key
77
Cursor Keys
78
HELP Key
82
ENTER Key
82
RESET Key
83
Program/Run Key Switch
83
Function Keys
84
Hot Keys
84
Smartpac 2 Display Layout in Run Mode
85
Selecting an Item on a Display
86
Smartpac 2 Operating Modes
87
Table 3-1. Initialization, Program and Run Modes: Entry and Exit Procedures
88
Initialization Mode
89
Figure 3-23. Navigation Example: Initialization Mode
90
Program Mode
91
Figure 3-25. Navigation Example: Program Mode
92
Run Mode
93
Figure 3-27. Navigation Example: Run Mode
94
Screen Capture
95
Screen Capture in Smartpac 2 Main Versions Earlier than V 5.3.1
95
Screen Capture in Smartpac 2 Main Versions V 5.3.1 and Later
97
Chapter 4. Smartpac 2 Initialization Mode
98
Entering and Exiting Initialization Mode
98
Resolver Zero
99
Position Sensor
100
Position Sensor Mode
100
Resolver Motion Mode (Normal Motion - Link Motion)
101
Angle Wheel Rotation (Clockwise - Counterclockwise)
101
Tool Number Mode
101
Table 4-2. Numeric and Alphanumeric Tool Number Modes
102
Counter Setup Mode
103
Counter Increment Mode
103
Installed Options
104
Press Name
105
Set Brake Monitor
105
Calculating the Stop Time Limit
106
Setting Stop Time and Start Time Limits
107
SELECT CAM NAMES (Optional)
107
Figure 4-8. Cam Channel Name Menu
108
AUTO ADVANCE and Slow RPM (Optional)
109
Figure 4-10. Auto Advance Menu
110
Calculating the Auto Advance Constant
111
Setting Auto Advance Constants and Slow RPM
111
SET GLOBAL CAMS (Optional)
112
Figure 4-11. Global Cams Menu
113
CUSTOM SENSOR NAMES (Optional)
114
SENSOR ENABLE MODE (Optional)
115
Selecting Sensor Enable Mode
116
Enabling Setup Mode
117
Tool Information
117
Figure 4-15. Tool Information Setup Screen
118
Figure 4-17. Tool Information Units Selection Screen
119
Table 4-3. Tool Information Setup Screen: Abbreviations for Units
120
Security Access
121
Table 4-5. Security Access Settings
122
Setting Security Access
124
Changing Passwords
125
Backup/Restore
126
Backing up Tools to a USB Disk
127
Figure 4-23. Backup/Restore Control Menu
128
Restoring Tools from a USB Disk
129
SETUP DATA COMMS (Optional)
130
Setup Network
131
E-Mail Function
131
Smartview Function
132
Setup E-Mail
132
Figure 4-27. Setup E-Mail Screen
133
Change Network Settings
134
Press Type
135
Diagnostics
135
Communications
136
Set Clock
138
Save to Usb Disk
139
Update Firmware
139
Using Smartpac 2 with a Link-Motion Press
139
Setting Link Motion
140
Using a Servofeed Interface with Link Motion
140
Using a Computer Keyboard to Enter Names
142
Chapter 5. Smartpac 2 Program Mode
144
Entering and Exiting Program Mode
144
Tool Manager
145
Creating a New Tool
146
Copying an Existing Tool
147
Copying Tool Template to a New Tool
148
Loading a Tool
148
Changing Settings for a Loaded Tool
149
Deleting a Tool
150
TOOL NAME or TOOL ID
151
Tool Program Menu
151
Counters
152
Figure 5-11. Counters Screen
153
Changing Count Values
154
Setting Preset Values
154
Clearing the Total Hits Counter
155
Setting Batch Counter Output and Increment Modes
156
Setting Counter Increment Angle
157
Setting Parts Per Stroke or Strokes Per Part
157
Setting Batch Pre-Load Counts
158
DIE PROTECTION (Optional)
159
Understanding Sensor Terminology
159
Figure 5-17. Ready Signal Programming for a "Green" Sensor
161
Figure 5-18. Ready Signal Programming for a "Green Quick Check" Sensor
162
Programming Sensor Settings
163
Figure 5-20. "Enter Your Password" Screen
164
Figure 5-22. Sensor Names Screen
165
Figure 5-23. Custom Sensor Names Screen
166
Figure 5-25. Sensor Type Screen
167
Figure 5-26. Sensor Stop Type Screen
168
Figure 5-27. Critical Angle Programming Screen
169
Figure 5-28. Ready Signal Programming Screen
171
Figure 5-29. Green Special Sensor Stroke Count Screen
172
Figure 5-30. Sensor Settings Screen
173
Programming Dipropac 32 Sensors
174
Figure 5-32. Tool Program Menu with DIPROPAC 1-16 and DIPROPAC 17-32 Items
175
Figure 5-34. Sensor Names Screen with Stripper Function Highlighted
176
Figure 5-36. Sensor Stop Type Screen
177
Figure 5-38. Sensor Settings Screen
178
Figure 5-40. Sensor Type Screen with "GREEN SPECIAL" Highlighted
179
CAM SWITCH (Optional)
180
Selecting a Cam Channel
181
Making an ON/OFF Setting
182
Setting Multiple ON/OFF Cycles
183
Figure 5-47. Cam Channel On/Off Program Screen: One On/Off Arc
184
Making a Timed Output Setting
185
Figure 5-50. Cam Channel Timed Output Program Screen
186
Making an Auto Advance Setting
187
Setting DSV on Channel Timing
188
Deleting Channel Settings
189
Viewing the Cam Summary
189
Viewing Global Cams
190
Press Speed
191
Tool Information
192
Figure 5-58. Tool Information Screen
193
SENSOR ENABLE/DISABLE & STATUS (Optional)
194
Viewing Sensor Status
194
Enabling or Disabling All Sensors
195
Turning a Sensor off or on
195
Figure 5-61. "Sensor Turned Off" Message
196
Chapter 6. Smartpac 2 Run Mode
198
Entering and Exiting Run Mode
199
Loading a Tool
199
Programming Hot Keys
200
Settings Locked, or Password Required
201
Disable (Enable) Sensors
202
Displaying Multiple Faults
202
Figure 6-7. Main Run Menu with SENSORS ENABLED and SENSORS DISABLED Displays
203
Counters
204
Figure 6-10. Counters Screen with "Reload Batch Counters" Function
205
DIE PROTECTION (Optional)
206
Adjusting the Ready Signal for Green Sensors
207
Adjusting the Stroke Preset for Green Special Sensors
209
Viewing the Sensor Summary
209
Viewing Sensor Status
209
Figure 6-13. Sensor Status Screen
210
Adjusting Dipropac 32 Sensors
211
Figure 6-15. die Protection Sensor Menu for Sensors 17-32
212
CAM SWITCH (Optional)
213
Viewing Cam Timing
214
Viewing the Global Cam Summary
215
Viewing the Cam Summary
216
Brake Monitor
216
Determining the Stopping Time of Your Press
217
Performing the 90× Stop-Time Test
217
Calculating the Safety Distance
218
Figure 6-21. View of Light Curtains and Press Showing Safety Distance
219
Table 6-2. Shadow Light Curtain Response Time and Object Sensitivity
220
Press Speed
224
Tool Information
225
Figure 6-23. Tool Number Information Screen
226
Error/Event Log
227
Load New Tool
228
Messaging
229
Figure 6-27. Messaging Screen: List of Recipients
230
Sending E-Mail to Wintriss Technical Support
231
Toggle Hot Keys
232
Chapter 7. Smartpac 2 Fault Messages
234
Responding to Fault Messages
234
Responding to the Brake Warning LED
234
Counter Preset Reached Messages
235
Messages for Equipment or Brake Monitor Problems
236
Messages for Programming Problems
239
Messages for Sensor Faults
241
Miscellaneous Fault Messages
243
Troubleshooting Using the Error/Event Log
244
About Smartpac PM Monitor
246
Comparison with Traditional Preventive Maintenance
246
How the PM Monitor Works
247
Examples of How to Use the PM Monitor
247
Appendix A. Smartpac Preventive Maintenance (PM) Monitor
246
Installing the PM Monitor
248
For New Systems from the Factory
248
For Existing Systems
248
Table A-1. Preventive Maintenance Items
248
Using the PM Monitor in Initialization Mode
249
How to Get into Smartpac Initialization and PM Monitor
249
Figure A-1. "PM Monitor" Highlighted on Smartpac 2 Initialization Menu
249
Figure A-2. PM Password Screen
250
Initializing the PM Monitor
251
Figure A-3. PM Password Screen Showing Password Retrieval Number
251
Figure A-4. PM Entry Screen
252
Assigning a New PM Password Number
253
Selecting PM Item Names
253
Figure A-6. Initialize Warning Screen
253
Figure A-7. PM Monitor Screen
254
Figure A-9. Alphanumeric Display Superimposed over PM Names Screen
255
Figure A-11. Superimposed Number Display
256
Using the PM Monitor in Run Mode
257
How to Get into Smartpac Run Mode
257
A Tool Number Must be Loaded before Switching to Run Mode
257
Figure A-13. "PM Monitor" Highlighted on Smartpac 2 Run Menu
257
Viewing and Modifying PM Alerts
258
Figure A-14. Run Mode Screen Showing PM Monitor in "Normal" Status Mode
258
Figure A-15. Run Mode Screen Showing "Slide Adjust Motor" in "Alert" Mode
259
Appendix B. Updating Smartpac 2 Firmware
260
Updating Firmware Using a USB Disk
260
Installing Updated Firmware from USB Disk to Smartpac 2
261
Table B-1. Record of Current Counts
261
Figure B-1. Firmware Load Menu with "XFER from USB DISK" Highlighted
262
Figure B-2. Firmware Load Menu with "LOAD NEW FIRMWARE" Highlighted
263
Figure B-3. Firmware Load Menu with Yellow Status Window
264
Figure B-4. Smartpac 2 Display with "Loading Firmware" Message
265
Downloading Updated Firmware from the Wintriss Server
266
Installing Firmware from a Replacement Compact Flash (CF) Card
268
Figure B-5. Firmware Load Menu with "RELOAD CURRENT FIRMWARE" Highlighted
269
Figure B-7. Smartpac 2 Display with "Loading Firmware" Message
270
Appendix C. Smartview Remote Viewing and E-Mail Setup
272
Network Requirements
272
Network Setup
272
Plugging in the Network Cable
273
Programming Network Settings
273
Changing Network Settings
274
Table C-1. Smartpac 2 Board: PS 2 and Y-Cable Configuration
275
Installing Smartview
277
Checking Explorer Settings
277
Figure C-1. Internet Explorer Window with "Internet Options" Selected
277
Figure C-2. Internet Options Screen
278
Installing Smartview on Your Computer
279
Figure C-4. Smartview Introductory Page
279
Figure C-6. Mabry Winsock Activex Control Window
280
Smartview Operation
281
Setup Page
281
Figure C-7. Smartview Main Page
281
Main Page
282
Press Status Information Page
283
Figure C-8. Smartview Main Page with Status of Multiple Presses Shown
283
Figure C-9. Press Status Information Page
284
Remote Messaging
284
E-Mail Setup
285
Figure C-10. Smartpac 2 Remote Message
285
Figure C-11. Email Setup Page
286
Smartview Ping Utility
286
Figure C-12. Mabry Internet Ping Window
287
Figure C-14. Ping Utility Window with Example of a Successful Ping
288
Appendix D. Upgrading from Original Smartpac to Smartpac 2
290
Backing up Tools on Original Smartpac
290
Figure D-1. Backup/Restore Control Menu
291
Removing Smartpac 1 and Mounting Smartpac 2
292
Wiring the Smartpac 2
293
Table D-1. Smartpac 1 to Smartpac 2 Wiring Changes: Main Power
295
Table D-4. Smartpac 1 to Smartpac 2 Wiring Changes: Resolver Port
296
Table D-7. Smartpac 1 to Smartpac 2 Wiring Changes: Dipropac, 16-Channel
297
Table D-9. Smartpac 1 to Smartpac 2 Wiring Changes: Procampac, 16-Channel
298
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 2
301
Figure D-2. Smartpac 2 AC Wiring (Inside Enclosure, Top Right)
301
Restoring Tools to Smartpac 2
301
Figure D-3. Backup/Restore Control Menu with Restore Confirmation Message Displayed
302
System Checkout
303
Appendix E. Replacing Smartpac 2 PC Board
304
Unpacking the Replacement Board
304
Installing the Replacement Board
305
Figure E-1. Smartpac 2 PC Board
306
Figure E-2. Firmware Load Menu with "RELOAD CURRENT FIRMWARE" Highlighted
308
Appendix F. Reporting Downtime and Scrap to SFC
310
Machine States to Which SFC Logs Press Time
310
Smartpac 2 Downtime Reporting Features
311
Forced Idle Dialog Mode
311
Backfilling Vs. Forward Filling
311
Putting the Press "Back on Line
312
Forced Error Dialog Mode
313
Persist Dialog Mode
314
Single-Stroke Mode
315
Reset Strokes Counters
315
Setting up Smartpac 2 to Report Downtime
316
Making Downtime Reporting Settings
316
Figure F-4. Smartpac 2 Main Initialization Menu
317
Table F-1. Set Communications Menu Settings
318
Programming Downtime Reasons
321
Figure F-6. Dialog Fixed Name Choice Menu
322
Figure F-7. Dialog Special Choice Name Menu
324
Documenting Downtime on the Dialog Menu
325
Documenting Downtime in Response to the Forced Dialog Message
325
Figure F-9. Dialog Menu ("16/16" Dialog Screen Mode)
326
Figure F-11. Dialog Menu with F2/F3 Option Window Displayed
327
Documenting Downtime in Other Situations
328
Ending a Job
329
Creating Hot Keys for Dialog Menu Functions
330
Reporting Scrap and Good Parts to SFC
331
Making Scrap Entries
331
Figure F-14. Counters Screen with "Scrap Value" Function (F3) Shown
332
Figure F-16. Counters Screen with Scrap Value Updated to 30 Items
333
Adjusting the Good Parts Counter
334
Figure F-19. Good Parts Counter Adjustment Confirmation Window
335
Appendix G. Reporting Downtime and Scrap to LETS
336
Machine States to Which LETS Logs Press Time
336
Smartpac 2 Downtime Reporting Features
337
Forced Idle Dialog Mode
337
Backfilling Vs. Forward Filling
337
Putting the Press "Back on Line
338
Forced Error Dialog Mode
339
Persist Dialog Mode
340
Single-Stroke Mode
341
Reset Strokes Counters
341
Setting up Smartpac 2 to Report Downtime
341
Making Downtime Reporting Settings
342
Table G-1. Set Communications Menu Settings
343
Programming Downtime Reasons
346
Figure G-7. Dialog Special Choice Name Menu
348
Documenting Downtime on the Dialog Menu
349
Documenting Downtime in Response to the Forced Dialog Message
349
Figure G-8. Smartpac 2 Run Mode Main Menu with Forced Dialog Message Displayed
350
Figure G-10. Dialog Menu with F2/F3 Option Window Displayed
351
Documenting Downtime in Other Situations
352
Creating Hot Keys for Dialog Menu Functions
353
Reporting Scrap and Good Parts to LETS
354
Making Scrap Entries
355
Figure G-15. Counters Screen with Scrap Value Updated to 30 Items
356
Figure G-16. Counters Screen with Scrap Value Entry Window Displayed (40 Items Shown)
357
Adjusting the Good Parts Counter
358
Glossary
360
Index
364
Wintriss Manuals
370
Smartpac 2 Setup Sheets
371
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Wintriss SmartPAC2 Specifications
General
Brand
Wintriss
Model
SmartPAC2
Category
Controller
Language
English
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