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Honeywell SmartPAC 2 User Manual Download Page 17

SmartPAC 2 with WPC Integration

1126800

Table of Contents

page xiii

List of Figures and Tables

Figure 4 - 10.  Number Entry Box......................................................................................................................215
Figure 4 - 11.  Global Cams, Select Cam Channel .............................................................................................217
Figure 4 - 12.  Global Cam Timing Type ...........................................................................................................217
Figure 4 - 13.  Custom Naming Sensors.............................................................................................................218
Figure 4 - 14.  Sensor Enable mode (used with DiProPAC only) ......................................................................219
Figure 4 - 15.  Main Initialization Menu ............................................................................................................220
Figure 4 - 16.  Setup Mode Status ......................................................................................................................220
Figure 4 - 17.  Tool Information Setup...............................................................................................................221
Figure 4 - 18.  Tool Information Names.............................................................................................................222
Figure 4 - 19.  Text Entry Box............................................................................................................................222
Figure 4 - 20.  Units Selection Menu..................................................................................................................223
Table 4 - 2.  Units for Tool Information setup....................................................................................................223
Figure 4 - 21.  Completed Tool Number Information screen .............................................................................224
Table 4 - 3.  Decimal places and formats ...........................................................................................................224
Figure 4 - 22.  Press Control Initialization Mode ...............................................................................................225
Figure 4 - 23.  "User Interlock" Display.............................................................................................................227
Figure 4 - 24.  "Select Name" Display................................................................................................................228
Table 4 - 4.  User Input (Interlock) Names.........................................................................................................228
Figure 4 - 25.  Press Control Parameter Menu ...................................................................................................229
Figure 4 - 26.  Selecting "Brake Monitor" from SmartPAC's Run Menu...........................................................231
Figure 4 - 27.  Viewing "Stop Time" in Run Mode............................................................................................231
Figure 4 - 28.  WPC Initialization Menu ............................................................................................................233
Figure 4 - 29.  "Press Parameters" Display in SmartPAC's Initialization Mode.................................................233
Figure 4 - 30.  Selecting "Auto Carry-up Angle" ...............................................................................................236
Figure 4 - 31.  "Micro-Inch" Display..................................................................................................................237
Figure 4 - 32.  "Press Parameters" screen...........................................................................................................240
Figure 4 - 33.  Press Control Option Switches ...................................................................................................241
Table 4 - 5.  Switch 1 and Switch 2 Settings for Different Top Stop Angles .....................................................242
Table 4 - 6.  Switch 3 Settings for One-hand Control or Foot Switch Mode......................................................243
Table 4 - 7.  Switch 4 Settings for Auto Compensated Top Stop.......................................................................244
Table 4 - 8.  Switch 5 Setting for Prior Act Timing ...........................................................................................245
Table 4 - 9.  Switch 6 Setting for Single or Dual Light Curtains........................................................................246
Table 4 - 10.  Switch 7 Setting to Enable/Disable Changes to Stop Time Limit and Auto Carry-up Angle ......247
Table 4 - 11.  Switch 8 Settings for Top Stop with F and H Errors....................................................................248
Table 4 - 12.  Switch 8 Setting for Auxiliary 1 Response to Interrupted Stroke ................................................249
Figure 4 - 34.  “Enter Your Password” Screen ...................................................................................................252
Table 4 - 13.  Security Access Settings ..............................................................................................................253
Figure 4 - 35.  Security Access Menu.................................................................................................................254
Figure 4 - 36.  Set Passwords Menu ...................................................................................................................256
Figure 4 - 37.  “Enter a New Password” Screen.................................................................................................256
Figure 4 - 38.  Press Control Adjustments Locked.............................................................................................257
Figure 4 - 39.  PACNet Set Communications Menu ..........................................................................................258
Figure 4 - 40.  Network Setup Menu ..................................................................................................................259
Figure 4 - 41.  Setup Email Screen.....................................................................................................................260
Table 4 - 14.  Setup E-mail Items .......................................................................................................................262
Figure 4 - 42.  Diagnostics Menu .......................................................................................................................263
Figure 4 - 43.  Communications .........................................................................................................................264
Figure 4 - 44.  Communications Data Combined (Left), Split (Right) ...............................................................265
Figure 4 - 45.  Clock Setting Screen...................................................................................................................266
Figure 4 - 46.  Alphabetic Entry Window ..........................................................................................................271
Figure 5 - 1.  Program Mode Main Menu...........................................................................................................273
Figure 5 - 2.  SmartPAC 2 and Original SmartPAC...........................................................................................274
Figure 5 - 3.  Program Mode Main Menu...........................................................................................................276
Figure 5 - 4.  Tool Manager................................................................................................................................277

Summary of Contents for SmartPAC 2

Page 1: ...T www wintriss com includes optional DiPro PAC and ProCam PAC 1126800 Rev 1 September 2003 with Wintriss WPC Clutch Brake Control Wintriss Wintriss Controls Group 100 Discovery Way Acton MA 01720 3648 USA Phone 978 264 9550 800 586 8324 Fax 978 263 2491 PRINTED IN USA DA70194 3 ...

Page 2: ...two hand control used as a safety device is located at least the safety distance away from the hazardous area Install any light curtain or curtains at least the safety distance away from the hazardous area safety distance is defined in the OSHA and ANSI regulations Install other safeguarding devices as needed to ensure operator safety Follow the machine guarding requirements of OSHA standard 1910 ...

Page 3: ...machinery or other devices are not maintained or do not meet the applicable regulations or standards Ensure that supervisors die setters maintenance persons machine operators foremen and any others responsible for operation of the machinery have read and understood all instructions for use of the WPC clutch brake control DO NOT use touch buttons for any safeguarding use Failure to comply with thes...

Page 4: ...e Please be sure to carefully pack all returned items and ship to our Acton MA location Expedited Repair Program Rush service providing 48 hour turn around is available for most products upon request A 50 Expedite Fee will be applied to our standard repair rate if the unit is not within its warranty period Board Exchange Program If your needs are urgent you can take advantage of our Board Exchange...

Page 5: ...or Stop Type 18 ProCamPAC Programmable Cams Optional 18 SmartPAC 2 s Three Modes of Operation 19 Specifications SmartPAC 2 with WPC 20 Chapter 2 Installing WPC and SmartPAC 2 23 Part 1 Installation Overview 26 Before You Start 26 The first step Checking the Press 27 Installation Guidelines 27 Overview of the Installation 30 How to Connect Wires to Terminal Block Connectors 30 How to Terminate Cabl...

Page 6: ...Single Stroke External Trip 62 Wiring Continuous on Demand 62 Installing Multiple Operator Stations 63 Auxiliary Outputs Optional 64 Wiring Auxiliary 1 Output Optional 64 Wiring Auxiliary 2 Output Optional 65 Wiring Auxiliary 3 Output Optional 66 Wire a Keylock Switch to Prevent Changes to WPC Settings in Program and Run Optional 66 Installing Flywheel Speed Sensor Optional Hardware Required 67 Mo...

Page 7: ... Install Magnet for Overrun Limit Sensor 116 Install Magnet for Overrun Sensor 125 Check the ON and OFF Time of the Overrun Sensor 126 Part 7 Perform Checkout Tests 127 WPC Power Supply Test 129 Check Safeguarding Devices 130 Check Dual Safety Valve DSV Wiring 132 Check the Emergency Stop Circuit 134 Check the Top Stop Circuit 135 System Static Test 136 Anti tiedown Test 138 Anti repeat Test 139 S...

Page 8: ...C Initialization Mode 201 SmartPAC 2 and Original SmartPAC 202 How to Enter and Exit Initialization Mode 203 Initialize Press Parameters 204 RESOLVER ZERO 204 POSITION SENSOR 205 Position Sensor Mode 205 Resolver Motion Mode Normal Motion Link Motion 206 Tool Number Mode 206 Counter Setup Mode 208 INSTALLED OPTIONS 209 PRESS NAME 210 SELECT CAM NAMES Optional 211 AUTO ADVANCE and Slow RPM 213 Sett...

Page 9: ...250 SECURITY ACCESS 251 Selecting Security Access Options 254 Reset Mode 255 Changing Passwords 255 Additional Security 257 PACNET 258 SETUP NETWORK 259 E MAIL FUNCTION 259 SMARTVIEW FUNCTION 260 SETUP E MAIL 260 CHANGE NETWORK SETTINGS 262 PRESS TYPE 263 DIAGNOSTICS 263 COMMUNICATIONS 264 SET CLOCK 266 UPDATE FIRMWARE 266 SAVE TO USB DISK 267 Using SmartPAC 2 with a Link motion Press 268 Setting ...

Page 10: ...w Global Cams 304 View Cam Summary 305 Make an ON OFF Setting for a Channel 305 Multiple ON OFFs for Cam Channels 307 Selecting a Channel and Making a Timed Output Setting 309 Selecting a Channel and Making an Auto Advance Setting 311 Setting DSV ON Channel Timing 312 Set Other Channels for the Tool 313 Delete Channel Settings 313 PRESS CONTROL 314 TOOL INFORMATION 315 SENSOR ENABLE DISABLE STATUS...

Page 11: ... Angle 346 Brake Warning 346 Performing the 90 Stop Time Test 346 Calculating the Safety Distance 348 PRESS CONTROL 353 Adjusting Top Stop Angle Press Speed Limits Counterbalance Setpoint Main System Air Limit 353 Show Overrun Angles 354 Viewing Actual Counterbalance and Main Air Pressure Limits Optional 354 TOOL INFORMATION Optional 355 ERROR LOG 356 LOAD NEW TOOL 357 Load Next Tool Number Availa...

Page 12: ...m the Display 385 Status Code 10 386 Interrupted Stroke 386 Lockout 387 Brake Monitor Brake Warning 388 Brake Monitor Stop Time Exceeded 388 Customized Status Codes 390 Description of Status Codes and How to Correct 390 Messages Displayed Due to Press Control Problems 391 Resolver faults 392 Operational faults 393 Inter processor failures 397 Input buffer test failures 397 Air pressure limits exce...

Page 13: ...reventive Maintenance 437 How the PM Monitor Works 438 Examples of How to Use the PM Monitor 438 SmartPAC 2 and Original SmartPAC 440 Installing the PM Monitor 441 For New Systems from the Factory 441 For Existing Systems 441 Using the PM Monitor in Initialization Mode 441 How to Get into SmartPAC Initialization and PM Monitor 441 Initializing the PM Monitor 443 Assigning a New PM Password Number ...

Page 14: ... Figure 4 Wintriss Clutch Brake Control Shadow V Herion XSV DSV Wiring Figure 5 Wintriss Clutch Brake Control Dual Operator Station Wiring Figure 6 Wintriss Clutch Brake Control Shadow V Ross EP DSV Wiring Figure 7 Stop Start Motor Control Station Wiring with Lockout Figure 8 Wintriss Clutch Brake Control OEM Operator Station with Separate One Hand Control Figure 9 WPC with Separate One hand Contr...

Page 15: ...2 Mounting and Cutout Dimensions Panel Mount 73 Table 2 2 Resolver Wiring on SmartPAC 2 75 Figure 2 20 Wiring AC to SmartPAC 2 Top Right Inside Enclosure 76 Figure 2 22 Input check switch S101 78 Table 2 3 Wiring to Input Check and Stop Circuits 78 Figure 2 23 ProCamPAC Output Assembly 85 Figure 2 24 Cam Outputs Board 86 Table 2 4 ProCamPAC to Cam Output Assembly TB301 Cams 1 8 87 Table 2 5 ProCam...

Page 16: ...76 Figure 3 6 Numeric Entry Box left Alphabetic Entry Box right 176 Figure 3 7 Alphanumeric Mode Entry Box 176 Figure 3 8 HELP Key 178 Figure 3 9 Cursor Keys and Help Key 179 Figure 3 10 Highlighted Item on Run Menu 179 Figure 3 11 ENTER Key 181 Figure 3 12 RESET Key 182 Figure 3 13 Function Keys 184 Figure 3 14 Run Main Menu Showing Hot Keys Programmed 185 Figure 3 15 SmartPAC 2 Display Run Mode ...

Page 17: ... 32 Press Parameters screen 240 Figure 4 33 Press Control Option Switches 241 Table 4 5 Switch 1 and Switch 2 Settings for Different Top Stop Angles 242 Table 4 6 Switch 3 Settings for One hand Control or Foot Switch Mode 243 Table 4 7 Switch 4 Settings for Auto Compensated Top Stop 244 Table 4 8 Switch 5 Setting for Prior Act Timing 245 Table 4 9 Switch 6 Setting for Single or Dual Light Curtains...

Page 18: ...00 Figure 5 27 Cam Program Menu 303 Figure 5 28 Global Cam Summery 304 Figure 5 29 Cam Summary 305 Table 5 1 Examples of Using Extra ON OFFs 8 channel Unit 307 Table 5 2 Examples of Using Extra ON OFFs 16 channel Unit 307 Figure 5 30 Select Type of Cam Timing 306 Figure 5 31 Programming Channel 1 Part blow off 306 Figure 5 32 One ON OFF Arc 308 Figure 5 33 Add a New Arc 308 Figure 5 34 Selected an...

Page 19: ...sage 388 Figure 7 7 User Input Status Code Message 390 Table 7 1 User Inputs Interlocks SmartPAC with WPC 401 Figure 7 8 Error Log Accessed from Run Mode 418 Figure 7 9 E mailing Error Log to Wintriss Tech Support 419 Figure 7 10 WPC Initialization menu 420 Figure 7 11 Display WPC Input Status Menu 421 Figure 7 12 Display of Buttons Switches Input Status 421 Figure 7 13 Display of Estops Top Stops...

Page 20: ...s you need to know about using SmartPAC in Initialization mode Chapter 5 explains how to use SmartPAC in Program mode Use it to look up things you need to know about Program mode Chapters 6 explains how to use SmartPAC in Run mode You can look up things you need to know about Run mode Chapter 7 shows you fault messages or other types of messages you will see on your display when SmartPAC sends a s...

Page 21: ...minently hazardous situation which if not avoided will result in death or serious injury WARNING A WARNING symbol indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION A CAUTION symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTICE A NOTICE symbol indicates important information that m...

Page 22: ...ligence accident or unauthorized modification The provisions of this warranty do not extend the original warranty of any product which has either been repaired or replaced by Honeywell No other warranty is expressed or implied Honeywell accepts no liability for damages including any anticipated or lost profits incidental damages consequential damages costs time charges or other losses incurred in ...

Page 23: ...ing WPC and Control Reliability Wintriss Clutch Brake Control WPC is an easy to use dual micro processor based system that controls part revolution mechanical power presses With its two independent micro processor systems in a single modular enclosure WPC provides dual diverse redundancy the latest technology in maintaining optimum clutch brake control and operator safety Both of these micro proce...

Page 24: ...re some of the benefits you will come to appreciate when using your SmartPAC 2 with WPC Standard features All the settings are made at the operator console using SmartPAC 2 s keyboard and large bright color display All settings for a tool are automatically saved in SmartPAC 2 s non volatile memory To use the settings when you run the job again simply re load your stored tool number and you are rea...

Page 25: ...ny of these functions issues a stop command a unique status code message is displayed to help you to identify why the press has stopped 90 stop time test as required in order to set the proper safety distance for personnel guarding devices including light curtains two hand controls and type B movable barriers Inputs for multiple Shadow light curtains WPC tests up to two Shadow light curtain inputs...

Page 26: ...TO CAM SWITCH ACCESS SELECTION BRAKE MONITOR TONNAGE WAVEFORM PROCESS MONITOR PRESS CONTROL FEED CONTROL PM MONITOR TOOL INFORMATION SHUTHGT CNTRBAL ERROR LOG LOAD NEW TOOL DIALOG MENU TOGGLE HOT KEYS 1 270 ENTER RESET PROG RUN OFF INCH SINGLE STROKE CONT POWER BRAKE WARNING HELP 1 2 3 4 5 6 9 8 7 0 CLEAR SmartPAC 2 Wintriss Press Automation Control F1 F2 F3 F4 F5 F6 F7 F8 Figure 1 1 SmartPAC 2 Fr...

Page 27: ...u have made or the number you have keyed in RESET key Tells SmartPAC 2 you are done with a programming or other procedure Also resets SmartPAC 2 after fault or event messages appear on the display System Components Resolver which provides WPC with accurate crank angle position information at every point in the stroke Operator Station from which the press is run The Operator Station available from ...

Page 28: ... many popular sizes System air pressure switches which monitor the system air pressure Shadow light curtain The Shadow light curtain is a presence sensing device that places an infrared light field between the point of operation and the operator When something enters the sensing field and a light beam is blocked the object is detected and the press is immediately stopped The standard WPC package i...

Page 29: ...t One hand Control see Chapter 2 for installation and Chapter 6 for operation Foot Switch frees up the operator s hands for increased fully guarded protection and productivity Shadow light curtain is required with Foot Switch Bar Mode Control allows operators and setup personnel to bar the press by hand for die setting and adjustment recommended for smaller capacity presses of 65 ton capacity or l...

Page 30: ...n including panel mount clock display with selector switches no enclosures clock display kit without panel with selector switches and second clock either panel mount display or clock display kit How SmartPAC 2 Works The Resolver Lets SmartPAC 2 and WPC Know Where the Crankshaft Is SmartPAC 2 with WPC is connected to a resolver mounted on the press which turns one to one 1 1 with the crankshaft Sim...

Page 31: ...for the tool SmartPAC 2 retains all settings for a tool even with power off Record tool information for each tool number With this option you can record up to 30 characters of information for each tool such as installation notes Protect settings with lockout and optional password security Using SmartPAC 2 s Security Access menu in Initialization mode you can lock many of the settings in Run mode o...

Page 32: ...Review recent errors SmartPAC 2 s Error event Log feature displays the 100 most recent errors that caused the press to stop and events such as tool changes along with the date time and stroke count at which the event occurred You can easily view the Error Log from the Run menu at any time It lists the error code along with the stroke count and crankshaft angle when the error occurred SmartPAC 2 wi...

Page 33: ... to SmartPAC 2 with DiProPAC Many sensors made by other manufacturers can also be used Detailed application information is available on Wintriss sensors listed below Miniature fiberoptic photoelectric sensors thru beam and reflective types with adjustable sensitivity detect objects as small as 0006 in 015 mm Requires 12 to 24 VDC for power Proximity sensors miniature electronic sensors that detect...

Page 34: ...sors can be switched to work either as normally open or normally closed Ready signal The ready signal is the portion of the stroke where a sensor must actuate For many of your sensors like those that monitor part ejection blow off or feed advance you need to be sure that the event occurs during a specific portion of each stroke If the event occurs late or not at all you are likely to have tooling ...

Page 35: ...at least once during a set number of strokes When you make settings for a tool you select the sensor type for each sensor connected to SmartPAC 2 s sensor inputs You can have any combination of reds yellows or greens for a tool You will see how to select sensor type in Chapter 5 where you learn how to make sensor settings Here we discuss what each type means Yellow sensors Yellow sensors are norma...

Page 36: ... it easy to set the ready signal for the sensor You just make the ready signal a little longer or shorter than the actuation time depending on the sensor See the procedures in Chapter 5 and Chapter 6 for complete instructions on making and adjusting sensor settings The four types of green sensors are described below Green When you set a sensor input to green the sensor must turn on at least moment...

Page 37: ...l The sensor must turn on then turn off within the ready signal Otherwise SmartPAC 2 sends the stop signal to the press KEY Ready Signal Green Quick Check Sensor not allowed press stops Sensor never goes ON Stop signal sent at end of ready signal TDC BDC OK Sensor goes ON only inside ready signal TDC BDC Sensor is ON outside ready signal Stop signal sent when sensor is ON outside ready signal not ...

Page 38: ...e ready signal Sensor never goes ON Stop Signal sent at end of ready signal TDC BDC not allowed press stops Sensor goes OFF before ready signal ends Stop signal sent immediately not allowed press stops TDC BDC OK Sensor staysON during entire ready signal and goes OFF at least momentarily outside the ready signal TDC BDC KEY Sensor ON Green Constant Sensor not allowed press stops Sensor never goes ...

Page 39: ... green sensor the green special must actuate at least once during a preset number of strokes Rather than setting a ready signal you set the maximum number of strokes that the press can make without this sensor actuating Here is how it works You install a sensor so that it will actuate when a slug passes through the slug ejection hole In this example assume that the die clears all the slugs out of ...

Page 40: ...type executed becomes emergency stop Otherwise if the error is detected after this angle the stop type executed is top stop The general rule is to use Smart Stop when you have properly identified the critical angle and you want SmartPAC 2 to select the ideal stop type depending upon the die protection situation Use emergency stop when you always want to ensure that the press will stop before the n...

Page 41: ... in detail in Chapter 4 Program mode Used to make your sensor and cam timing counter and other settings if installed for your tools You cannot use this mode while the press is running You can load settings for a tool in this mode The displays you see in Program mode are described in Chapter 5 Run Mode You must be in Run mode to operate the press You can adjust timing for your sensors and cam chann...

Page 42: ... monitors clutch air supply pressure 150 PSI maximum Electrical SmartPAC 2 Input 115 230 10 VAC 50 60 Hz 50 VA Input check circuit 12 250 VAC or VDC WPC Input 115 230 10 VAC selectable 50 60 Hz 100 VA Oper Temp 32 to 122 F 0 to 50 C Speed 7 800 SPM 14 1600 SPM optional at reduced accuracy Accuracy 2 3 1 33 for high speed version Counters Good parts strokes 3 batch with presets 7 digits Number of h...

Page 43: ...Pro RCB 4 56 x 2 56 x 4 06 116 x 65 x 103 mm DiProPAC sensor disabled output open collector 8 mA max SmartPAC 2 Options continued ProCamPAC provides up to 16 programmable cam switch output channels Programmable cam output assembly NEMA 12 holds up to 8 outputs Enclosure 9 x 11 x 3 5 229 x 279 x 89 mm shock mounted Relay SPDT 0 4 A resistive 240V DC solid state SPST 2A 5 60 VDC AC solid state SPST ...

Page 44: ...re information WPC Options Firmware Muting for Shadow light curtain on the upstroke Two hand only One hand two hand or foot operation Automatic Single Stroke external trip Continuous on Demand Auto Compensated Top Stop ACTS High Speed 500 SPM WPC Options Selector Switches One hand two hand or foot operation Automatic Single Stroke External Trip to slave the press to an external device control swit...

Page 45: ...y guarding device Perform the checkout procedure after installation and after any modification or repair of the WPC clutch brake control Lockout Tagout the press during all installation modification repair or maintenance procedures Ensure that supervisors die setters maintenance persons machine operators foremen and any others responsible for operation of the machinery have read and understood all...

Page 46: ...se instructions will result in death or serious injury NOTICE OPTIONAL MODULES PROCAMPAC AND DIPROPAC INCLUDED IN MANUAL Your SmartPAC WPC System comes standard with press control capabilities You may also include one or both of the following options DiProPAC die protection or ProCamPAC programmable cam switch This manual includes instructions for installing and using these options Remember that t...

Page 47: ... Install and Wire WPC Options page 55 Part 4 Install and Wire SmartPAC page 69 Part 5 Install SmartPAC Options page 80 Part 6 Set Up SmartPAC2 with WPC page 95 Part 7 Perform Checkout Tests page 127 Part 8 PC Board Illustrations and Wiring Tables page 158 NOTICE Mark Part 8 PC Board Illustrations and Wiring Tables page 158 with a slip of paper a marker or other means You will refer to this section...

Page 48: ...SE SMARTPAC 2 BEFORE INSTALLING ON A PRESS If you have not used SmartPAC 2 before learn how to initialize and program it before installing it on a press On the bench connect your unit to a resolver see Mounting and Wiring the Resolver page 42 and to AC power see page 76 You can then use all the menus and make settings See Chapter 3 for instructions for using the keyboard and displays See also Chap...

Page 49: ...ing There are two exceptions to this rule The power and logic wiring for the light curtains can be in the same conduit The power and logic wires for the Dual Safety Valve can be in the same conduit Run flexible liquid tight conduit for high voltage lines 120V power input check circuit relay circuits to the upper right hand corner of SmartPAC 2 and to the upper right hand corner of WPC Run one or t...

Page 50: ... Finding a good place for a ground is sometimes difficult but it should be close to where the press receives its ground Correctly Terminate All Cable Shields Terminate all cable shields to the studs provided in the enclosure or to a good grounding location See How to Terminate Cable Shields page 31 Install suppressors across inductive loads All relays and solenoids that are controlled by SmartPAC ...

Page 51: ...ir pressure switch Motor Control Resolver overrun limit sensor and air pressure switch wiring Operator Station Wintriss Clutch Brake Control SmartPAC 2 AC power Resolver comms Estop Top stop DSV input check wiring AC high voltage wiring from customer control transformer DSV wiring Connections to option modules cam outputs DSI 2 etc Figure 2 1 Installation Overview ...

Page 52: ...mber that data communications wires must not be run with other wires NOTICE UPGRADING FROM ORIGINAL SMARTPAC See Appendix E Upgrade from Original SmartPAC page 457 for instructions on upgrading from original SmartPAC to SmartPAC 2 How to Connect Wires to Terminal Block Connectors NOTICE CONNECTOR WIRING The connector can only plug in one way Make sure you do not start at the wrong end when connect...

Page 53: ...or terminating cable shields at the point of entry Secure drain wire under nut on ground stud Drain wire Strip cable jacket as far as end of conduit fitting Figure 2 3 Connecting Shield Drain Wire to Ground Stud For each shielded cable perform the following steps Refer to the figure above 1 Strip the cable jacket as far as the end of the conduit fitting 2 Cut the drain wire to a length that can wr...

Page 54: ...ing the WPC Control Enclosure next section Install WPC without Enclosure page 34 Wiring the WPC page 35 Connecting AC Wiring to WPC page 35 Installing and Wiring Dual Safety Valve and Sensors for Clutch and Counterbalance Air Pressure page 37 Mounting and Wiring the Operator Station and Light Curtain s page 47 Install the Resolver page 41 Install the Overrun Limit Sensor Magnetic Switch page 44 Co...

Page 55: ...unted to the press It can be mounted on a free standing pedestal console pendant or column For easy access to the interior make sure that there is enough room to open the control enclosure door at least 120 Plastic cable ties and self sticking cable clamps are provided in the accessory parts bag Use them to position the cable and wiring inside the control enclosure in a neat and orderly fashion Di...

Page 56: ... have to be mounted to the press It can be mounted on a free standing pedestal pendant or column For easy access to the interior make sure that there is enough room to open your control enclosure door at least 120 After you mount the control assembly in your enclosure go to Wiring the WPC page 35 and make the necessary connections 7 00 178 0 3 5 89 1 0 25 15 5 394 1 0 25 15 5 394 Control assembly ...

Page 57: ...p the press as soon as the ram adjust switches on For help in determining how to connect this wiring contact Wintriss Tech Support Connecting AC Wiring to WPC DANGER ELECTRIC SHOCK OR HAZARDOUS ENERGY Disconnect main power before installation Remove all power to the press press control and other equipment used with the press Remove all fuses and tag out per OSHA 1910 147 Control of Hazardous Energ...

Page 58: ...the power wires to WPC through flexible liquid tight conduit to the enclosure Because WPC is rated NEMA 12 protected against dust and oil you must use conduit of the same rating and make proper connections to ensure NEMA 12 protection with the enclosure 5 To make ground connections refer to the diagrams at the end of the manual and to the WPC connections wiring Table A at the end of the manual 6 C...

Page 59: ...ffler periodically A clogged muffler can degrade stopping time Tighten the muffler securely to the valve body Periodically check to make sure the muffler is securely installed Vibration may cause it to loosen and fall To tighten the muffler secure the valve body hold the muffler with both hands and turn clockwise as tightly as possible without stripping the threads Failure to comply with these ins...

Page 60: ... above NEMA 12 Connect the wires Refer to Figure 1 at the end of the manual and wire the sensor as follows WPC terminal Clutch Air Pressure Sensor Wire Color 32 Red 33 White 34 Black To set the clutch air pressure value see Setting Clutch and Counterbalance Air Pressure Limits page 238 4 Since you are using a pressure sensor to monitor the clutch aid pressure you must ground the clutch air pressur...

Page 61: ...h if not already present 2 Connect shop air to the clutch air pressure switch input port 3 Run the cable through flexible liquid tight conduit as noted above NEMA 12 4 Connect the wires For the clutch air pressure switch refer to wiring diagram Figure 3 at the end of the manual Wire the normally open terminals of the switch between WPC terminal 8 and ground terminal 10 5 Set the clutch air pressur...

Page 62: ...OTICE If terminal 83 has already been assigned for other user selected auxiliary equipment then wire the counterbalance switch contacts across a terminal on the WPC main processor board that generates an E stop when the connection to ground is broken See Wiring WPC User Inputs page 52 for more information 5 Set the counterbalance pressure switch to the pressure recommended by the press manufacture...

Page 63: ...ing a defective resolver you may not be able to move the ram to TDC before mounting the resolver See page 43 for special instructions for installing the replacement The resolver must be driven smoothly at a 1 1 ratio with the crankshaft of the press The resolver signals WPC the exact position of the crankshaft at every degree of the stroke see How WPC works in Chapter 1 Design a method of driving ...

Page 64: ... past the true stopping point and snap backward Resolver shown in zero degrees position with key perpendicular to base 3 62 91 9 0 34 8 6 dia holes 2 places RESOLVER IS AT ZERO WHEN KEYWAY IS ALIGNED WITH ARROW 3 00 76 2 3 75 95 3 1 50 38 1 9 16 232 7 2 75 69 9 1 06 26 9 1 75 44 5 2 00 50 8 Electrical connector for cable 3 4 dia shaft 19 05 standard key in keyway Figure 2 7 Resolver Mounting and W...

Page 65: ...olver connector Refer to wiring diagram Figure 1 at the end of the manual and connect the resolver wires accordingly Also see Table 2 3 page 75 Measure the resolver wires to fit and cut the wires If you also ran the overrun limit switch cable through do not cut these wires until the overrun limit switch is installed 5 Notice that the resolver wires are plugged into the L shaped resolver connector ...

Page 66: ... The overrun limit switch also known as the overrun limit sensor provides a signal to WPC at the same point on every stroke This enables WPC to check the resolver s operation If for some reason the resolver is no longer rotating at a 1 1 ratio with the crankshaft WPC receives the signal from the overrun sensor at an unexpected point in the stroke WPC then signals an emergency stop and displays an ...

Page 67: ...stroke at a distance of 1 8 3 16 about 3 5 mm close enough for the switch to sense the presence of the magnet The switch must be hard mounted to the press or other stationary surface Normally the magnet should be mounted to a rotating component 4 to 6 about 100 to 150 mm in diameter Other types of installation are possible for assistance contact Wintriss Tech Support NOTICE INSTALL MAGNET AFTER CO...

Page 68: ...mit switch are installed Run the magnetic switch s cable through conduit to the WPC Connect the wires to terminal blocks on the WPC control board as shown in the table below See also the Figure 3 wiring diagram at the end of the manual You will install the overrun sensor magnet as part of the initialization process after you finish the installation procedures in this chapter Table 2 1 WPC Overrun ...

Page 69: ...ss Mounting the operator station at the correct safety distance prevents an operator from leaving the station and reaching the pinch point before the press stops If you are installing light curtains the operator station needs to be installed outside of the area guarded by the light curtain The light curtain is normally mounted in front of the die space at least the safety distance away from any pi...

Page 70: ...ure 2 at the end of this manual Place the operator station in a temporary location on the floor or on a cart Then wire the operator station to the control enclosure and continue with all other installation checkout steps and operation procedures in Chapters 2 and 3 After you find the proper safety distance Calculating the Safety Distance page 348 you can permanently mount the operator station at t...

Page 71: ...nstructions will result in death or serious injury DANGER INCORRECT LIGHT CURTAIN INSTALLATION Mount the light curtains at the correct safety distance as instructed in this manual See Calculating the Safety Distance page 348 under Brake Monitor in Chapter 6 The light curtain will only provide full protection for operators when mounted at the correct safety distance Install and wire your light curt...

Page 72: ... When using the OSHA formula the Precision Metalforming Association PMA recommends that you add additional time for brake wear as shown in the ANSI formula found in Chapter 3 By not adding in this additional time you may compromise operator safety as the brake wears for more information see Appendix A Using Two Light Curtains on Your Press Refer to the wiring schematics at the end of this manual t...

Page 73: ...80 or between terminals 79 and 81 Refer to Figure 2 at the end of this manual for specific wiring schematics Use customized status code wiring see Wiring WPC User Inputs page 52 when the auxiliary equipment that you are connecting does not have its own self explanatory displays as is available in DiPro 1500 or AutoSet load analyzers ...

Page 74: ... serious injury DANGER INPUT STOP TYPE DIFFERENT FROM PREVIOUS VERSIONS OF WPC Be sure to wire the WPC inputs according to the table below and the instructions in this manual With WPC firmware version 3 91 and higher some of the inputs operate differently from previous versions Failure to comply with these instructions could result in death or serious injury WARNING PRESS DOES NOT STOP WHEN USER I...

Page 75: ...osed Input pairs 8 9 and 10 11 are always activated and cannot be turned off If you do not want to use one or both pairs of inputs leave them wired to ground as indicated in Table 2 2 below For more information about how the cross checked user inputs work see User Interlocks page 225 in the Initialization chapter As a help to troubleshooting and installation you can also display the status of the ...

Page 76: ...er 5 72 GROUND 55 User 6 84 GROUND 56 User 7 73 GROUND 57 User 8 paired with 9 ESTOP or ESTOP LOCKOUT 85 GROUND 58 17 User 9 paired with 8 ESTOP or ESTOP LOCKOUT 74 GROUND User 10 paired with 11 ESTOP or ESTOP LOCKOUT 86 GROUND 50 18 User 11 paired with 10 ESTOP or ESTOP LOCKOUT 18 GROUND On older versions of WPC these inputs had different functions Be sure to wire these inputs correctly according...

Page 77: ...uired page 67 Mounting and Wiring the Bar Control Enclosure Optional page 68 NOTICE HIGH SPEED OPTION FOR SMARTPAC 2 WITH WPC To set up the High Speed option for SmartPAC 2 with WPC see Set Up High Speed Version of SmartPAC 2 with WPC page 94 Wiring Lockout Relay Optional The lockout function in WPC provides an added safety feature to the product Whenever a serious error condition occurs a lockout...

Page 78: ...s operator mode As an example the following schematic illustrates how to monitor when WPC is in Automatic Single Stroke Example showing wiring for a relay to turn on when Automatic Single Stroke mode is selected Pin 118 117 116 115 114 113 112 111 110 109 108 Pin Designation 13 5 VDC Power Ground 5 VDC Unused ON in Continuous 2 Hand or Foot ON in Automatic Single Stroke ON in Foot Single Stroke ON...

Page 79: ...ng protection from accidental actuation by falling or moving objects or unintentional stepping on the control Failure to comply with these instructions will result in death or serious injury The Foot Switch when used with Shadow safety light curtains frees up the operator s hands without sacrificing safety Wire the Foot Switch s normally closed contact to terminal 4 and the normally open contact t...

Page 80: ...NE HAND and SINGLE STROKE modes One hand Control must be used in conjunction with a Shadow light curtain for guarding point of operation One hand Control is mounted on or near the press and allows the press operator to cycle the press without using the operator station Optional firmware is required for One hand operation See also wiring diagram Figure 9 at the end of the manual To cycle the press ...

Page 81: ...6800 Installing SmartPAC 2 and WPC Chapter 2 page 59 Button Shroud top view side view Dimensions inch mm Conduit opening 3 88 98 6 4 00 101 6 2 50 dia 63 5 4 5 114 3 3 25 dia 82 6 Base Cover Figure 2 12 One hand Control Switch Dimensions ...

Page 82: ...ions in One hand Control Switch Switch Cover Bottom View Light Curtain Break Mode You can use One hand Control in light curtain break mode In this mode you must push the button on One hand Control within eight seconds after removing your hands from the light curtain Otherwise the press will not cycle This mode prevents inadvertent operation when an operator is loading or unloading parts If this mo...

Page 83: ...ous injury To wire One hand Control to WPC you need to connect three wires from the One hand Control to contact blocks inside the operator station Follow these instructions to wire One hand Control Be sure to refer to wiring diagram Figure 9 at the end of this manual 1 Turn off power to the press and to the WPC 2 Loosen the clips at the bottom of the front panel of the operator station Swing the f...

Page 84: ...n also use solid state switches proximity for example or outputs from a programmable logic controller PLC To make sure that the contacts are clean and reliable the switch or relay should be new and unused To use Automatic Single Stroke you must set Press Option Switch 5 to the appropriate setting see page 245 To run in this mode see Operating the Press in Automatic Single Stroke Mode page 373 Wiri...

Page 85: ...can only wire up to two operator stations directly to the main processor board Refer to Figure 2 15 below and Figure 5 end of manual and Table A at the end of the manual for specific wiring information If you wire more than two stations you will need to connect each additional one to a Dual Operator Selection Control Wintriss part no 4152100 Serving as a junction box the Dual Operator Selection Co...

Page 86: ...sing Press Options page 242 in chapter 4 Also see Figure 3 at the end of this manual for wiring Aux 1 Response to Interrupted Stroke Setting Switch 8 NOTICE If you want Auxiliary Output 1 to stay ON while you are inching the press during an Interrupted stroke set Switch 8 to CLOSED See page 364 for more information about Interrupted Stroke Auxiliary 1 is normally ON and turns OFF when any of the f...

Page 87: ...o Interrupted Stroke page 248 For wiring see wiring diagram Figure 3 at the end of the manual Wiring Auxiliary 2 Output Optional DANGER NON SAFETY OUTPUTS USED FOR SAFETY FUNCTIONS Use auxiliary outputs 1 2 and 3 for non safety functions only They cannot protect personnel from a moving hazard You can use them for convenience in automation Failure to comply with these instructions will result in de...

Page 88: ...SV is energized This is true except when Bar Control is in use so that loss of rotation errors are not generated NOTICE The following instructions describe how to connect Auxiliary 3 to DiPro 1500 The same instructions apply for connecting to ProCam 1500 Refer to the DiPro 1500 or ProCam 1500 manual for details Wire a Keylock Switch to Prevent Changes to WPC Settings in Program and Run Optional Yo...

Page 89: ...ce per revolution 2 Fabricate a bracket to position the LMCS 1 16 to 1 8 from the face of the magnets If possible make the bracket adjustable 3 Install the LMCS as shown in Figure 2 16 To mount the magnets make sure you use non magnetic brass or nylon screws or epoxy adhesive The magnets should be installed plastic side up with a non ferrous metal screw It is important not to use a ferrous screw b...

Page 90: ... mode you will need to release the machine s brake Therefore mount the Bar Control enclosure in a place that is convenient to the operator while he is barring the press Make sure that the operator will not possibly block a light curtain while pressing the BAR control operate button Refer to Figure 2 17 for dimensions See wiring diagram Figure 3 and Table A at the end of the manual for pinouts 6 75...

Page 91: ...procedures before connecting to the AC power source Failure to comply with these instructions will result in death or serious injury NOTICE UPGRADING FROM ORIGINAL SMARTPAC See Appendix E Upgrade from Original SmartPAC page 457 for instructions on upgrading from original SmartPAC to SmartPAC 2 NOTICE MOVE RAM TO TDC BEFORE INSTALLING SMARTPAC 2 This is an important step because the press must be a...

Page 92: ...t the enclosure follow the steps below 1 Determine a convenient place for the control enclosure Ideally it should be close to where operators and setup personnel can easily see the readouts and reach the keyboard Make sure all cables will reach Leave enough room to open the door at least 120 The enclosure can be mounted on a pedestal pendant or on the press itself SmartPAC 2 is also available for ...

Page 93: ... clearance of approximately 18 inches 460 mm from mounting surface to fully open the enclosure s door ENTER RESET PROG RUN POWER BRAKE WARNING HELP 1 2 3 4 5 6 9 8 7 0 CLEAR SmartPAC 2 13 25 336 6 12 51 317 8 1 00 25 4 TYP 10 00 254 0 14 2 REF 360 F1 F2 F3 F4 F5 F6 F7 F8 OFF INCH SINGLE STROKE CONT Figure 2 18 SmartPAC 2 Mounting Dimensions Enclosure ...

Page 94: ...n for Mounting SmartPAC 2 Using Your Enclosure To prepare for mounting SmartPAC 2 using your panel enclosure follow these steps 1 Determine a convenient place to mount SmartPAC 2 into your panel enclosure Ideally it should be close to the press control so operators and setup personnel can easily see the readouts and reach the keyboard 2 Cut out a hole in your panel enclosure and drill and tap twel...

Page 95: ...se the same size cutout 9 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 70 271 8 5 50 139 7 0 35 8 9 TYP Allow 6 inches 153 mm minimum clearance behind the panel Panel Cutout OFF...

Page 96: ...ver is the slave 1 Locate the 4 conductor shielded cable without connector You will use this wire for both slaving the resolver and the communications described below Run the cable through low voltage conduit from terminals 89 to 95 on the main processor board to the bottom right knockout of WPC This cable should be routed through the knockout located at the bottom right of SmartPAC Both WPC and S...

Page 97: ...llow 217 R2 Orange 218 S4 Brown Shown for clockwise rotation facing shaft For counterclockwise swap black and yellow wires Connecting Communications Between SmartPAC 2 and WPC 1 Locate TB105 on the SmartPAC 2 board Figure 2 39 page 162 and TB501 on the WPC Interface Board Figure 2 38 page 161 See Figure 1 at the end of this manual for wiring 2 Run the four conductor shielded cable through the same...

Page 98: ...tscrew terminal L2 Neutral AC Input Voltage 115 230 V Figure 2 20 Wiring AC to SmartPAC 2 Top Right Inside Enclosure Run the AC power wires through the high voltage conduit described earlier in this chapter Bring the wires for AC power the emergency stop and top stop circuits and for the input check circuit through the top right knockout No 16 wire No 14 if local codes require it with a minimum 75...

Page 99: ... strip the ground wire about 6 4 mm from end loosen screw on the terminal slide wire in hole and tighten screw to secure wire in place For SmartPAC 2 panel mount Connect the ground wire to the ground stud that is on the face plate below the AC input terminal block Connect Stop Circuits and Input Check Circuit to SmartPAC 2 Supply your own multi conductor cable minimum 6 wires Run this cable throug...

Page 100: ...fault could be low air pressure to the clutch or a bad clutch 2 Run the stop circuit and input check circuit wires to SmartPAC 2 through flexible liquid tight conduit to the enclosure Because SmartPAC 2 is rated NEMA 12 protected against dust and oil you must use conduit of the same rating and make proper connections to ensure NEMA 12 protection with the enclosure 3 Locate connector TB102 for the ...

Page 101: ...k your network administrator must make the necessary connections and settings The Ethernet cable plugs into the Ethernet connector on the SmartPAC 2 PC board see Figure 2 39 page 162 NOTICE SETTING STATIC IP ADDRESS SmartPAC 2 comes from the factory set up for a Dynamic Host Configuration Protocol DHCP network which automatically assigns IP addresses If your network requires static IP addresses ha...

Page 102: ...T INTERCHANGEABLE It is important that you install these boards correctly The 8 and 16 channel ProCamPAC boards are interchangeable and the 8 and 16 sensor DiProPAC boards are also interchangeable SmartPAC 2 will recognize whether the board is 8 or 16 channel configuration See Figure 2 42 NOTICE UPGRADING FROM ORIGINAL SMARTPAC See Appendix E Upgrade from Original SmartPAC page 457 for instruction...

Page 103: ...Then go to step 4 3 If replacing an existing board or boards Complete these steps for each board you are replacing a Look inside SmartPAC 2 and locate the board that you wish to replace Figure 2 42 illustrates ProCamPAC and DiProPAC superimposed on the main processor board b Remove the connector s attached to this board If you have an 8 sensor or 8 cam system there will only be one connector Conve...

Page 104: ...connectors will connect correctly with the mating pins on the main SmartPAC 2 processor board c After the board is properly seated use the four screws that came with the kit to secure the board d Connect the cable s to the new board s Note that if you are going from an 8 to 16 system you will have to connect two cables to the board If you are upgrading ProCamPAC the connector or connectors in ques...

Page 105: ...needs Making the Connections If installed you must connect the optional cam channel board either eight or sixteen configuration inside the SmartPAC 2 controller to the ProCam output assembly The output assembly contains the relays that control the timing signals for your equipment The relays open and close circuits to your equipment at the angles degrees of the stroke that you set You can purchase...

Page 106: ...l blocks marked TB301 inside the ProCam output enclosure Notice that there are two cables one for 1 through 8 and another for 9 through 16 5 Attach one end of the cable to the connector for TB451 for channels 1 8 Note that TB452 on the 16 channel board is for channels 9 16 Refer to the Table 2 5 and Table 2 6 later in this section for proper wiring If you have an 8 cam board only then connect chan...

Page 107: ...t clearance hole for 6 screw 4 places sockets for solid state relays only channels 5 through 8 TB303 TB302 CHAN 1 CHAN 2 CHAN 3 CHAN 4 CHAN 5 CHAN 6 CHAN 7 CHAN 8 DS301 TB301 6 00 152 4 5 50 139 7 NOTE For each channel 5 8 plug in standard or solid state but not both CH1 CH2 CH3 CH4 CH5 CH6 CH7 CH8 Connections to control 6 00 152 4 0 312 7 9 dia 4 places 8 00 203 2 10 00 254 0 3 50 88 9 10 75 273 ...

Page 108: ...1 Relay 2 K302 Relay 3 K303 Relay 4 K304 Relay 5 K305 Relay 6 K307 Relay 7 K309 Relay 8 K311 use only one relay mechanical or solid state for each channel Mechanical Relays TB303 TB302 CHAN 1 CHAN 2 CHAN 3 CHAN 4 CHAN 5 CHAN 6 CHAN 7 CHAN 8 Fuses DS301 TB301 Cam 1 Cam 3 Cam 2 Cam 8 Cam 7 Cam 6 Cam 5 Figure 2 23 Cam Outputs Board See previous figure for mounting hole locations ...

Page 109: ...Ch 5 264 Ch 5 8 Yellow Ch 4 263 Ch 4 9 Orange Ch 3 262 Ch 3 10 Purple Ch 2 261 Ch 2 11 Brown Ch 1 260 Ch 1 12 Note that the pin numbers for A and B are out of order Table 2 6 ProCamPAC to Cam Output Assembly TB301 Cams 9 16 Wire 16 cam TB452 9 16 pin 2 nd Cam Output Board TB301 pin CHAS 1 White Relay Pwr 281 A 3 Black GND 280 B 2 Red 5 279 5 VDC 4 Tan Ch 16 278 Ch 8 5 Pink Ch 15 277 Ch 7 6 Gray Ch...

Page 110: ...rectly installed They must not be installed across the relay contacts inside the cam outputs enclosure If a suppressor is installed across the relay contacts and it fails shorted the equipment controlled by that relay will remain energized all the time Failure to comply with these instructions could result in death or serious injury 10 You must install arc suppressors across each inductive load mo...

Page 111: ...ower in Power Return RIGHT Suppressor ProCamPAC output relay c n o Power in ACCEPTABLE Suppressor not prefered Power Return Power Return c n o Power in WRONG Suppressor Power Return Load Load Load ProCamPAC output relay ProCamPAC output relay Figure 2 25 How to Connect Suppressors Across the Load ...

Page 112: ...ble shields to ground studs close to the point of entry into the enclosure Up to 8 sensors For sensors 1 8 follow the wiring instructions in Table 2 8 below 9 to 16 sensors For sensors 1 8 follow the wiring instructions in Table 2 8 below For sensors 9 16 follow the wiring instructions in Table 2 9 below NOTICE If you have an 8 sensor DiProPAC board connect sensors 1 8 to TB501 NOTICE If there are...

Page 113: ... 6 Green Sensor 5 286 Sensor 5 5 Yellow Sensor 4 285 Sensor 4 4 Orange Sensor 3 284 Sensor 3 3 Red Sensor 2 283 Sensor 2 2 Brown Sensor 1 282 Sensor 1 1 Table 2 9 SmartPAC 2 to DSI 2 DiPro Sensor Interface Sensors 9 16 Wire SmartPAC 2 DiProPAC TB552 pin 2 nd DSI 2 pin GND 10 Black GND 301 GND 9 Sensor power 300 no connection Gray Sensor 16 299 Sensor 8 8 Violet Sensor 15 298 Sensor 7 7 Blue Sensor...

Page 114: ...d using the mounting holes on each flange Make sure sensor cables can be easily connected to it and that the RCB cable will reach SmartPAC 2 2 Connect the RCB cable to SmartPAC 2 s terminal block TB501 if DiPro 8 or TB551 if DiPro 16 If you are connecting a second RCB to SmartPAC 2 connect to terminal block TB552 at SmartPAC 2 s DiPro 16 Refer to the wiring in the following tables Because SmartPAC...

Page 115: ... 6 Red none 290 Sensor power Black GND 291 GND Provides power for electronic sensors used in inputs 1 3 Lumberg connectors 12 VDC 100 mA total Table 2 11 DiPro RCB to SmartPAC 2 continued Wire RCB Sen SmartPAC 2 TB552 At SmartPAC 2 Brown 1 288 Sensor 7 Purple 2 289 Sensor 8 Orange 3 292 Sensor 9 Yellow 4 293 Sensor 10 Green 5 294 Sensor 11 Blue 6 295 Sensor 12 Red none 300 Sensor power Black GND 3...

Page 116: ...lly the setup mode circuit is enabled when the Inch mode is selected on your clutch brake control Then when you inch the press SmartPAC 2 will not stop the press when a fault condition is detected and will not count parts The setup mode terminal Pin 252 on TB107 can be wired to an extra contact on the inch position of the stroke selector switch of your press control or you can use an external swit...

Page 117: ...ed in the press during test and setup procedures Failure to comply with these instructions could result in property damage Turn On Power to SmartPAC 2 and WPC next page Problems at Startup page 98 Verify Proper Installation of ProCamPAC and or DiProPAC Options page 100 Initialize WPC Press Parameters page 101 Create and Load a Test Tool Number page 103 Check and Set Direction of Resolver Rotation ...

Page 118: ...e main menu for the mode it is in If it is not press RESET repeatedly until the main menu appears 1 Make sure there is no die in the press 2 Turn the Program Run key toward Prog 3 Power up the SmartPAC 2 and the WPC The green Power light on the SmartPAC 2 front panel illuminates A red SmartPAC 2 screen appears for a few seconds Then the display goes off and the brake warning light flashes about ev...

Page 119: ...operating mode If another error message appears when SmartPAC 2 starts up press RESET If the message still appears find the error message in Chapter 7 and follow the instructions for correcting the problem If you cannot find the error message or you cannot fix the problem contact Wintriss Tech Support 4 Press and hold down both the 1 and CLEAR keys at the same time for one second The Initializatio...

Page 120: ... 2 again If the display remains off contact Wintriss Tech Support If the green Power light illuminates but the display remains off Power down SmartPAC 2 and WPC Check that the connectors are correctly seated on both ends of the cables between the SmartPAC 2 PC board and the display Power up SmartPAC 2 and WPC again If the display remains off contact Wintriss Tech Support PRESS CONTROL does not app...

Page 121: ...pears on the menu go to the next section and continue to set up your system If PRESS CONTROL still does not appear there contact Wintriss Tech Support If the green Rx6 does not blink power down SmartPAC 2 and WPC Recheck the communications wiring Refer to Wiring between WPC and SmartPAC 2 page 74 Power up both units and go to the SmartPAC 2 Main Initialization menu If PRESS CONTROL appears go to t...

Page 122: ...on the Initialization menu see page 189 to enter Initialization mode Press ENTER The list of Installed options appears Check to see that the options you installed are on the list ProCamPAC and or DiProPAC If the appropriate option or options are on the list go to the next section If you do not see the appropriate option on the list go to Adding or Upgrading ProCamPAC or DiProPAC page 80 and verify...

Page 123: ...ess parameters only when you set up a new SmartPAC 2 with WPC or install new WPC firmware When you first set up your SmartPAC 2 with WPC or when you install new WPC firmware initialize the press parameters by following the steps below If you install new WPC firmware in an existing system record the WPC Press parameters before you install the new firmware Re enter the parameters after you re initia...

Page 124: ...RT LIMIT SHUT DOWN LIMIT FLYWHEEL TIMER ACTS ANGLE 220 DEG 149 DEG 100 MSEC 185 DEG 0 PSI 0 PSI 250 MSEC 199 MSEC 5 MIN 6 SEC 0 DEG INITIALIZE PARAMETERS USE THE CURSOR KEYS TO CHOOSE THE VALUE YOU WANT TO CHANGE PRESS THE ENTER KEY TO CHANGE THE VALUE PRESS THE RESET KEY WHEN DONE PRESS CONTROL PARAMETER MENU 250 Figure 2 32 Press Parameters Display in SmartPAC s Initialization Mode 3 Select INIT...

Page 125: ...ay turn the stroke select key to OFF and then back to the desired operating mode to clear the message NOTICE SELECT HIGHLIGHT ENTER When this manual says select it means highlight the item and press ENTER 1 Turn the Prog Run key to Prog In the display that appears select Go to the Tool Manager The Tool Manager screen appears 2 Press F7 New Tool Key in a number such as 100 in the box that appears F...

Page 126: ...ck to the desired operating mode to clear the message 1 Make sure a tool number is loaded see previous section Turn the Prog Run key to Run 2 Inch the press Watch the crank angle on the display If the angle increases goes up from 0 toward 359 the resolver wiring is correct Go to the next section If the angle of the crankshaft decreases goes down from 359 toward 0 instead of increasing correct the ...

Page 127: ...y using a dial indicator or other means go to step 1 below If the ram is not at TDC move it to TDC as follows Make sure a tool number is loaded in SmartPAC 2 refer to Create and Load a Test Tool Number page 103 Turn the Prog Run key to Run Inch the press until it is at TDC Use a dial indicator on the face of the ram or other means to ensure that the ram is as close to TDC as possible Go to step 1 ...

Page 128: ...as closely as possible with the arrow on the resolver housing so the Current Resolver Angle reads close to 0 preferably between 355 and 5 but SmartPAC 2 can adjust for any angle between 330 and 30 Go to step 2 below NOTICE Make sure the ram is at TDC 0 when you zero the resolver 2 To zero the resolver make sure the screen in Figure 2 34 above is on the display Double check that the Current Resolve...

Page 129: ...mine the correct Top Stop angle and set it for your press NOTICE RE ADJUSTING TOP STOP ANGLE If you have previously set up your press and set the Top Stop Angle skip the next section and start with Prepare to Determine Top Stop Angle Set Top Stop Angle for the First Time NOTICE If you have already set the Top Stop Angle at least once on this WPC on this press go to the next section The first time ...

Page 130: ...and 4 are set to OPEN To change the switch setting highlight it and press ENTER to toggle between OPEN and CLOSED For more information about the switches see Setting Switches page 242 3 Power down the SmartPAC 2 and power it up again to make the new switch settings take effect 4 If your WPC has Micro inch disable this feature by setting the Micro inch angle to 185 see page 236 5 Set the Stroke Sel...

Page 131: ... consistently stopped before 358 go to the next step If the press consistently stopped after 2 go to the next step If the press sometimes stopped before 358 and sometimes after 2 call Wintriss Tech Support 4 From the angles you wrote in the boxes in step 2 above find the average of the Angles the Press Stopped Write this average in the box below You will use this value later Average Angle the Pres...

Page 132: ...find the Average value for the Angle the Press Stopped Write it in the box below You will use this as Angle the Press Stopped Angle the Press Stopped 2 Select PRESS CONTROL from the Run menu Read the Top Stop Angle on the screen that appears The Top Stop Angle is the number of degrees it took the press to stop after the Top Stop cam turned on Write the Top Stop Angle in the box below Use this as t...

Page 133: ...0 270 Old Top Stop Angle 38 _308 _270 _38 Angle Old the Press Top Stop Stopping Stopped Angle Angle 4 Fill in the boxes below to find the New Top Stop Angle by subtracting the Stopping Angle from 360 360 __ New 360 Stopping Top Stop Angle Angle Example TDC 360 0 270 Old Top Stop Angle 38 New Top Stop Angle 322 _360 _38 _322 New 360 Stopping Top Stop Angle Angle 5 In Run mode select PRESS CONTROL T...

Page 134: ...Top Stop Angle Highlight the Top Stop Angle value and press ENTER Adjust the setting by pressing the up and down cursor keys as required When the New Top Stop Angle value shows in the display press RESET and go to the next section Go to page 115 to check how the press top stops with the new top stop angle ...

Page 135: ...ct PRESS CONTROL Read the value of the Top Stop Angle at the top of the menu that appears This will be the Old Top Stop Angle in your calculations below Write this value in the box _ Old Top Stop Angle Example __270 Old Top Stop Angle 2 Press RESET In step 4 on page109 you wrote the Average Angle the Press Stopped Write this number in the box below This is where the press actually stopped and sinc...

Page 136: ... _270 _15 _255 Old New Top Stop Overshoot Top Stop Angle Angle Angle from step 1 from step 2 4 In Run mode select PRESS CONTROL The value of the Old Top Stop Angle appears next to Top Stop Angle at the top of the menu 5 Enter the New Top Stop Angle Highlight the Top Stop Angle value and press ENTER Adjust the setting by pressing the up and down cursor keys as required When the New Top Stop Angle v...

Page 137: ...een 358 and 2 the Top Stop Angle is correct Go to the next section Prepare to Install Magnet for Overrun Limit Sensor to install the overrun limit sensor magnet If the press does not stop consistently between 358 and 2 repeat setting the Top Stop Angle from Determine the Correct Top Stop Angle page 109 The New Top Stop Angle that you just set now becomes the Old Top Stop Angle in the instructions ...

Page 138: ...2 Overrun Limit Switch Setting page 242 WPC LED map Figure B at the end of the manual NOTICE The Top Stop Angle which you just set is the point in the stroke at which the Top Stop cam turns on The Top Stop cam stays on for 20 The following instructions enable you to install the Overrun Limit Sensor magnet so the overrun sensor turns on after the Top Stop cam turns off 1 In Run mode select PRESS CO...

Page 139: ...nt Zero Correction value in the appropriate column in the table Circle the Crankshaft Angle next to it Table 2 12 Top Stop Angle 240 or less Mounting Overrun Magnet Unzeroed Resolver Angle 270 Zero Correction 0 30 Zero Correction 330 359 Current Zero Correction Crankshaft Angle on Display Current Zero Correction Crankshaft Angle on Display Current Zero Correction Crankshaft Angle on Display Curren...

Page 140: ... turn the Prog Run key and nothing happens press RESET repeatedly until the SmartPAC 2 changes modes If PRESS CONTROL IS IN LOCKOUT MODE appears on the display turn the stroke select key to OFF and then back to the desired operating mode to clear the message Go to Install Overrun Sensor Magnet page 125 ...

Page 141: ...ro Correction value in the appropriate column in the table Circle the Crankshaft Angle next to it Table 2 13 Top Stop Angle bet 241 and 270 Mounting Overrun Magnet Unzeroed Resolver Angle 300 Zero Correction 0 30 Zero Correction 330 359 Current Zero Correction Crankshaft Angle on Display Current Zero Correction Crankshaft Angle on Display Current Zero Correction Crankshaft Angle on Display Current...

Page 142: ... turn the Prog Run key and nothing happens press RESET repeatedly until the SmartPAC 2 changes modes If PRESS CONTROL IS IN LOCKOUT MODE appears on the display turn the stroke select key to OFF and then back to the desired operating mode to clear the message Go to Install Overrun Sensor Magnet page 125 ...

Page 143: ...rent Zero Correction value in the appropriate column in the table Circle the Crankshaft Angle next to it Table 2 14 Top Stop Angle bet 271 and 300 Mounting Overrun Magnet Unzeroed Resolver Angle 330 Zero Correction 0 30 Zero Correction 330 359 Current Zero Correction Crankshaft Angle on Display Current Zero Correction Crankshaft Angle on Display Current Zero Correction Crankshaft Angle on Display ...

Page 144: ... turn the Prog Run key and nothing happens press RESET repeatedly until the SmartPAC 2 changes modes If PRESS CONTROL IS IN LOCKOUT MODE appears on the display turn the stroke select key to OFF and then back to the desired operating mode to clear the message Go to Install Overrun Sensor Magnet page 125 ...

Page 145: ...15 Find the Current Zero Correction value in the appropriate column in the table Circle the Crankshaft Angle next to it Table 2 15 Top Stop Angle 301 or Greater Mounting Overrun Magnet Unzeroed Resolver Angle 359 Zero Correction 0 30 Zero Correction 330 359 Current Zero Correction Crankshaft Angle on Display Current Zero Correction Crankshaft Angle on Display Current Zero Correction Crankshaft Ang...

Page 146: ... turn the Prog Run key and nothing happens press RESET repeatedly until the SmartPAC 2 changes modes If PRESS CONTROL IS IN LOCKOUT MODE appears on the display turn the stroke select key to OFF and then back to the desired operating mode to clear the message Go to Install Overrun Sensor Magnet next page ...

Page 147: ...t cycle in all modes without fault follow the instructions in the notice below NOTICE ERROR CODES WHEN RUNNING THE PRESS The press may stop and an error message may appear on the first stroke after you install the magnet If this happens push RESET and try another stroke If the error code is between F80 and F89 or H80 through H89 this indicates a problem with the overrun sensor Re check your instal...

Page 148: ... signals 3 Permanently install the magnet where it is temporarily mounted Drill and tap a hole using a No 36 drill and 6 32 tap Mount the magnet plastic side up with the 6 32 brass screw provided 4 After you permanently install the magnet run the press to make sure it operates without error Cycle the press a few times in Single Stroke mode If the press runs in Continuous mode run it in Continuous ...

Page 149: ...re to comply with these instructions will result in death or serious injury NOTICE Use the test tool you created and loaded during setup procedures page 103 NOTICE For help in using SmartPAC 2 see Chapter 3 Keyboard and Displays Chapter 4 Initialization mode Chapter 5 Program mode Chapter 6 Run mode Before you operate your press you must perform the tests in this section to verify that your Wintri...

Page 150: ... Static Test page 136 Anti tiedown Test page 138 Anti repeat Test page 139 Shadow Light Curtain Test page 140 Single Stroke Mode Test with Light Curtain page 142 Single Stroke Mode Test Without Light Curtain s page 145 Continuous Mode Test with Light Curtain page 147 Continuous Mode Test Without Light Curtain s page 149 Foot Switch Test with Optional Foot Switch page 151 One hand Control Switch Te...

Page 151: ...on the power to WPC 4 At the WPC control board check whether the 24 VDC 5 VDC A and 5 VDC B LED indicators are illuminated If all these LEDs are on go to the next test If all the LEDs are off check that line voltage is being applied to the system Then check power fuse labeled F1 found on the power supply board see Figure 2 37 page 160 for power supply board layout If necessary power down the WPC a...

Page 152: ... safeguarding applications Failure to comply with these instructions will result in death or serious injury Before turning on the press verify the following All fixed safeguards prevent entry of a hand or other body part into the hazardous area All moveable safeguards are correctly installed and wired to prevent operation of the press when they are open and prevent entry of a hand or other body pa...

Page 153: ...ch Support 2 Run the press in INCH mode One at a time keeping hands outside the guarded area open any moveable guards just enough to open the interlock switch In each case the press should stop immediately If the press stops immediately when you open the guard go on to the next step If the press does not stop check the wiring and correct any problems Test again as indicated in this step If the pre...

Page 154: ...e of the DSV fuses See Figure 2 36 page 159 3 Power up the press and SmartPAC 2 with WPC Select INCH with the Stroke Select switch Push both RUN INCH buttons Observe what happens If the ram does not move and the display show F79 or one of the DSV valve faults this is correct Go on to the next step If the ram moves and or the display shows a different fault check the wiring of the DSV valve Repeat ...

Page 155: ... 5 8 Power up the press and press control Make sure the press is still in Inch mode Push the RUN INCH buttons briefly The ram should move If the ram moves go on to the next test If the ram does not move check the wiring and correct any problems Power up the press and control Push the RUN INCH buttons again If the ram still does not move contact Wintriss Tech Support ...

Page 156: ...e EMERGENCY STOP button The press should Emergency stop immediately If the press Emergency stops go to the next test If the press does not Emergency stop there is a problem in your E stop circuit Recheck all wiring and correct any problems Re run this test If the press still does not Emergency stop contact Wintriss Tech Support Do not run the press or continue with this checkout procedure until th...

Page 157: ... depress the TOP STOP button The press should stop at top dead center If the press top stops go to the next test If the press does not top stop there is a problem in your top stop circuit Recheck wiring and correct the cause of the problem Re run this test If the press does not top stop contact Wintriss Tech Support Do not run the press or continue with this checkout procedure until the press top ...

Page 158: ... enclosure at the WPC control board whether INCH SEL LED is on If it is not check the stroke select switch wiring and correct any problems If the INCH SEL LED is still off contact Wintriss Tech Support 4 At the Operator Station press and hold the EMERGENCY STOP RESET button 5 Notice that F13 appears on the display If a status code F13 appears go to the next step If F13 does not appear at the WPC c...

Page 159: ...d down the counterbalance air pressure 13 At the Operator Station push both RUN INCH buttons at the same time The ram should not move and the error code should appear that is associated with the input the counterbalance pressure switch is connected to See counterbalance pressure error code 46 page 398 If the ram does not move and the appropriate error code appears this is correct Restore the count...

Page 160: ...perator station is correctly installed and wired to require two hands to press both run buttons simultaneously 1 Set the STROKE SELECT switch to SINGLE STROKE 2 Press and hold down both run buttons The press cycles to makes one stroke 3 While still holding down the left button do the following Remove your right hand from the right button for a moment Then press the right button again The press sho...

Page 161: ...n the run buttons have guard rings or other means in place to prevent unintentional operation Failure to comply with these instructions will result in death or serious injury Perform the following test to verify that the press will cycle only once in Single Stroke when you press both run buttons simultaneously 1 Set the STROKE SELECT switch to SINGLE STROKE 2 Press and hold down both run buttons w...

Page 162: ...not lit power down the light curtain check the wiring to the transmitter and check the power fuse in the receiver for Shadow V in the control box for the Shadow VI and replace if necessary Power up again If the amber indicator is still off power down the transmitter and replace the indicator Power up again If the amber indicator is still not lit contact Wintriss Tech Support 2 At the Shadow receiv...

Page 163: ...ver s green indicator goes off and the red indicator lights up this is correct Go to the next step If the receiver s green indicator stays on when the curtain is blocked check the wiring and repeat this step If the green indicator still stays on contact Wintriss Tech Support 4 Remove the obstruction from the light curtain At the receiver verify that the red indicator goes off and the green indicat...

Page 164: ...e light curtain is clear and off when the light curtain is blocked See the WPC LED map Figure B at the end of the manual Run this test if you use light curtains with your WPC installation 1 Set the STROKE SELECT switch to SINGLE STROKE Turn the Prog Run key to Run Make sure the light curtain is unobstructed On the WPC control board the INCH SEL LED should be off and the SNGL STK SEL should be lit ...

Page 165: ... curtain heads connected to your WPC repeat the test starting with step 3 removing the blockage from the first light curtain and blocking the second light curtain When you have successfully completed the test with the second light curtain go on to the next step If the ram does move check to make sure the correct version of WPC firmware is installed and check the wiring Re run the test starting wit...

Page 166: ...essage flashes on the display continue on to step 14 If the ram does not move or if it moves but does not stop immediately when you release the buttons or if the INTERRUPTED STROKE message does not flash on the display check the wiring and run the test from step 11 again If the ram still does not move or moves but does not stop immediately or if the ram stops but the INTERRUPTED STROKE message doe...

Page 167: ...L STK SEL should be lit Run this test if you do not use light curtains with your WPC installation 1 Set the STROKE SELECT switch to SINGLE STROKE Turn the Prog Run key to Run 2 Push and hold both RUN INCH buttons 3 Observe the ram s motion If the ram makes a full stroke and stops at or near top dead center go to step 6 If the ram does not make a full stroke or does not stop at top dead center go t...

Page 168: ... release the RUN INCH buttons The ram should start then stop The INTERRUPTED STROKE message should flash on the display and the press should now be in the TWO HAND MAINTAINED SINGLE STROKE mode If the press behaves as indicated above go to the next step If the press behaves differently check the wiring and repeat the test described in this step If after you have corrected the wiring the press stil...

Page 169: ...LOSURE WITH POWER ON DO NOT touch electrical connections or circuit boards Ensure that this test is performed by qualified personnel Failure to comply with these instructions could result in death or serious injury NOTICE Refer to the WPC LED map Figure B at the end of the manual If your press runs in continuous mode and has a light curtain perform this test If your press runs in continuous mode a...

Page 170: ...hould flash in the display If the press comes to an immediate stop go to step 7 to complete the test If your SmartPAC 2 with WPC does not have the muting option and the press does not come to an immediate stop when you interrupt the light curtain check the wiring and rerun the test starting with step 5 If it still does not stop immediately contact Wintriss Tech Support If you have a SmartPAC 2 wit...

Page 171: ...esult in death or serious injury WARNING ELECTRIC SHOCK HAZARD WHEN WORKING INSIDE ENCLOSURE WITH POWER ON DO NOT touch electrical connections or circuit boards Ensure that this test is performed by qualified personnel Failure to comply with these instructions could result in death or serious injury NOTICE Refer to the WPC LED map Figure B at the end of the manual If your press runs in continuous ...

Page 172: ...rn off the press Contact Wintriss Tech Support 3 Press the PRIOR ACT switch indicator and before the light goes out press both RUN INCH buttons Release the RUN INCH buttons after bottom dead center BDC of the first stroke The press should continue running If the press continues to run go to the next step If the press stops check the wiring and correct any problems Re run this test If the press sti...

Page 173: ...omply with these instructions could result in death or serious injury Perform this test only if your SmartPAC 2 with WPC is equipped with a Foot Switch If necessary refer to the LED map Figure B at the end of the manual when you are directed to the WPC control board NOTICE These instructions refer to the Auto Carry up angle which is factory set to 170 if it does not have a light curtain 149 if the...

Page 174: ...wer up SmartPAC 2 with WPC to enable the change You are now in the foot control mode The press should cycle to top stop only if the Foot Switch is held down until after the Auto Carry up angle 7 Press and hold the Foot Switch through the Auto Carry up angle Release Foot Switch after bottom dead center The press should run and stop at top stop 8 Press and hold the Foot Switch again This time releas...

Page 175: ...DE ENCLOSURE WITH POWER ON DO NOT touch electrical connections or circuit boards Ensure that this test is performed by qualified personnel Failure to comply with these instructions could result in death or serious injury NOTICE Refer to the WPC LED map Figure B at the end of the manual NOTICE Depress the One hand Control Switch quickly and fully to initiate a stroke If you depress the One hand Con...

Page 176: ...ol The press should not cycle If the press does not cycle go to the next step If the press cycles check the wiring and make sure Press Option Switch 3 is set to CLOSED and the MODE is set to ONE HAND Repeat the test If the press still cycles call Wintriss Tech Support 5 This time break the light curtain with your hand or another object Remove your hand from the light curtain and immediately depres...

Page 177: ...ged to Two hand Maintained mode You must depress and hold the run buttons to complete the stroke and clear the Interrupted Stroke see Interrupted Stroke page 364 One hand Control will not work while the Interrupted Stroke message is on 4 Momentarily depress the One hand Control Switch The press should make a single stroke and stop at top dead center At the WPC control board notice that the Palm Sw...

Page 178: ...e SELECT switch to on 3 At the WPC control board the Bar Selector LED should come on 4 Turn the press motor off 5 While the press s flywheel is still turning press the OPERATE button on the Bar Mode Control 6 Notice that the Dual Safety Valve momentarily energizes and then de energizes 7 At the WPC control board the Bar actuator LED should remain illuminated while the Bar Mode Control OPERATE butt...

Page 179: ...does not display check the wiring and rerun this test If the press still does not stop and or the correct fault code does not display contact Wintriss Tech Support Cam Channels Test Optional with ProCamPAC Go into Run mode and create some test settings for your cam channels see Chapter 6 Load the tool and run the press Ensure that the equipment feed blow off lube etc controlled by each channel is ...

Page 180: ...olver Table 2 17 WPC Wiring Power Supply Connectors Table 2 18 SmartPAC 2 Wiring Resolver TB101 Table 2 19 SmartPAC 2 Wiring Input Check and Stop Circuits TB102 Table 2 20 SmartPAC 2 Wiring SFI Port 1 and Module Port 2 TB103 Table 2 21 SmartPAC 2 Wiring Special Port 3 and PACNet Port 4 TB104 Table 2 22 SmartPAC 2 Wiring Spare 1 Port 5 and WPC Port 6 TB105 Table 2 23 SmartPAC 2 Wiring Spare 3 Port ...

Page 181: ...Proc LED DS151 Hi Lo Speed J112 24V I O LED DS150 B PROC EPROM U125 I O B PROCESSOR A PROCESSOR GREEN LED GREEN LED GREEN LED GREEN LED A PROC EPROM U108 RAM U109 5V A Proc LED DS149 GREEN LED RESOLVER TB 105 Hi Lo Speed J111 Figure 2 36 WPC Processor Board Important Components Shown and Labeled ...

Page 182: ...2 and WPC Lockout Relay DSV Relay DSV Relay Lockout DSV DSV 24VDC 120V Volt Switch Fuses Power Caution Power Transformer Caution Power Transformer Caution Power Transformer 24V LED DS404 Main Power I O TB401 Figure 2 37 WPC Power Supply Board Important Components Shown and Labeled ...

Page 183: ...gration 1126800 Installing SmartPAC 2 and WPC Chapter 2 page 161 Group 8 LEDs Comms TB501 Operator mode outputs TB502 Green LED Connector for Opt Clock Display J506 for Opt Clock Display Figure 2 38 WPC Serial Interface Board ...

Page 184: ...HERNET LEDS LINK ACTIVITY USB INPUT CHECK LED DS103 E STOP LEDS COMPACT FLASH ACCESS LED K101 K102 F101 F102 F103 INPUT CHECK FUSE E STOP FUSE TOP STOP FUSE 224 225 226 227 228 229 230 231 232 233 234 245 246 247 248 249 250 251 252 253 254 212 213 214 215 216 217 218 TB107 235 236 237 238 239 240 241 242 243 244 205 206 207 208 209 210 PS 2 ZERO CAM LED DS102 TOP STOP RELAY BATTERY Tx6 Rx6 Tx5 Rx...

Page 185: ...AC 2 and WPC Chapter 2 page 163 DiProPAC 8 board DiProPAC 16 board Sensors 1 8 TB501 TB551 Sensors 9 16 TB552 LEDs 1 8 LEDs 9 16 Aux Out TB500 Aux Out TB550 Fuse F501 Fuse F551 Figure 2 40 DiProPAC Boards Location of Components 8 channel left 16 channel right ...

Page 186: ...on Page 164 Chapter 2 Installing SmartPAC 2 and WPC Cams 1 8 TB401 TB451 Cams 9 16 TB452 ProCamPAC 8 board ProCamPAC 16 board Fuse F401 Fuse F451 Figure 2 41 ProCamPAC Boards Location of Important Components 8 channel left 16 channel right ...

Page 187: ... 15 16 1 2 3 4 5 6 7 8 DiProPAC 16 board ProCamPAC 16 board RESOLVER Figure 2 42 ProCamPAC and DiProPAC Boards Installed on SmartPAC 2 Board NOTICE INSTALL PROCAMPAC AND OR DIPROPAC BOARDS IN CORRECT LOCATIONS Install these boards in the locations shown If you install a board in the wrong location SmartPAC 2 will not recognize that the option is there Eight and sixteen channel configurations of th...

Page 188: ...RAL 123 Ground 124 Chassis ground 125 L1 out HI 126 L2 out NEUTRAL 127 Ground 128 L1 out 129 L2 out 130 Ground 131 DSVA relay in 132 DSVA relay out 133 DSVB relay in 134 DSVB relay out 135 Lockout relay in 136 Lockout relay out 137 Lockout relay out Table 2 18 SmartPAC 2 Wiring Resolver TB101 SmartPAC 2 TB 101 Pin Resolver connections Wire Color Shield Terminate to ground stud near to entry point ...

Page 189: ...2 SmartPAC 2 TB102 Terminal Wiring Designation WPC Control Board Pin 205 A 41 206 B 29 207 E Stop 68 208 E Stop 67 209 Top Stop 80 210 Top Stop 79 Table 2 20 SmartPAC 2 Wiring SFI Port 1 and Module Port 2 TB103 SmartPAC 2 TB103 Signal Port 235 RXD1 SFI PORT 1 236 RXD1 237 TXD1 238 TXD1 239 TXD1 240 Grd 241 RXD2 MODULE PORT 2 242 RXD2 243 TXD2 244 TXD2 ...

Page 190: ... TB104 Connections Port 224 RXD3 SPECIAL PORT 3 225 RXD3 226 TXD3 227 TXD3 228 TXD3 229 Grd 230 RXD4 PACNET PORT 4 231 RXD4 232 TXD4 233 TXD4 234 TXD4 Table 2 22 SmartPAC 2 Wiring Spare 1 Port 5 and WPC Port 6 TB105 SmartPAC 2 TB105 Pin Connections Port 330 TXD6 WPC PORT 6 329 TXD6 328 RXD6 327 RXD6 326 Grd 325 TXD5 SPARE 1 PORT 5 324 TXD5 323 TXD5 322 RXD5 321 RXD5 ...

Page 191: ...rtPAC 2 TB106 Pin Connections Port 320 TXD8 SPARE 2 PORT 8 319 TXD8 318 TXD8 317 RXD8 316 RXD8 315 Grd 314 TXD7 SPARE 3 PORT 7 313 TXD7 312 TXD7 311 RXD7 310 RXD7 Table 2 24 SmartPAC 2 Wiring Aux I O TB107 SmartPAC 2 TB107 Pin Connections 245 15 V 246 POSITION SENSOR 247 GRD 248 ZERO 249 REMOTE RESET 250 GRD 251 LOCKOUT 252 INCH SETUP 253 OP STA 2 254 OP STA 1 ...

Page 192: ...1126800 SmartPAC 2 with WPC Integration Page 170 Chapter 2 Installing SmartPAC 2 and WPC ...

Page 193: ...lay tell you which key to press in order to proceed to the next step After you learn how you will find it very fast and easy to make settings While you are learning how to use SmartPAC 2 do not be afraid to try things Push the keys Select items on the displays See what happens You cannot hurt SmartPAC 2 by pushing a wrong key or making a wrong selection SmartPAC DEMO TOOL NUMBER 6160 PART CNTR 0 D...

Page 194: ... This chapter contains the following instructions Comparing SmartPAC 2 with Original SmartPAC next section SmartPAC 2 Keyboard page 174 SmartPAC 2 Display page 186 The Three Operating Modes page 188 Initialization Mode page 190 Program Mode page 192 Run Mode page 194 Using Cursor Keys to Set Timing page 195 ...

Page 195: ...E PROTECTION CAM SWITCH TOOL INFORMATION RAM POSITION RAM TONNAGE ERROR LOG LOAD NEW TOOL USE THE CURSOR KEYS TO MAKE SELECTIONS PRESS ENTER TO ACCESS SELECTION TOOL NUMBER 6160 PART CNTR 0 CHAIR BRACKET ENABLE SENSORS Crank Angle SPM display 8 Function keys 6 Function keys Help key SmartPAC 2 only Contrast keys original SmartPAC only SmartPAC 2 with WPC Integration OFF INCH SINGLE STROKE CONT OFF...

Page 196: ...AR key Cursor keys HELP key HELP ENTER key RESET key RESET ENTER F1 F2 F3 F4 F5 F6 F7 F8 Function keys F keys 1 2 3 4 5 6 9 8 7 0 CLEAR Number keys Program Run Key Switch PROG RUN Figure 3 3 SmartPAC 2 Keyboard Stroke Select Key Switch next section Number Keys page 176 CLEAR Key page 177 HELP Key page 178 Cursor Keys page 179 RESET Key page 182 ENTER Key page 181 Program Run Key Switch page 183 Fu...

Page 197: ... or CONT continuous mode of press operation You can set the key switch to the desired operating mode and then remove the key to prevent anyone from changing the operating mode When the Lockout message appears on the display clear it by turning the Stroke Select key switch to OFF and then back to the desired operating mode DANGER PRESS NOT PROPERLY GUARDED FOR CONTINUOUS OPERATION Disconnect the co...

Page 198: ...se the number keys or cursor keys page 179 to enter the value or name you want Use the CLEAR key page 177 to delete a number USE THE KEYPAD TO ENTER NUMBERS USE THE UP DOWN CURSOR KEYS TO INCREMENT DECREMENT PRESS ENTER WHEN DONE PRESS RESET TO CANCEL 0 F L R X A G M S Y B H N T Z C I O U D J P V E K Q W PRESS CLEAR TO CLEAR TEXT USE THE KEYPAD TO ENTER NUMBERS USE CURSORS TO SELECT THE LETTERS PR...

Page 199: ... press the F2 key to change between upper and lower case letters To accept an alphabetic or alpha numeric entry press function key F6 For more information about the alphanumeric mode see Chapter 4 To cancel your selection in either case press RESET Clear Key CLEAR ENTER RESET PROG RUN POWER BRAKE WARNING HELP 1 2 3 4 5 6 9 8 7 0 CLEAR SmartPAC 2 F1 F2 F3 F4 F5 F6 F7 F8 CAMBIE AL ESPANOL CLEAR key ...

Page 200: ... Key ENTER RESET PROG RUN POWER BRAKE WARNING HELP 1 2 3 4 5 6 9 8 7 0 CLEAR SmartPAC 2 F1 F2 F3 F4 F5 F6 F7 F8 CAMBIE AL ESPANOL Cursor arrow keys HELP key HELP Figure 3 8 HELP Key The HELP key is at the center of the cursor keys Press the HELP key any time you need more information about the display you are in ...

Page 201: ...nd the ready signal for sensors Highlighting Items Using the Cursor Keys Figure 3 10 Highlighted Item on Run Menu On each menu an item is highlighted a colored or white bar surrounds the item The figure above shows the Run menu with CAM SWITCH highlighted Use the cursor keys to move the highlight bar to different items To select an item you highlight it and then press ENTER UP and DOWN Cursor Keys...

Page 202: ...s However only two columns can appear on the screen at a time To see a new column press the RIGHT cursor key to move the bar to the rightmost column then press the key again A new column will appear at the right if there are more tool numbers You can keep pressing the RIGHT cursor key to see more columns To go back to the first two columns move the highlight to the leftmost column using the RIGHT ...

Page 203: ...AR SmartPAC 2 F1 F2 F3 F4 F5 F6 F7 F8 CAMBIE AL ESPANOL ENTER key ENTER Figure 3 11 ENTER Key NOTICE SELECT HIGHLIGHT ENTER When this manual says select it means highlight the item and press ENTER To choose an item on a menu use the cursor keys see Cursor Keys above to highlight the item you want on the menu Then press the ENTER key SmartPAC 2 goes to the display relating to the item you selected ...

Page 204: ...aking settings or looking at different screens or menus Example In Program mode you are looking at the list of tools To leave this screen and not make any changes to any tools press RESET SmartPAC 2 returns to the previous screen The instructions on the display always tell you when you can press the RESET key The message will say something like Press Reset when done or Press Reset to cancel To Res...

Page 205: ...switch had a removable key so that access to Program and Run modes can be controlled When you turn the key toward Run SmartPAC goes into Run mode When you turn the switch toward Prog it goes into Program mode For more information about SmartPAC 2 s operating modes see The Three Operating Modes page188 and chapters 4 5 and 6 NOTICE SmartPAC will change from Run to Program or vice versa only when th...

Page 206: ...ll you which function key to press F1 through F8 The small rectangle next to each function key contains a descriptive label if the key is currently active In Run mode you can program function keys as Hot keys to give you quick access to frequently used screens Identify Hot keys in the main Run menu screen by the red border around their descriptive labels See the next section for more information a...

Page 207: ...T SETPOINTS Figure 3 14 Run Main Menu Showing Hot Keys Programmed Hot keys are special assignments for function keys that you create in Run mode to take you directly to the screens you want After you have programmed Hot keys in the main Run menu screen you can simply press the F key next to the label describing the screen and SmartPAC 2 goes to that screen For detailed instructions on how to use H...

Page 208: ...Function keys and Hot keys Crank Angle SPM readout Crank angle clock Instructions Menu Run window Figure 3 15 SmartPAC 2 Display Run Mode The SmartPAC 2 display shows at the top a status box that contains information such as the press name and the press speed or angle Below that is an area the Run window that contains menu items instructions graphics and other components Next to the function keys ...

Page 209: ...ght the item and press ENTER Figure 3 16 ENABLE SENSORS Is Highlighted in Main Run Menu To select an item on a menu use the cursor keys to move the highlight bar until it highlights the item you want Then press ENTER Highlight the appropriate selection and then press ENTER SmartPAC 2 goes to the display you want where you can make another selection or make a setting In each display a message tells...

Page 210: ... pages noted and the chapter about each mode SELECT HIGHLIGHT ENTER When we say select in this manual it means highlight the item and then press ENTER NOTICE To exit any mode be sure you are in the main menu shown below If you are not in the main menu press RESET repeatedly until the main menu appears Initialization Mode Chapter 4 Program Mode Chapter 5 white text on dark blue display black text o...

Page 211: ...rn the Program Run key toward PROG _________________________ From Initialization mode Go to the main Initialization menu Press RESET or Turn the Program Run key to RUN and then back to PROG To go to Run mode Turn the Program Run key toward RUN _________________________ To go to Initialization mode Press the 1 and CLEAR keys simultaneously and hold down a few seconds until the Main Initialization m...

Page 212: ...in the Program mode You use Initialization mode extensively when you install a new SmartPAC 2 and will likely use it only occasionally after you set it up and the press is running The figure above shows the main Initialization menu The next figure shows examples of how to navigate through the SmartPAC 2 menus in Initialization mode See Chapter 4 for detailed instructions on how to use SmartPAC 2 i...

Page 213: ...R RESET STROKES SINGLE STOKE MODE ENABLE IDLE TIMER SET SPECIAL NAMES SET CANNED NAMES RESOLVER COMMUNICATIONS INPUT STATUS ANALOG STATUS OUTPUT STATUS SET CLOCK MEMORY CHECKSUMS TOOL TABLES CLEAR TABLES SHOW SBC ERRORS UPDATE PROGRAM menu item Function Key PROGRAM ON OFF PROGRAM TIMED OUTPUT PROGRAM AUTO ADVANCE PROGRAM DSV ON DELETE CAM CHANNEL POSITION SENSOR MODE RESOLVER MOTION MODE TOOL NUMB...

Page 214: ... you can create copy modify and delete tools as well as enable or disable sensors The figure above shows the main Program menu The next figure shows examples of how to navigate through the SmartPAC 2 menus in Program mode See Chapter 5 for detailed instructions on how to use SmartPAC 2 in Program mode For HELP press the HELP key located at the center of the cursor arrow keys ...

Page 215: ...ENSOR SUMMARY SENSOR NAME SENSOR TYPE STOP TYPE READY WINDOW select cam channel F5 VIEW GLOBAL CAMS F6 VIEW CAM SUMMARY PROGRAM ON OFF PROGRAM TIMED OUTPUT PROGRAM AUTO ADVANCE PROGRAM DSV ON DELETE CAM SETTINGS OPERATING MODE HIGH PERCENTAGE LOW PERCENTAGE REPEATABILITY SAMPLE PERIOD F7 SHOW WAVEFORMS SHUT HEIGHT COUNTERBALANCE MODE MAX UPPER DIE WEIGHT UPPER DIE WEIGHT F4 SAVE THE SHUT HEIGHT me...

Page 216: ...per minute is displayed in the center of the clock diagram When the press is stopped or running in inch or single stroke the crankshaft angle is displayed You may be able to adjust cam timing and perform other operations in Run mode if allowed by the security access settings see CAM SWITCH Optional page 340 The figure above shows the main Run menu The next figure shows examples of how to navigate ...

Page 217: ...WINDOW TOP STOP ANGLE CONTINUOUS SPEED SINGLE STROKE INCHING SPEED COUNTER BAL MAIN AIR F3 SHOW OVERRUN ANGLES Figure 3 23 Navigation Example Run Mode Press ENTER to go in direction of arrow Press RESET to return to previous menu This illustration includes some optional features your menus may be different Using Cursor Keys to Set Timing For HELP press the HELP key located at the center of the cur...

Page 218: ...N setting moves the ON end of the arc clockwise LEFT cursor key decreases the ON setting moves the ON end of the arc counter clockwise UP cursor key increases the OFF setting moves the OFF end of the arc clockwise UP cursor key decreases the OFF setting moves the OFF end of the arc counter clockwise Go to the next page and follow the instructions for setting timing NOTICE See page 307 for informat...

Page 219: ...are at the same point in the crankshaft rotation Figure 3 25 ON at 1 OFF at 0 3 To make the ON setting press the right cursor key You can hold it down so ON edge of the arc keeps moving The edge of the arc moves clockwise around the circle from 0 toward 90 and beyond Stop when the ON edge of the arc reaches 239 This is the desired setting Look to see that the value in the box for ON shows 239 If y...

Page 220: ... the arc moves counter clockwise Stop when the OFF edge is at 270 Check the OFF setting in the box It should show 270 If you go too far use the UP cursor key to back up Now your sensor is on at 239 off at 270 Here is an illustration Figure 3 27 Setting OFF Angle You are done making the ON OFF setting for the cam You can adjust this setting any time you want using the cursor keys The on and off set...

Page 221: ...C 2 display press the 8 and 0 zero keys simultaneously for a second or two until you see Capturing Screen appear in very small letters at the top of the display on the right hand side When Capturing Screen disappears a copy of the screen is in SmartPAC 2 s memory 2 Go to Run mode main menu see page 325 Select MESSAGING 3 Press F3 Select Recipient Highlight the recipient you want to receive the scr...

Page 222: ...1126800 SmartPAC 2 with WPC Integration Page 200 Chapter 3 SmartPAC 2 Keyboard Displays and Operating Modes ...

Page 223: ...and the press is running In Initialization mode you make initial settings that affect the operation of SmartPAC 2 regardless of which tool is loaded You make settings for individual tools in Program mode see the next chapter This manual covers the ProCamPAC and DiProPAC options If you have any other optional modules with your SmartPAC 2 refer to the applicable user manual This chapter describes ho...

Page 224: ...OR TONNAGE WAVEFORM PROCESS MONITOR FEED CONTROL PM MONITOR TOOL INFORMATION SHUTHGT CNTRBAL ERROR LOG LOAD NEW TOOL DIALOG MENU TOGGLE HOT KEYS 1 330 PRESS 14 TOOL NUMBER 6160 PART CNTR 0 FLANGE TWO HAND S S INTERRUPTED STROKE PRESS ANGLE 330 1 4 7 2 3 5 6 8 9 0 CLEAR Contrast CURSOR INTERRUPTED STROKE BRAKE WARNING ENTER RESET F1 F2 F3 F4 F5 F6 Wintriss Press Automation Control SmartPAC PROG RUN...

Page 225: ...Program mode Press RESET ____________________________________ To go to Run mode Turn the Program Run key toward RUN If you turn the key and nothing happens press RESET repeatedly until the SmartPAC 2 changes modes To prevent this problem make sure SmartPAC 2 is in the main or top menu for the mode it is in before you turn the Program Run key If it is not press RESET repeatedly until the main menu ...

Page 226: ...y when you set up a new SmartPAC 2 with WPC or install new SmartPAC 2 firmware NOTICE RECORD YOUR WPC SETTINGS BEFORE YOU INSTALL NEW WPC FIRMWARE AND INITIALIZE WPC PRESS PARAMETERS Use the WPC Parameters setup sheets at the end of this manual to record the parameters before you initialize WPC parameters See Chapter 2 page 101 When you first set up your SmartPAC 2 with WPC or install new WPC firm...

Page 227: ...nu a display appears similar to that in the next figure You should disable the position sensor mode with a SmartPAC 2 WPC integration system To make this and other settings see the following sections POSITION SENSOR MODE Should be disabled See next section RESOLVER MOTION MODE page 206 TOOL NUMBER MODE page 206 COUNTER SETUP MODE page 208 Figure 4 4 Position Sensor Display Position Sensor Mode INI...

Page 228: ...AC 2 decide which tool number mode you will use numeric or alpha numeric Set up your SmartPAC 2 in that mode and do not change tool number modes afterward NOTICE UPGRADING FROM ORIGINAL SMARTPAC Follow the instructions below regarding tool number mode See When You Upgrade from an Original SmartPAC next section and Appendix E Upgrade from Original SmartPAC page 457 for more information about upgrad...

Page 229: ...SmartPAC page 457 for more information about upgrading from original SmartPAC to SmartPAC 2 When you replace an original SmartPAC with SmartPAC 2 and transfer over the tool setup information the existing tools will default to the Numeric mode If you want to change to Alpha numeric mode you must perform the following procedure before you change the tool number mode Check all the tool setups to make...

Page 230: ...ing ENTER to toggle among items explained below After you press RESET to exit the screen your choice is confirmed NOTICE The strokes counter will increment regardless of the mode that you are in IS INCREMENTED IN ALL MODES This means that the batch and parts counters will increment on every stroke whether the press is in setup mode or not NOT INCREMENTED IN SETUP MODE This means that the parts cou...

Page 231: ...t indicates how your SmartPAC 2 has been configured It includes firmware version numbers and the specific optional capabilities that have been installed It also tells you how many cam channels and or sensors you can connect to SmartPAC 2 The following figure shows an example of a list of installed options Figure 4 5 List of Installed Options Your screen will look different ...

Page 232: ...nd symbols See Chapter 3 for more information on entering data The name you choose can be any combination of alphabetic and numeric characters symbols etc Pressing the CLEAR key clears the text To enter other characters do the following 1 To key in letters and symbols Use the up down left and or right cursor keys to highlight the desired character then press ENTER 2 To key in numbers Use the numbe...

Page 233: ...5 CHANNEL 16 CAM CHANNEL NAME MENU USE CURSOR KEYS TO SELECT THE CHANNEL PRESS ENTER TO CHANGE THE NAME PRESS RESET WHEN DONE UNNAMED UNNAMED UNNAMED UNNAMED UNNAMED UNNAMED UNNAMED UNNAMED UNNAMED UNNAMED UNNAMED UNNAMED UNNAMED UNNAMED UNNAMED UNNAMED Figure 4 6 Select Cam Names display Notice that we are illustrating 16 cams Depending upon the way that your SmartPAC 2 has been configured with P...

Page 234: ...ears the text F L R X A G M S Y B H N T Z C I O U D J P V E K Q W PRESS CLEAR TO CLEAR TEXT USE THE KEYPAD TO ENTER NUMBERS USE CURSORS TO SELECT THE LETTERS PRESS ENTER TO ENTER THE LETTERS PRESS F6 WHEN DONE PRESS RESET TO CANCEL Figure 4 8 Custom Name Entry Box a To key in letters Use the up down left and or right cursor keys to highlight the desired letter then press ENTER b To key in numbers ...

Page 235: ...ant for top stop follow these steps 1 Determine the fastest press speed RPMa and the angle at which the press stops at this speed Aa 2 Determine the slowest press speed RPMb and the angle at which the press stops at this speed Ab NOTICE If either stopping angle occurs after 0 or 360 then add 360 to the angle For instance 12 would really be 12 360 or 372 3 Subtract the two angle values We will call...

Page 236: ... entered in slow RPM SmartPAC 2 would not auto advance certain press functions at the right time Setting Auto Advance Constant and Slow RPM 1 To set the auto advance constants and slow RPM select Auto Advance from the Initialization menu You will see the following display 2 The bar highlights advance constant 1 Press ENTER to change advance constant 1 If you prefer changing one of the other items ...

Page 237: ...value 6 Here again you can use either the number keypad or the cursor keys to set Slow RPM Refer to step 3 on how to use these keys The maximum value is 2000 7 When you are done with slow RPM press RESET As soon as you do this the bar jumps back to Advance constant 1 You can repeat the above steps if you decide to modify any of your entries Press RESET one more time to return to the Initialization...

Page 238: ...mpensated Top Stop ACTS See Setting the ACTS Angle Optional page 240 and Switch 4 Auto Compensated Top Stop ACTS Enabled page 244 NOTICE CHANNELS 6 7 AND 8 CANNOT BE USED FOR GLOBAL CAMS You can set any channel as a global cam except channels 6 7 and 8 NOTICE TO DELETE A GLOBAL CAM To delete a global cam select it from the cam list In the Global Cam Timing Type screen Figure 4 12 select Delete Cha...

Page 239: ...he cam you want to program The following screen appears Figure 4 12 Global Cam Timing Type 4 Select the type of cam timing you want to set Set the timing according to the instructions at CAM SWITCH page 302 in Chapter 5 5 When you have completed setting the timing press RESET NOTICE If you set or change global cams while a tool is loaded you must reload the tool to make the global cams take effect...

Page 240: ...ou can use a separate computer keyboard to enter names See page 270 CUS TOM 1 CUS TOM 2 CUS TOM 3 CUS TOM 4 CUS TOM 5 CUS TOM 6 CUS TOM 7 CUS TOM 8 CUS TOM 9 CUS TOM 10 CUS TOM 11 CUS TOM 12 CUS TOM 13 CUS TOM 14 CUS TOM 15 CUS TOM 16 CUSTOM SENSOR NAMES USE CURSOR KEYS TO SELECT A CUSTOM NAME PRESS ENTER TO SET CHANGE A NAME PRESS RESET WHEN DONE Figure 4 13 Custom Naming Sensors 1 Select Custom ...

Page 241: ...es to Auto by Tool Auto by Sensor MANUAL ENABLE Figure 4 14 Sensor Enable mode used with DiProPAC only Enabling Sensors Select MANUAL ENABLE when you wish to manually enable or disable sensors in DiProPAC Keep in mind that if you make this selection DiProPAC will not re enable sensors for you You have to remember to do that yourself in Programming and Run modes See Disable enable sensors discussed...

Page 242: ...To enable or disable Setup mode in the Main Initialization menu select SENSOR ENABLE MODE MAIN INITIALIZATION MENU USE THE CURSOR RESOLVER ZERO KEYS TO CHOOSE POSITION SENSOR MENU ITEMS PRESS INSTALLED OPTIONS THE ENTER KEY TO SELECT CAM NAMES SELECT SWITCH TO AUTO ADVANCE RUN WHEN DONE CUSTOM SENSOR NAMES SENSOR ENABLE MODE PROCESS MONITOR TOOL INFORMATION RAMPAC INIT PRESS CONTROL SECURITY ACCES...

Page 243: ...tion you can enter up to 30 characters of special information about each tool See Tool information chapters 5 and 6 Follow the steps below to set up the six items NOTICE Tool Information serves only as a convenient place to record information about the tool It does not control any aspect of press operation Note This feature is not available if you have the optional PLC interface installed 1 From t...

Page 244: ... you to enter up to twelve characters of text for a custom name next figure After you enter the characters for the custom name press F6 to accept NOTICE You can use a separate computer keyboard to enter names See page 270 A B C D E PRESS CLEAR TO CLEAR F G H I J K TEXT USE THE KEYPAD L M N O P Q TO ENTER NUMBERS USE R S T U V W CURSORS TO SELECT THE X Y Z LETTERS PRESS ENTER TO ENTER THE LETTERS P...

Page 245: ...IN millimeters per minute BAR bars GALS gallons LBS pounds QTS quarts TONS tons GRAMS grams OUNCES ounces SPM strokes per minute DEG F degrees Fahrenheit FPM feet per minute DEG C degrees Celsius MPM meters per minute 5 To enter the number of decimal places for each item select the places column next to the desired item A screen appears where you can enter the number of decimal places you want fro...

Page 246: ...decimal places any value you entered will be changed by a factor of ten for each decimal place added or removed 5 When you have finished setting up the tool number information press RESET to return to the main Initialization menu Table 4 3 Decimal places and formats Number of decimal places Example digits to digits to left of right of decimal decimal point point Range 0 whole numbers press speed S...

Page 247: ...ons page 241 Check input status see Using the WPC Input Status Display in Chapter 7 page 420 User Interlocks INITIALIZATION PRESS CONTROL USER INTERLOCKS DANGER USER INPUTS 1 THROUGH 7 ARE NOT CONTROL RELIABLE Do not use inputs 1 through 7 as part of any personnel protection system Failure to comply with these instructions will result in death or serious injury DANGER USER INPUTS PAIRS 8 9 AND 10 ...

Page 248: ... instructions will result in death or serious injury WPC has eleven user inputs two pairs of which are cross checked so they are control reliable when wired correctly to safety devices These cross checked input pairs can be used to connect such devices as interlocked barrier guards to WPC As a help to troubleshooting and installation you can also display the status of the interlocks from Initializ...

Page 249: ...URSOR KEYS TO CHOOSE THE USER STOP TYPE YOU WISH TO CHANGE PRESS THE ENTER KEY TO CHANGE THE USER STOP TYPE PRESS THE RESET KEY WHEN YOU ARE DONE ESTOP Figure 4 23 User Interlock Display NOTICE Input pairs 8 9 and 10 11 operate only as ESTOP and LOCKT lockout If you set the stop type for one of these inputs to UNUSED or TSTOP SmartPAC sets it to ESTOP or LOCKT when you exit the User Interlock menu...

Page 250: ...f what name you enter for Input 9 The name you enter for Input 10 applies to the input pair 10 11 regardless of what name you enter for Input 11 Table 4 4 User Input Interlock Names UNNAMED HIGH LOOP RECOILER CUSTOM NAME HIGH OIL TEMP STOCK BUCKLE BEARING TEMP HIGH OIL PRES TRANSFER CHAIN BREAK HYDRAULIC OVLD STR OFF COILER CONVEYOR LOAD MONITOR STOCK LUBE COUNTER BAL LOW AIR PRESS HYD DIE CLAMPS ...

Page 251: ...PARAMETERS Figure 4 25 Press Control Parameter Menu You can set the parameters shown Highlight the value of the item you want to change and press ENTER An entry box appears Key in the value Press RESET For instructions see the sections indicated Stop Limit next section Using Auto Carry up page 235 Setting Clutch and Counterbalance Air Pressure Limits page 238 Setting Shutdown and Flywheel Timer Li...

Page 252: ... the actual stopping of the press crankshaft WPC then displays this value in milliseconds When WPC is first initialized the stop time limit is factory set at 500 milliseconds One millisecond equals 1 1000th of a second or 0 001 second Be sure that you have completed the entire installation and that everything is operating properly If so you are ready to determine what your press s top stopping tim...

Page 253: ...isplay is in milliseconds ms 5 Do this test at least 5 more times Record the highest reading from all your tests This is the stopping time you will use to calculate and set the Stop Time Limit STOP TIME START TIME STOP ANGLE 90 STOP 300 200 75 PRESS THE UP CURSOR KEY TO START THE 90 DEGREE BRAKE TEST PRESS THE RESET KEY WHEN DONE STOP TIME STATUS TOOL NUMBER 1234567 PART CNTR 0 CHAIR BRACKET SENSO...

Page 254: ...d it up to 21 Add 21 to 207 207 21 228 228 ms is the calculated stop time limit Example 2 Your recorded stopping time is 175 ms and your brake is new Take 20 of 175 Tbm 20 x 175 35 Add 35 to 175 175 35 210 210 ms is the calculated stop time limit Setting Stop Time Limit at Press Parameters NOTICE To enable changes to Stop Time or Auto Carry up Angle you must first set Switch 7 to OPEN power down S...

Page 255: ... DEG 100 MSEC 185 DEG 0 PSI 0 PSI 250 MSEC 199 MSEC 5 MIN 6 SEC 0 DEG INITIALIZE PARAMETERS USE THE CURSOR KEYS TO CHOOSE THE VALUE YOU WANT TO CHANGE PRESS THE ENTER KEY TO CHANGE THE VALUE PRESS THE RESET KEY WHEN DONE PRESS CONTROL PARAMETER MENU 250 Figure 4 29 Press Parameters Display in SmartPAC s Initialization Mode 4 The bar highlights the Stop Time Limit value To change this value press E...

Page 256: ...ng This elapsed time primarily taken by the clutch mechanism is called Start Time WPC needs an internal limit for the start time to detect resolver drive failure After initialization the start time limit defaults to 500 ms After the press makes its first stroke WPC automatically resets the start time to twice the actual start time Wintriss Controls recommends that you use this automatically set st...

Page 257: ...eleases his hands from the palm buttons the press automatically completes the stroke and stops at TDC So in order to properly set the Auto Carry up Angle value in degrees you need to know at what point it is safe to let the operator s hands release from the palm buttons Pinch points that are less than 1 4 6 mm are considered non hazardous to the operator To determine the Auto Carry up angle you ne...

Page 258: ...O CHOOSE THE VALUE YOU WANT TO CHANGE PRESS THE ENTER KEY TO CHANGE THE VALUE PRESS THE RESET KEY WHEN DONE PRESS CONTROL PARAMETER MENU 149 Figure 4 30 Selecting Auto Carry up Angle 9 Use the number keys to enter the new value and then press ENTER 10 Press RESET twice when you are done and you will return to the Initialization menu 11 Go to the SmartPAC s Main Initialization menu Figure 4 1 and s...

Page 259: ...185 to 300 If you set the Micro inch Angle to 186 the press will automatically Micro inch throughout the stroke from 186 to 185 1 If you are not already there get into SmartPAC s Initialization mode Figure 4 1 and select Press Control In the WPC Initialization menu that appears select Press Parameters Use the cursor keys to first highlight Micro Time in this display Then press ENTER to select TOP ...

Page 260: ... Programming and Adjust modes Here is an example of how it works We set the counterbalance tolerance Cntr Bal Diff to 5 PSI in Initialization And we program tool 1 s counterbalance setpoint to 40 PSI in SmartPAC s Programming mode This means that our counterbalance air pressure levels cannot deviate outside the range of 35 to 45 PSI whenever the press is at or passing through 0 degrees or Top Dead...

Page 261: ... or activating the Bar mode while the flywheel is still turning With this feature WPC monitors the flywheel movement A flywheel speed sensor including an LMCS and two magnets mounted on the flywheel detects approximately how long it takes for the flywheel to turn one revolution As the flywheel slows down the amount of time it takes for one revolution increases You set a Flywheel Timer in seconds r...

Page 262: ... the value 4 Now select Flywheel Timer 5 Use the number keys to set the value and then press ENTER 6 Press RESET twice to return to the Main Initialization menu Setting the ACTS Angle Optional See Switch 4 Auto Compensated Top Stop ACTS Enabled Optional page 244 for information about Auto Compensated Top Stop ACTS a firmware option available for WPC In most variable speed applications the ACTS ang...

Page 263: ...L PRESS OPTIONS Figure 4 33 Press Control Option Switches There are several press option switch settings you need to make so the WPC integration is fully operational You make these settings Initialization mode Press Control Option Switch menu shown in the previous figure Set these switches and parameters as described below Read the description of each switch setting in order to select the appropri...

Page 264: ...8 5 If you are done press RESET to return to the main menu If not proceed to Setting operator mode settings below NOTICE To e mail a copy of this screen see Screen Capture page 199 Switches 1 and 2 Overrun Limit Switch Setting NOTICE After you change switch settings power down the SmartPAC 2 WPC Power it up again to enable the new settings If you do not this the previous switch settings will remai...

Page 265: ... initiate the next stroke When Switch 3 is set to OPEN One hand Control is enabled all the time just like the One hand Control on your operator station This allows you to initiate a single stroke every time you push the One hand Control switch If you are using Foot Switch mode Switch 3 enables either Foot Trip or Foot Control Set Switch 3 to OPEN for Foot Trip so the press runs for one stroke afte...

Page 266: ...g in the shortest stopping angle As the press runs faster the stopping angle increases Auto Compensated Top Stop ACTS notices when the press has not stopped exactly on top and compensates the Top Stop Angle by advancing its position ACTS cannot advance beyond 211 degrees the same limit as with the manual Top Stop Angle setting ACTS will require a few top stops so that the press stops as close to 0...

Page 267: ...r act time for both modes 30 seconds 1 minute respectively The switch in the CLOSED position selects the longer prior act time for both modes 5 minutes 10 minutes respectively Refer to the table below For more information about Automatic Single Stroke mode see Operating the Press in Automatic Single Stroke Mode page 373 For more information about Continuous on Demand mode see Operating the Press i...

Page 268: ...s will remain in effect Set this switch to CLOSED if you have two light curtains connected to WPC Refer to Figures 3 or 12 for Herion valve or Figure 5 for Ross to properly wire the dual light curtains end of this manual Set Switch 6 in the Press Control Option Switches screen Figure 4 33 page 241 Table 4 9 Switch 6 Setting for Single or Dual Light Curtains Option Switch 6 Setting Light Curtain Co...

Page 269: ...itch OPEN you can change the settings for Stop Time Limit and Auto Carry up Angle When this switch is set to CLOSED you cannot change these settings Table 4 10 Switch 7 Setting to Enable Disable Changes to Stop Time Limit and Auto Carry up Angle Option Switch 7 Setting Changes to Stop Time Limit and Auto Carry up Angle OPEN Enabled CLOSED Disabled NOTICE CHANGE FROM PREVIOUS VERSIONS OF WPC TOP ST...

Page 270: ...Press Control Option Switches screen Figure 4 33 page 241 according to the following table Table 4 11 Switch 8 Settings for Top Stop with F and H Errors Option Switch 8 Setting Top Stop Behavior for F and H Errors OPEN If the error occurs after 210 the control allows the press to complete another stroke before it top stops If the error occurs before 210 the control top stops the press on the same ...

Page 271: ... is caused Operator Mode Settings on Press Control Option Switch Screen In the Press Control Option Switch screen Figure 4 33 you can also set specific operator mode settings including Dual Operators Automatic Single Stroke Inch Setup Mode and Two Hand Only Dual Operators Set Dual Operators when you have two or more operator stations wired to WPC See Chapter 2 for installation of dual operator sta...

Page 272: ...Menu 2 Use the down cursor key to highlight the next selection Two Hand Only or press RESET to exit Two Hand Only NOTICE This selection affects only the SmartPAC 2 WPC controls with Shadow light curtain firmware installed One Hand and Foot modes are not available when Shadow firmware is not installed 1 In the Press Control Option Switch screen Figure 4 33 highlight the item next to Two Hand Only P...

Page 273: ...revents changes to actual counter values for strokes good parts total hits and batch counters so that these counter values cannot be altered in either Program or Run modes Init Password enables you to require the user to enter a password in order to access the Initialization menu To require a password select Must Be Used For no password select Not Required Load Monitor has four choices Allow Recal...

Page 274: ...SS RESET TO 60599 Give this number to Wintriss Tech Support if you forget your password Note Your number may be different Figure 4 34 Enter Your Password Screen IF YOU FORGET OR DO NOT KNOW YOUR PASSWORD S Contact Wintriss Tech Support at the telephone number on the cover of this manual Give the tech support person the 5 digit number from the bottom of the Enter your password display ...

Page 275: ... PASSWORD REQUIRED PASSWORD NOT REQUIRED ADJ PROPAC SENS PROGRAM AND RUN MODES PROGRAM MODE ONLY PASSWORD REQUIRED ADJ DIPRO SENS PROGRAM AND RUN MODES PROGRAM MODE ONLY PASSWORD REQUIRED DISABLE SENSORS PROGRAM AND RUN MODES PROGRAM MODE ONLY PASSWORD REQUIRED TURN OFF SENSORS ALLOWED NOT ALLOWED PASSWORD REQUIRED ADJUST CAMS PROGRAM AND RUN MODES PROGRAM MODE ONLY PASSWORD REQUIRED ADJ PRESS CNT...

Page 276: ...CNTL ADJUST FEED LOAD MONITOR ADJ TOOL INFO INIT PASSWORD PROGRAM AND RUN MODES PROGRAM AND RUN MODES PROGRAM AND RUN MODES PROGRAM AND RUN MODES PROGRAM AND RUN MODES PROGRAM AND RUN MODES PROGRAM AND RUN MODES PROGRAM AND RUN MODES ALLOW RECALC ADJUST PROGRAM AND RUN MODES NOT REQUIRED PROGRAM AND RUN MODES Figure 4 35 Security Access Menu NOTICE Be sure to check your passwords before changing a...

Page 277: ...l PASSWORD REQUIRED appears Press RESET Now the cams cannot be adjusted without the user entering the correct password Reset Mode Set the Reset mode security access with care If you set access to Program mode only or Password required personnel cannot reset SmartPAC 2 in Run mode after a malfunction that stops the press If you want the operator to reset the machine after errors select Program and ...

Page 278: ... In the Initialization menu select Security access 2 The display appears similar to Figure 4 35 Press F1 3 The display shows the Set Passwords menu Figure 4 36 Figure 4 36 Set Passwords Menu 4 Highlight the password you want to change Press ENTER The display looks like the next figure ENTER A NEW PASSWORD UP TO 4 DIGITS LONG USE THE KEYPAD TO ENTER NUMBERS USE THE UP DOWN CURSON KEYS TO INCREASE D...

Page 279: ... switch overrides the Security Access settings discussed in the previous sections Here are the messages that you will see in SmartPAC s Program and Run modes when the keylock switch is closed at input 1 message indicating selected operating mode is locked TOP STOP ANGLE MAX PRESS SPEED MIN PRESS SPEED CNTR BAL SETPOINT 270 200 150 40 DEGREES SPM SPM PSI THE PRESS CONTROL EDIT MODE IS LOCKED PRESS ...

Page 280: ... should set the CPU number for this unit In addition you set parameters relating to the PACNet computerized pressroom reporting software The CPU number is from 1 to 99 Make sure each control connected to the software has a unique CPU number Select the value next to CPU NUMBER An entry box appears Enter the CPU number using the number keys or the up and down cursor keys See your PACNet manual for m...

Page 281: ...his menu contains items relating to connection to your computer network setting up e mail and using SmartView remote viewing utility see Appendix D SmartView page 455 E MAIL FUNCTION INITIALIZATION SETUP NETWORK NOTICE Consult with your network administrator when setting up e mail Use SmartView remote viewing utility See Appendix D SmartView page 455 to set up e mail messages and recipients If you...

Page 282: ...oggle between ENABLED and DISABLED When the correct choice is showing press RESET SETUP E MAIL INITIALIZATION SETUP NETWORK SETUP E MAIL NOTICE Consult with your network administrator when setting up e mail Use SmartView remote viewing utility See Appendix D SmartView page 455 to set up e mail messages and recipients F1 F2 F3 F4 F5 F6 F7 F8 Figure 4 41 Setup Email Screen If you will use SmartPAC 2...

Page 283: ...dix D SmartView page 455 for your SmartPAC 2 1 Highlight an item and press ENTER A text entry window appears 2 Fill in the appropriate name or text Press F6 to accept the text 3 Repeat for each item 4 When you have finished filling in the items press F2 to apply the changes you have made NOTICE You can use a separate computer keyboard to enter names See page 270 NOTICE To e mail a copy of this scr...

Page 284: ...e mail fails to be delivered ErrorRecipient yourcompany com joe user yourcompany com E mail From Name Name listed on the e mail as who sent the message Some networks require a particular format of from name FromRecipient yourcompany com Press_14 yourcompany com Wintriss E mail Addr The e mail address for Wintriss Tech Support Use default unless instructed otherwise Wintriss Acton honeywell com CHA...

Page 285: ...ess type appears press RESET to exit this screen DIAGNOSTICS INITIALIZATION DIAGNOSTICS Figure 4 42 Diagnostics Menu This is the screen that appears when you select DIAGNOSTICS in the Initialization main menu The only items you are likely to use are COMMUNICATIONS view communications and run a loopback test see next section SET CLOCK set the SmartPAC 2 s internal clock to local time see page 266 S...

Page 286: ...gure 4 44 Press F2 Stop Start Buffer if you want to examine the transmitted and or received data If you do not see any data or only partial data this means that SmartPAC 2 and the other module are not communicating properly There are two formats for this display See Figure 4 44 for examples Press F1 to choose Combined TX and RX Transmit data appears as blue on a white background while Receive data...

Page 287: ...lines together and then press F1 to check communications In effect you are actually receiving the communications data that you are transmitting This test is useful when verifying the accuracy of the transmit and receive hardware and wiring Call Wintriss Tech Support for instructions on running a loopback test Be sure to supply the following information when you call product name e g SmartPAC 2 sta...

Page 288: ... and time that you want to change Press ENTER A number entry box appears 2 Use the number keys or the up and down cursors to place the number you want in the entry box 3 Press ENTER when done press RESET to cancel and close the box To stop the clock press F1 To start it again press F1 again NOTICE You will have to change the clock setting when your local time changes from Standard to Daylight Savi...

Page 289: ... or console to access the SmartPAC 2 board 3 Find the USB connector on the board J121 Refer to Figure 2 39 page 162 4 The USB disk can fit into the USB connector only in the correct orientation Determine this orientation and without forcing it carefully insert the USB disk into the USB connector 5 Close the enclosure or console door Power up the SmartPAC 2 with WPC 6 Go to the main Initialization ...

Page 290: ...s 180 This will likely result in a top dead center reading of less than 360 which in this case is acceptable Refer to your user manual for instructions on installing and zeroing the resolver Setting Link Motion INITIALIZATION POSITION SENSOR Set SmartPAC 2 to Link Motion mode if the press speed on the display varies during the stroke in Continuous mode After you set Link Motion SmartPAC 2 will dis...

Page 291: ...for one tool and set the settling time to the appropriate value you can use the Feed Advisor for all other tools on this press 1 In Initialization Mode select FEED CONTROL Select SETTLING TIME and set it to 30 ms 2 In Program Mode select the tool that is currently loaded Select FEED CONTROL 3 Select FEED ADVISOR Select CALCULATE 4 Load the tool number in SmartPAC 2 for the tool that is in the pres...

Page 292: ...ou are finished with Link Motion compensation If feeding is completed too late go to Program Mode and increase the Press Speed in the Feed Advisor by 3 and select CALCULATE again Load the tool number Run the press and observe the feeding again Continue to increase Press Speed in the Feed Advisor by 3 increments until feeding is complete at the correct time If feeding is completed too soon decease ...

Page 293: ...PRESS NAME an entry window Figure 4 46 opens Type on the separate keyboard You can use all the alphabetic characters the numbers and the symbols that are shown in the entry window as well as the backspace key and the space bar As you type the characters appear in the entry box at the top of the window 5 When you have finished typing in the characters press F6 to accept the entry ...

Page 294: ...1126800 SmartPAC 2 with WPC Integration Page 272 Chapter 4 SmartPAC 2 Initialization Mode ...

Page 295: ... programmable cams die protection sensors and other optional features of SmartPAC 2 You can program up to 200 tools and store them in the SmartPAC 2 s memory In Program mode you can make settings for all your tools but you cannot run the press In Run mode you can run the press and make certain minor adjustments only for the installed tool Refer to Chapter 3 for instructions on using the keyboard a...

Page 296: ...TONNAGE WAVEFORM PROCESS MONITOR FEED CONTROL PM MONITOR TOOL INFORMATION SHUTHGT CNTRBAL ERROR LOG LOAD NEW TOOL DIALOG MENU TOGGLE HOT KEYS 1 330 PRESS 14 TOOL NUMBER 6160 PART CNTR 0 FLANGE TWO HAND S S INTERRUPTED STROKE PRESS ANGLE 330 1 4 7 2 3 5 6 8 9 0 CLEAR Contrast CURSOR INTERRUPTED STROKE BRAKE WARNING ENTER RESET F1 F2 F3 F4 F5 F6 Wintriss Press Automation Control SmartPAC PROG RUN EN...

Page 297: ...o prevent this problem before you turn the Program Run key make sure SmartPAC 2 is in the main or top menu for the mode it is in If it is not press RESET repeatedly until the main menu appears If PRESS CONTROL IS IN LOCKOUT MODE appears on the display turn the stroke select key to OFF and then back to the desired operating mode to clear the message NOTICE Refer to Chapter 3 for instructions on usi...

Page 298: ... as number 9999999 Any tool number that is named Tool Template acts as the Tool Template See page 280 The next figure shows the first display you see in Program mode the main Program mode menu You can easily recognize Program mode screens because they have black text on a green background Figure 5 3 Program Mode Main Menu NOTICE SELECT HIGHLIGHT ENTER When this manual says select it means highligh...

Page 299: ...itialization page 206 Numeric mode Tools listed by tool number Alpha numeric mode Tools listed by tool name The example above is numeric listed by tool number Refer to the pages indicated for instructions for performing the following procedures Load an Existing Tool page 278 Delete a Tool page 279 Tool Template page 280 Create a New Tool page 281 Copy an Existing Tool page 282 Change Settings for ...

Page 300: ...s display appears you need to enter the general password to access these settings Password access is set under Security Access in Initialization mode See Security Access page 251 NOTICE You can also load tool numbers in Run mode if allowed by security access as long as the press is stopped Figure 5 5 Load Tool Information Box 2 A box appears similar to the figure above which gives the tool number ...

Page 301: ...information product name e g SmartPAC 2 standard installed options e g DiProPAC ProCamPAC etc and firmware version number e g Vs 2 00 Find the last two items by going into Installed options in Initialization mode see Chapter 4 Delete a Tool PROGRAM GO TO THE TOOL MANAGER F6 DELETE TOOL 1 To delete a tool first highlight it using the cursor keys 2 Then press F6 Delete Tool The following message app...

Page 302: ...ng Tool Template below NOTICE PASSWORD PROTECTION FOR TOOL TEMPLATE To prevent unauthorized changes to the Tool Template you can set Security Access page 251 to require a password before the template is changed Program Tool Template First program the Tool Template tool as follows 1 In the Tool Manager screen select Tool Template 2 Program it with the parameters common to two or more of your tools ...

Page 303: ...he number numeric or alphanumeric for the tool If you need assistance see Chapter 3 3 Press ENTER after keying in a numeric tool number or F6 after entering an alphanumeric tool number The following box appears DO YOU WANT TO COPY THE TOOL TEMPLATE PROGRAMMING INTO THIS NEW TOOL NUMBER PRESS THE ENTER KEY TO COPY THE TOOL TEMPLATE PRESS THE RESET KEY TO START WITH A BLANK TOOL If you want to copy ...

Page 304: ...nstructions on entering numbers and text 4 Go to Tool Program Menu page 285 and program the tool Change Settings for an Existing Tool PROGRAM GO TO THE TOOL MANAGER select tool number DANGER ANCILLARY EQUIPMENT MAY OPERATE WHEN TOOL IS LOADED Ensure that all personnel stand clear when you load a tool Failure to comply with these instructions will result in death or serious injury 1 On the Tool Man...

Page 305: ...F YOU CHANGE ANY OF ITS SETTINGS If you change settings for a tool that is currently loaded you should load the tool again after you make the settings If you do not re load the tool the old settings will be used until you load the tool again 3 Go to Tool Program Menu next section and program the tool 4 After you change settings for the tool and the Tool Program menu is on the display you can do on...

Page 306: ...th WPC Integration page 284 Chapter 5 SmartPAC 2 Program Mode Figure 5 10 Load Tool Warning Box If you want to load the tool press ENTER The tool will be loaded in SmartPAC 2 If you do not want to load the tool press RESET ...

Page 307: ...enu appears F1 F2 F3 F4 F5 F6 F7 F8 Figure 5 11 Tool Programming Menu Includes some options Your display may look different Find instructions for the following Tool Program menu items on the pages listed TOOL NAME or TOOL ID next section COUNTERS page 286 DIE PROTECTION page 292 CAM SWITCH page 302 PRESS CONTROL page 314 TOOL INFORMATION page 315 For HELP press the HELP key located at the center o...

Page 308: ... KEYPAD TO ENTER NUMBERS USE THE UP DOWN CURSOR KEYS TO INCREMENT DECREMENT PRESS ENTER WHEN DONE PRESS RESET TO CANCEL 0 Figure 5 12 Tool Name Entry Box left Tool Number Entry Box right 3 Follow the instructions in the box to enter the Tool Name or Tool ID See Chapter 3 for assistance Press F6 to accept the Tool Name Press ENTER to accept the Tool ID 4 When you are completely done naming your too...

Page 309: ...to either toggle or pulse the counter display shows the PLS channel that is controlled by that batch counter see figure above The total hits counter counts all hits on a tool If the tool number is loaded again after other tools are used the counter starts counting from the last recorded number for the previous job The counter is useful for deciding when a tool needs regrinding NOTICE In Run mode w...

Page 310: ...r command Press the Up cursor key to confirm this selection If you do not want to make a change to that counter value just press RESET 4 To set another counter value cursor down to the desired choice press ENTER and then repeat the steps explained above NOTICE Disable counters by setting the preset value for parts and batch counters to zero Clearing the Total Hits Preset Message NOTICE See Securit...

Page 311: ...ions in counter setup mode the previous display shows batch 2 set to toggle and batch 3 to pulse Factory settings are configured to top stop and stroke 2 Using cursor keys highlight the output mode for batch 1 3 As you press ENTER notice that the selections change from top stop to toggle to pulse and back again Make your selection and then cursor down to batch 2 COUNTER MODE SELECTIONS ADV MODES C...

Page 312: ... when done 2 Next move the cursor down to the next one batch 2 and repeat step 1 3 Repeat the above steps for batch 3 Setting Counter Increment Mode A third selection in count mode is the ability to set counter increment mode Here you determine whether the batch counter increments with the good parts counter or the strokes counter If you want the batch to count ALL strokes then select stroke Howev...

Page 313: ... appears on the screen as shown below ADVANCED COUNTER MODE SELECTIONS PARTS MADE PER EACH STROKE 1 STROKES TO MAKE EACH PART 1 USE THE KEYPAD TO ENTER NUMBERS USE THE UP DOWN CURSOR KEYS TO INCREASE DECREASE PRESS ENTER WHEN DONE PRESS RESET TO CANCEL 1 1 Figure 5 16 Setting Parts Stroke or Strokes Part 3 Use the keypad or cursor keys to change the number of parts stroke or strokes to make each p...

Page 314: ... 11 after entering a new tool number or selecting an existing one Select Die Protection ENTER YOUR PASSWORD USE THE KEYPAD TO ENTER NUMBERS USE THE UP DOWN CURSON KEYS TO INCREASE DECREASE PRESS ENTER WHEN DONE PRESS RESET TO CANCEL 60599 If this display appears you need to enter the general password to access these settings Password access is set under Security Access in Initialization mode See S...

Page 315: ...nable by Tool Counter 3 Next you will see a list of sensors to program SENSOR 2 SENSOR 3 SENSOR 4 SENSOR 5 SENSOR 6 SENSOR 7 SENSOR 8 SENSOR 9 SENSOR 10 SENSOR 11 SENSOR 12 SENSOR 13 SENSOR 14 SENSOR 15 SENSOR 16 USE CURSOR KEYS TO CHOOSE A SENSOR PRESS THE ENTER KEY TO PROGRAM PRESS THE RESET KEY WHEN DONE TOOL 1234567 CHAIR BRACKET SENSOR 1 Figure 5 18 List of sensors to program NOTICE We are il...

Page 316: ...not to name a sensor by selecting unnamed 4 If you do not find a suitable name but you still want to select a name the sensor you can select Custom Name by highlighting it and pressing Enter 5 If you select Custom name another display appears that lists all the customized names up to 16 possible choices that you set in Initialization mode see Custom sensor names in Chapter 4 Assign any one of thes...

Page 317: ...ntinue in this manner until all your sensors have been configured accordingly Setting Sensor Type After selecting the sensor name you will see this display You can set sensor type Notice that the sensor name now appears at the top right of the display This display shows Part ejection NOT USED RED NC YELLOW NO GREEN GREEN QUICK CHECK GREEN CONSTANT GREEN SPECIAL USE CURSOR KEYS TO CHANGE SENSOR TYP...

Page 318: ...llows SmartPAC 2 to initiate either an emergency stop or top stop depending upon the angle where the sensor detected the fault Highlight Smart Stop and press ENTER USE CURSOR KEYS TO CHANGE SELECTION PRESS ENTER TO SELECT RESET WHEN DONE EMERGENCY STOP TOP STOP SMART STOP SET CRITICAL ANGLE F5 TOOL NUMBER 1234567 CHAIR BRACKET CRITICAL ANGLE 0 SENSOR 1 PART EJECTION GREEN ESTOP if critical angle h...

Page 319: ...or all sensors in the tool set for variable stop CRITICAL ANGLE FOR THIS TOOL DEGREES THIS AFFECTS ALL SENSORS SET FOR VARIABLE STOP FOR THIS TOOL USE THE CURSOR KEYS TO CHANGE THE ANGLE PRESS THE ENTER KEY WHEN DONE PRESS THE RESET KEY TO CANCEL IS TOOL NUMBER 1234567 CHAIR BRACKET CRITICAL ANGLE 59 59 SENSOR 2 TRANSFER GREEN SMART Figure 5 23 Setting critical angle for variable stop sensors Use ...

Page 320: ...e keyboard in Chapter 3 for step by step instructions This display shows a green sensor with the ready signal for part ejection set to 180 on 265 off USE L R CURSOR KEYS TO SET READY ON USE U D CURSOR KEYS TO SET READY OFF PRESS RESET WHEN DONE programmed ready signal arc on circle diagram graphically shows ready signal READY ON 180 OFF 265 0 90 180 270 TOOL NUMBER 1234567 CHAIR BRACKET CRITICAL A...

Page 321: ... set more sensors select the next sensor from the list and make settings for the sensor Make settings in the same way for the rest of the sensors you are using Going Back to the Main Programming Menu When you are done making settings for all sensors and have the list of sensors on your display press RESET once more You will again see the main Tool Program menu Figure 5 11 You can select tool name ...

Page 322: ...l ignore any signals from that input even if a sensor is connected SmartPAC 2 will list an unused sensor on the sensor list as sensor 1 or sensor 2 whatever number it is Sensor type is automatically set to not used if no settings have been made To change a sensor input to not used select not used for sensor type The list of sensors will be immediately displayed Any sensor settings for this sensor ...

Page 323: ...anged the currently loaded tool load it Otherwise the change will not take effect Delete a ProPAC Sensor Either Analog or NPN PNP Process Monitor option only PROG PROGRAM OR LOAD TOOL NUMBERS select tool PROCESS MONITOR 1 In the Process Monitor Sensor list screen select the sensor you want to delete The Sensor Summary Screen appears 2 Press the CLEAR key 3 The following display appears X represent...

Page 324: ...imed output cam channels NOTICE DO NOT USE CAM CHANNEL 6 7 OR 8 WHEN USING THE ASSOCIATED BATCH COUNTERS Cam channels 6 7 and 8 are also used for batch counters 1 2 and 3 respectively To use cam switch you need to Select Cam switch from the Main Programming menu Select a channel select the type of timing on off auto or timed and make an output settings for it Repeat for the other channels you want...

Page 325: ... in Initialization mode Chapter 4 the channel number will be replaced with the name F1 F2 F3 F4 F5 F6 F7 F8 Figure 5 27 Cam Program Menu Go to the page indicated for instructions on performing the following operations View Global Cams next section View Cam Summary page 305 Make an ON OFF Setting for a Channel page 305 Multiple ON OFFs for Cam Channels page 307 Selecting a Channel and Making a Time...

Page 326: ...o make the global cams take effect Events that remain the same on all tools can be programmed once as global cams in Initialization mode and will apply to all the tools entered into this SmartPAC 2 This saves programming the same cam information for each tool and ensures that the cam always operates the same Cams programmed as global cams are not available for programming for individual tools To s...

Page 327: ... number cam name type of timing and the timing settings The global cams do not appear in this screen Figure 5 29 Cam Summary Make an ON OFF Setting for a Channel NOTICE You can set multiple ON OFF cycles for cam channels if you want See Multiple ON OFFs for Cam Channels page 307 1 Select a channel from the complete list see previous figure You will see the display below Notice that the tool number...

Page 328: ...he display See Cursor keys under Using the keyboard in Chapter 3 for instructions on how to set the on and off angles 4 Press RESET to go back to the display showing the cam channels You can select another channel to set Here is an example of a display for a part blow off set at 185 on 220 off arc moves around circle diagram as you press cursor keys to set timing angles when cam channel turns on a...

Page 329: ...hannel ProCamPAC Extra ON OFFs you set on Global Cam channels count toward the 6 extras The tables below give examples of how you might use the extra ON OFFs on 8 or 16 channel ProCamPAC Table 5 1 Examples of Using Extra ON OFFs 8 channel Unit C h 1 C h 2 C h 3 C h 4 C h 5 C h 6 C h 7 C h 8 Total ON OFFs Total extra ON OFFs 1 1 1 1 1 1 1 1 8 0 1 2 2 1 1 1 2 1 11 3 1 2 2 2 2 2 2 1 14 6 4 4 1 1 1 1 ...

Page 330: ...lete the channel settings page 313 and start over again 1 Set the first ON OFF arc as described above Make an ON OFF Setting for a Channel page 305 The display looks something like the following figure F1 F2 F3 F4 F5 F6 F7 F8 Figure 5 32 One ON OFF Arc 2 Add another arc by pressing F6 Add a New Arc The arc you already set turns dark gray A new arc appears as a green line at the zero 0 position F1 ...

Page 331: ...e channel settings page 313 for this channel and make the ON OFF settings again Inactive arcs are gray Selected active arc listed here and indicated by green color on circle diagram Figure 5 34 Selected and Inactive Arcs Selecting a Channel and Making a Timed Output Setting NOTICE MAXIMUM NUMBER OF TIMED CHANNELS PER TOOL Each tool can have up to four timed output cam channels A timed output setti...

Page 332: ... display as the key is pressed Hold down the key until the T moves to the degrees you want If you overshoot your setting press the left cursor key to go back The degrees setting is also shown in the box next to angle NOTICE The zero next to the T indicates the ON time which is set next 4 Use the UP or the DOWN cursor keys to set the time that the channel should be on in milliseconds A millisecond ...

Page 333: ...an also use auto settings for feed pilot release lube etc You can set up a maximum of two channels as auto NOTICE You can program up to two auto output settings in Program mode The first advance constant set in Initialization mode affects the lowest numbered channel that you set as auto in Program mode and likewise the next numerically higher channel number uses the second advance constant setting...

Page 334: ...BER 1234567 CHAIR BRACKET CHANNEL 1 UNNAMED ON 185 OFF 220 DWELL 35 AUTO Figure 5 36 An Auto Advance Channel 4 Press RESET to go back to the list of channel names Setting DSV ON Channel Timing When you want a channel to stay on all the time that the press is running plus perhaps a while longer use the DSV ON cam timing The channel will turn on when dual safety valve DSV goes on and the press start...

Page 335: ... for that channel 2 Make settings for all your other channels 3 When you are done with all channels display the list of channels Then press RESET You will return to the display allowing you the choice of setting counters cams or batch mode You can perform other tasks If you press RESET again you will return to the first display in Program mode NOTICE SmartPAC 2 saves your settings automatically Yo...

Page 336: ...the general password to access these settings Password access is set under Security Access in Initialization mode See Security Access in Chapter 4 page 251 A display similar to the following appears Figure 5 38 Press Control Parameters These items enable you to set the top stop angle counterbalance setpoint and press operating speeds for this tool Select the item you want to change key in the valu...

Page 337: ...PAD TO ENTER NUMBERS USE THE UP DOWN CURSON KEYS TO INCREASE DECREASE PRESS ENTER WHEN DONE PRESS RESET TO CANCEL 60599 If this display appears you need to enter the general password to access these settings Password access is set under Security Access in Initialization mode See Security Access in Chapter 4 page 251 You will see a display similar to the following Use cursor keys to move selection ...

Page 338: ...ne A screen overlay Figure 5 28 appears that enables you to enter fifteen characters of numbers and alphabetic text for each line When you complete each line press F6 to accept it A B C D E PRESS CLEAR TO CLEAR F G H I J K TEXT USE THE KEYPAD L M N O P Q TO ENTER NUMBERS USE R S T U V W CURSORS TO SELECT THE X Y Z LETTERS PRESS ENTER TO ENTER THE LETTERS PRESS F6 WHEN DONE PRESS RESET TO CANCEL Fi...

Page 339: ... The screen shows sensors 1 8 If you have sixteen sensor options press F4 Next 8 Sensors to see the other eight sensors To get back to the first eight press F4 again NOTICE When a tool is loaded or when SmartPAC 2 is powered up all sensors are turned ON and enabled Controlling Which Sensors SmartPAC 2 Monitors There are three ways to control which sensors SmartPAC 2 monitors You can enable or disa...

Page 340: ...le all sensors in Run mode See your user manual Turn a Sensor OFF or ON PROG SENSOR ENABLE DISABLE STATUS 1 In Program Mode select SENSOR ENABLE DISABLE STATUS The Sensor On off Status screen appears It lists the sensor input numbers along with their status ON OFF or N U not used not programmed 2 Highlight the sensor you want to turn off or on 3 Press ENTER The status toggles between ON and OFF 4 ...

Page 341: ... tonnage monitor option select this item in the main Program menu Figure 5 11 If you have SmartPAC 2 recalculate the setpoints the new setpoints will replace the existing setpoints as described in your load monitor manual The following warning box appears Figure 5 42 Recalculate Setpoints Warning Box If you want to have the setpoints recalculated press ENTER If you do not want to have the setpoint...

Page 342: ...1126800 SmartPAC 2 with WPC Integration page 320 Chapter 5 SmartPAC 2 Program Mode ...

Page 343: ...2 is in Run mode because the display shows black text on a light blue background Refer to Chapter 3 for information on using the keyboard and display on SmartPAC 2 Figure 3 23 page 195 in that chapter shows an example of how to navigate through the Run menus This chapter describes how to use the displays you see in Run mode Part 1 starting on page 325 and tells how to run the press in different st...

Page 344: ...ecause sometimes you may not want personnel to get into Program mode So you keep SmartPAC 2 in Run mode by setting the key to Run and removing the key Now Program mode is locked out However the operator can still load a tool number in Run mode and make timing adjustments when necessary in order to correct malfunctions He or she cannot change tool settings in any other way however or create new too...

Page 345: ...n keys as Hot keys to give you quick access to frequently used screens Identify Hot keys in the top Run menu screen by the red border around their descriptive labels See How to Use Hot Keys page 327 for instructions on programming and using Hot keys For HELP press the HELP key located at the center of the cursor arrow keys ...

Page 346: ...NTROL PM MONITOR TOOL INFORMATION SHUTHGT CNTRBAL ERROR LOG LOAD NEW TOOL DIALOG MENU TOGGLE HOT KEYS 1 330 PRESS 14 TOOL NUMBER 6160 PART CNTR 0 FLANGE TWO HAND S S INTERRUPTED STROKE PRESS ANGLE 330 1 4 7 2 3 5 6 8 9 0 CLEAR Contrast CURSOR INTERRUPTED STROKE BRAKE WARNING ENTER RESET F1 F2 F3 F4 F5 F6 Wintriss Press Automation Control SmartPAC PROG RUN ENABLE SENSORS COUNTERS DIE PROTECTION CAM...

Page 347: ... To prevent this problem before you turn the Program Run key make sure SmartPAC 2 is in the main or top menu for the mode it is in If it is not press RESET repeatedly until the main menu appears NOTICE SELECT HIGHLIGHT ENTER When this manual says select it means highlight the item and press ENTER For HELP press the HELP key located at the center of the cursor arrow keys Load A Tool Number Before S...

Page 348: ...MBERS USE THE UP DOWN CURSON KEYS TO INCREASE DECREASE PRESS ENTER WHEN DONE PRESS RESET TO CANCEL 60599 If this display appears you need to enter the general password to access these settings Password access is set under Security Access in Initialization mode See Security Access in Chapter 4 page 251 Figure 6 4 Enter Your Password Display If settings are locked in Run mode you can display the inf...

Page 349: ... You frequently need to adjust the timing for the cam channel that controls part blowoff For convenience you set up a Hot key to take you directly to the cam channel s adjust screen from the main Run menu You can use all the function keys F1 through F8 as Hot keys unless you have the bilingual option which uses F1 to change languages You can recognize Hot keys in the main Run screen by the red fra...

Page 350: ...keys To look at the other set of Hot keys press the UP or DOWN cursor to toggle between the two sets of keys Figure 6 6 Hot Keys Instruction Box 3 Press the function key you want to program as a Hot key You can choose an F key that is blank or you can choose to re program a Hot key that is already programmed The instruction box closes and SmartPAC 2 goes to the next higher screen than the one for ...

Page 351: ...he user manuals for your SmartPAC 2 options DISABLE ENABLE SENSORS Optional page 330 COUNTERS page 332 DIE PROTECTION Optional page 333 CAM SWITCH Optional page 340 BRAKE MONITOR page 345 PRESS CONTROL page 353 TOOL INFORMATION Optional page 355 ERROR LOG page 356 LOAD NEW TOOL page 357 MESSAGING page 361 TOGGLE HOT KEYS page 363 NOTICE For HELP press the HELP key located at the center of the curs...

Page 352: ...sensor programming section called Die Protection in Chapter 5 to make the appropriate settings for the tool Even in Auto mode you can manually enable sensors at any time No matter which choice you had made you should always have sensors enabled to protect your tool But sometimes you may want to disable sensors during setup or for troubleshooting SmartPAC 2 will not stop the press when sensors are ...

Page 353: ...DISABLED ENABLE SENSORS DISABLE SENSORS Figure 6 8 Display Showing Sensors Enabled or Sensors Disabled Setup Mode Message If the setup mode circuit is connected and active you will see this message at the top left of the Run menu under the tool number SENSORS IN SETUP MODE This means green sensors are disabled SmartPAC 2 will not send a stop signal to the press when a green sensor signals a fault ...

Page 354: ...parts counter preset reached The value set for the parts counter has been reached The press should top stop Press RESET to clear the message The strokes count is automatically set to zero Strokes counter preset reached The value set for the strokes counter has been reached The press should top stop Press RESET to clear the message The strokes count is automatically set to zero Batch counter preset...

Page 355: ...unused you will only see the sensors used displayed in Run mode To adjust settings for the loaded tool number 1 Select Die Protection from the first display you see in Run mode 2 The Die Protection menu appears showing the list of sensors names you assigned for this tool F1 F2 F3 F4 F5 F6 F7 F8 Figure 6 10 Die Protection Menu NOTICE From this view you can choose to see a Sensor summary see page 33...

Page 356: ...isplay of your sensors You can choose another sensor to view and or adjust FOR MORE INFORMATION Refer to Understanding Sensor Technology in Chapter 1 for a detailed description of the different types of sensors available in SmartPAC 2 with die protection Refer to Die Protection in Chapter 5 for detailed instructions on modifying sensors starting on page 292 For HELP press the HELP key located at t...

Page 357: ...mmed See page 318 6 Without reloading the tool turn the Program Run switch to Run A message appears telling you the sensor is turned off Press ENTER 7 Run the press 8 In Run mode select Die Protection and select the sensor You can see the angles at which the sensor actually turned ON and OFF Adjust the ready window based on the sensor s actual ON and OFF angles 9 When done go back to Program mode ...

Page 358: ...to green constant it shows the latest on angle and earliest off angle shows a decrease in the actuation angle For instance if a green quick check sensor s on angle fluctuates between 190 and 195 from stroke to stroke SmartPAC 2 would show 190 However if the on angle changed to 189 or lower SmartPAC 2 would immediately display the earlier on angle A green quick check sensor s off angle is recorded ...

Page 359: ...stantly during the stroke In cases like this it is better to use an electronic sensor which is not prone to constant contact bounce For HELP press the HELP key located at the center of the cursor arrow keys View Sensor Summary RUN DIE PROTECTION Select Sensor F6 VIEW SENSOR SUMMARY The Sensor Summary next figure is a list of the sensors names giving for each the type of sensor it is its stop type ...

Page 360: ...sor connected to each input is indicated by the letters and or numbers under the numbered inputs G green GCON green constant RED is a red sensor GQC green quick check YEL yellow GS green special 11 represents maximum number of strokes allowed N U not used If the square actuation block representing the sensor is dark this indicates that the sensor is actuated SENSOR STATUS PRESS THE RESET KEY WHEN ...

Page 361: ... at 11 and the press makes a stroke without the sensor activating the counter will count down to 10 If another strokes occurs without a sensor actuation the counter drops down to 9 and so forth When the sensor activates the counter automatically resets to 11 Unused sensors It is possible to see an actuation block This may occur if you had a sensor connected to the input by mistake The display show...

Page 362: ...r starting on page 364 F1 F2 F3 F4 F5 F6 F7 F8 Figure 6 14 Cam Switch Menu In Run mode you can adjust the timing signals for each programmed cam channel To adjust cam timings for the loaded tool number 1 Select Cam switch from the main Run menu Figure 6 7 2 You will see a display showing the list of cam channels Cam Switch menu shown in the previous figure If you assigned names for your cam channe...

Page 363: ...ss the HELP key located at the center of the cursor arrow keys View Cam Timing RUN CAM SWITCH F7 SHOW CAM TIMING You can view real time graphic timing information about the currently loaded tool in Run mode You will see the degrees of rotation from 0 to 360 at the bottom of the display and a chart showing channel numbers from 1 through 8 press ENTER to see 9 through 16 if installed at the left of ...

Page 364: ...1126800 SmartPAC 2 with WPC Integration Page 342 Chapter 6 SmartPAC 2 Run Mode Figure 6 15 Viewing Cam Timing For HELP press the HELP key located at the center of the cursor arrow keys ...

Page 365: ...OTICE If you set or changed global cams while a tool was loaded you must reload the tool to make the global cams take effect You can also view a summary of the Global cams by pressing F5 View Global Cam Summary A screen similar to the following appears listing the channel number cam name type and ON OFF or time setting F1 F2 F3 F4 F5 F6 F7 F8 Figure 6 16 Viewing Global Cams NOTICE To e mail a copy...

Page 366: ...ary of the non global cams by pressing F6 View Cam Summary A screen similar to the following appears listing the channel number cam name type and ON OFF or time setting Note that the global cams here channels 1 and 2 are missing from the list F1 F2 F3 F4 F5 F6 F7 F8 Figure 6 17 Cam Summary NOTICE To e mail a copy of this screen see Screen Capture page 199 ...

Page 367: ...the time it takes for the crankshaft to start turning after the DSV has been activated Stop angle is the number of degrees that it takes the press to stop It is equal to the stopping position in degrees minus the crankshaft position when the DSV is closed Stop angle does not compensate for the complete rotation when it takes more than 360 to stop The stop angle helps you when you set up the top st...

Page 368: ...repairs on the press Whenever the stopping time is outside the safety range WPC immediately inhibits the press from further operation and displays a message on the LCD display see Chapter 7 When this happens you cannot run the press until you have completely corrected the problem Performing the 90 Stop Time Test The 90 stop time test is required in order to set the proper safety distance for perso...

Page 369: ...le speed drive set the speed to the fastest that you will normally run 4 Press the UP cursor key to start the 90 stop time test The message at the bottom of the display will now say 90 DEGREE BRAKE TEST ARMED PRESS RESET TO CANCEL TEST 5 The next time that the press reaches 90 the emergency stop relays will open and stop the press 6 Record the information displayed on the LCD display The stop time...

Page 370: ... mounted away from the pinch point or hazardous area of the machinery at a specific distance This distance is based on stopping time The safety distance must be calculated using a precise formula This ensures that Shadow can send the stop signal to the press and the press will stop before the operator s hand reaches the hazardous area The safety distance is also discussed in the Shadow light curta...

Page 371: ...a brake monitor where a light curtain is used to protect operators whose hands are routinely exposed to a hazardous area as required by OSHA 1910 217 c 3 5 A brake monitor continually checks that the machine s stopping time does not exceed a predetermined limit Failure to comply with these instructions will result in death or serious injury This is the formula Honeywell Wintriss Controls recommend...

Page 372: ...2 5 1 cm and Dpf 5 9 15 cm This means Dpf increases by 2 6 6 6 cm when you add one blanking window An example for calculating the safety distance using the ANSI formula Below is an example of how to use the formula to calculate safety distance Ds First take another look at the formula we must use Ds K x Ts Tc Tr Tbm Dpf Let s use these numbers for our variables in the formula and assume that the 9...

Page 373: ...ill result in death or serious injury The OSHA safety distance formula as specified in OSHA regulation 1910 217 is explained below As noted earlier Honeywell Wintriss Controls recommends you use the American National Standards Institute ANSI formula for calculating safety distance It contains more factors that allow you to calculate the safety distance more precisely The ANSI formula is explained ...

Page 374: ...ime measurement 20 x 190 038 We also must add response time of Shadow V 030 seconds Then Ts 190 sec 038 sec braking factor 030 sec Shadow response time Ts 258 Now we will calculate safety distance Ds 63 in sec x Ts Ds 63 x 258 Ds 16 3 in Shadow must be mounted more than 16 3 inches from the pinch point using the OSHA formula Adding to Safety Distance for Floating or Blanking Windows The above exam...

Page 375: ...cussed earlier in this chapter in the section Making WPC Settings in SmartPAC s Programming mode To set the Counterbalance tolerance and the Main system air limit go to Setting Main Air and Counterbalance Limits in Chapter 4 NOTICE If you use the RamPAC option to control Counterbalance pressure follow the instructions in the RamPAC manual Adjusting Top Stop Angle Press Speed Limits Counterbalance ...

Page 376: ...in Run menu Show Overrun Angles Wintriss Tech Support may ask you to check the overrun sensor ON and OFF angles To do this go to Run mode and select Press Control see previous section Press F3 Show Overrun Angles A box appears in the center of the display similar to Figure 6 21 F1 F2 F3 F4 F5 F6 F7 F8 Figure 6 21 Show Overrun Angles RUN PRESS CONTROL F3 SHOW OVERRUN ANGLES Viewing Actual Counterba...

Page 377: ... F6 F7 F8 Figure 6 22 Tool Information Screen Display the Next Tool available only with PACNet Software ARE YOU LOCKED OUT Access to changing the information on this screen may be limited to Program mode or may require a password The security access settings in the Initialization menu determine when changes can be made See Security Access in Chapter 4 page 251 To enter information about the items ...

Page 378: ...tool number The log also shows messages sent by SmartPAC 2 if it has network connection and e mail is enabled The log retains this information for the 100 most recent errors or events If your SmartPAC 2 is connected to a computer network you can send this error event log to Wintriss Tech Support See MESSAGING next section To see the error log select Error Log from the Run menu The Error Log displa...

Page 379: ... has been locked out by the security access setting in Initialization mode You cannot load a tool from Run mode if it is locked out With other security settings a password may be required For more information see Security Access in Chapter 4 page 251 1 Select Load New Tool from the Run menu One of the following will occur The Tool Manager screen will appear Go to Select a Tool to Load page 359 If ...

Page 380: ...umber you just loaded appears in the status box If you do not want to load the tool press RESET The display returns to the main Run menu NOTICE If you tried to load the tool and got an error message instead of the Tool Number Being Loaded message go to Chapter 7 and find the section describing that error message Follow the instructions there for correcting the problem If the error message is not d...

Page 381: ...e tool number you want to load Then press F5 Load Tool The following box appears Figure 6 27 Tool to Be Loaded 3 In this box you can enter values for job number part number and good parts preset Use the cursor keys to select any of those items you want to change A numeric entry box appears Enter the number and then press ENTER to accept it When you are done changing items highlight the tool number...

Page 382: ...stead of the Tool Number Being Loaded message go to Chapter 7 and find the section describing that error message Follow the instructions there for correcting the problem If the error message is not described there or you cannot fix the problem contact Wintriss Tech Support and be ready to provide some important information to expedite a resolution to the problem Please supply product name e g Smar...

Page 383: ...function you must set up the e mail recipients and messages using SmartView remote viewing utility See Appendix D SmartView page 455 1 In the main Run menu select MESSAGING A screen appears similar to the following which lists the recipients you have set up using SmartView F1 F2 F3 F4 F5 F6 F7 F8 Figure 6 29 E mail Select Recipient 2 Use the cursor keys to highlight the recipient you want to send ...

Page 384: ... 5 To send the message Press F5 Send Message and Exit If you do not want to send the message press F6 Exit Without Sending For HELP press the HELP key located at the center of the cursor arrow keys Send E mail to Wintriss Tech Support If you select Wintriss Tech Support as your recipient and Error Log Files as your message the Tech Support receives a message that looks something like the following...

Page 385: ...T KEYS RUN TOGGLE HOT KEYS Select this item to switch between the two sets of Hot keys See the following figure For more information about programming and using Hot keys see page 323 F1 F2 F3 F4 F5 F6 F7 F8 F1 F2 F3 F4 F5 F6 F7 F8 Figure 6 32 Toggle Hot Keys 1 and 2 For HELP press the HELP key located at the center of the cursor arrow keys ...

Page 386: ...h or serious injury An Interrupted Stroke occurs when the press has been emergency stopped before the completion of the stroke by either the operator or a safety device When an interrupted stroke occurs a stop command is immediately issued to the press and INTERRUPTED STROKE flashes in the status box at the top of the SmartPAC 2 screen WPC automatically switches to TWO HAND MAINTAINED SINGLE STROK...

Page 387: ...Depending on which options you have in this menu you can do the following Some items require optional firmware or hardware Enable Micro inch Select one of these operating modes Two hand One hand or Foot require Shadow light curtain The light curtain will be muted on the upstroke only if WPC has the muting option To use the Mode Select menu 1 Make sure that SmartPAC 2 s Program Run key is set to th...

Page 388: ...e as a production mode per ANSI B11 1 2001 Failure to comply with these instructions will result in death or serious injury Three Ways You Can Operate the Press in INCH Mode You can choose three different ways to operate the press in INCH mode Top Stop in Inch Enabled page 367 Top Stop in Inch Disabled Top Stop Bypass page 367 Micro inch page 367 Pin 13 on the WPC board controls whether the press ...

Page 389: ...in until you release the buttons and depress them again The ram will also stop if the light curtain is blocked during the non muted portion of the stroke or if a system fault is detected If you are jogging the press you may not notice that the ram has top stopped Top Stop in Inch Disabled Top Stop Bypass NOTICE To disable top stop in inch connect pin 13 on the WPC processor board to 24 VDC With to...

Page 390: ...talled and maintained according to OSHA standard 1910 217 ANSI B11 1 ANSI B11 19 and any other regulations and standards that apply Ensure that guarding is properly installed to prevent access to the machine over under or around any guarding device Failure to comply with these instructions will result in death or serious injury One hand Operation Single Stroke Mode next section Two hand Operation ...

Page 391: ...t in death or serious injury DANGER INCORRECT INSTALLATION Shadow light curtains must be properly installed and connected to WPC in order to use ONE HAND or FOOT modes Failure to comply with these instructions will result in death or serious injury First select ONE HAND in the mode select menu page 365 and turn the stroke select key to To initiate a stroke press the left RUN INCH button The left R...

Page 392: ...d operating light curtains Failure to comply with these instructions will result in death or serious injury DANGER Two hand control too close to hazardous area Verify at each shift change that any moveable two hand controls are located at least the safety distance away from the pinch point or hazardous area Failure to comply with these instructions will result in death or serious injury DANGER IMP...

Page 393: ...ns on each station must be depressed within 0 5 seconds of each other 4 Hold the buttons down at least until bottom dead center or until the Auto Carry up angle The upstroke is automatic The ram will stop if any RUN INCH button is released during the down stroke before the Auto Carry up angle if a system fault is detected or if the light curtain is blocked during the down stroke See the instructio...

Page 394: ...3 One hand Control or Foot Switch Mode page 243 for instructions on setting this switch In Foot Trip mode Option Switch 3 OPEN after you depress the Foot Switch the press runs for one stroke To run the press set the stroke select switch to FOOT Then press the Foot Switch The press will run for one stroke and then will top stop In Foot Control mode Option Switch 3 CLOSED you must depress and hold t...

Page 395: ...a stroke can occur unexpectedly Failure to comply with these instructions will result in death or serious injury The Automatic Single Stroke function allows an external event to automatically start a single stroke within thirty seconds Generally material feed is used as the signaling event However other events such as part ejection or positive part transfer can be used There are three requirements...

Page 396: ...ired for Automatic Single Stroke set the switches as follows Select TWO HAND the mode select menu page 365 Stroke select to SINGLE STROKE Automatic single stroke switch according to the timing you want see previous section To initiate the first stroke 1 Depress the PRIOR ACT button The prior act button will blink when PRIOR ACT is armed 2 Press the RUN INCH buttons until the ram passes bottom dead...

Page 397: ...wo hand Operation Continuous Mode DANGER IMPROPER SAFEGUARDING Ensure that the machine guarding system is installed and maintained according to OSHA standard 1910 217 ANSI B11 1 ANSI B11 19 and any other regulations and standards that apply Ensure that guarding is properly installed to prevent access to the machine over under or around any guarding device Failure to comply with these instructions ...

Page 398: ...lect switch to CONT and then press the PRIOR ACT switch While the PRIOR ACT LED is lit for eight seconds depress the foot switch The press will run in continuous as long as the foot switch is depressed If the foot switch is released the press will top stop If you remove your foot from the foot switch and the ram top stops you will have to press the PRIOR ACT switch again and then depress the foot ...

Page 399: ...der or around any guarding device Failure to comply with these instructions will result in death or serious injury DANGER PRESS STARTING UNEXPECTEDLY Ensure that light curtains and other safeguards are properly installed and operating to protect operators when using Continuous on Demand mode in which a stroke can occur unexpectedly Failure to comply with these instructions will result in death or ...

Page 400: ...urtains must be properly installed and connected to WPC in order to use ONE HAND or FOOT modes Failure to comply with these instructions will result in death or serious injury NOTICE With One hand Control installed you cannot use the run buttons in ONE HAND mode All other modes work normally as described in this manual One hand Control is a switch that can only be used with any Wintriss Press Cont...

Page 401: ...de set Switch 3 to CLOSED If you do not want to use light curtain break mode set Switch 3 to OPEN 2 Set the Stroke Select Switch to SINGLE STROKE 3 If an Interrupted Stroke message flashes on the display make one stroke by pressing and holding down the dual run buttons This clears the interrupted stroke mode 4 Start the press as follows If you are using One hand Control without light curtain break...

Page 402: ...perator Stations DANGER HAZARDS EXPOSED BY NON WORKING OPERATOR STATION Safeguard the point of operation exposed by the non working operator station when using multiple operator stations This exposed area near a disabled operator station must be properly guarded Ensure that guarding is properly installed to prevent access to the machine over under or around any guarding device Failure to comply wi...

Page 403: ...e multiple operator stations notice that there is a Operator Station Select Switch located on the front of your WPC Set the switch so that it enables either the first station the second station or both Contact Wintriss Tech Support for more information relative to Multiple Operator Stations ...

Page 404: ...1126800 SmartPAC 2 with WPC Integration Page 382 Chapter 6 SmartPAC 2 Run Mode ...

Page 405: ...adjustment RamPAC in die measurement ProPAC or other option modules see the user manual that came with the option module for details on its functionality and troubleshooting NOTICE INDICATES A FAULT THAT WILL RESULT IN A LOCKOUT CONDITION Follow the instructions on page 387 to clear a lockout condition after correcting the fault that caused it NOTICE E MAIL TROUBLESHOOTING INFORMATION TO WINTRISS ...

Page 406: ... TONNAGE WAVEFORM PROCESS MONITOR FEED CONTROL PM MONITOR TOOL INFORMATION SHUTHGT CNTRBAL ERROR LOG LOAD NEW TOOL DIALOG MENU TOGGLE HOT KEYS 1 330 PRESS 14 TOOL NUMBER 6160 PART CNTR 0 FLANGE TWO HAND S S INTERRUPTED STROKE PRESS ANGLE 330 1 4 7 2 3 5 6 8 9 0 CLEAR Contrast CURSOR INTERRUPTED STROKE BRAKE WARNING ENTER RESET F1 F2 F3 F4 F5 F6 Wintriss Press Automation Control SmartPAC PROG RUN E...

Page 407: ...me operation after an error message occurs clear the error message by pressing the RESET key or Remote Reset Button if installed Correct the malfunction or other problem before running the press If you cannot correct the problem after reading the remedy contact Wintriss Tech Support NOTICE PROVIDE IMPORTANT INFORMATION WHEN CALLING WINTRISS TECH SUPPORT When you contact Wintriss Controls for techn...

Page 408: ...nergy See Chapter 4 for more details Press Parameters The main motor on the press is not on Switch to the Inch mode to access the Adjust menu F10 ENERGY SAVER SHUT DOWN The main motor was shut down to save energy Switch to Inch mode to access the Adjust menu F10 PRESS MOTOR IS OFF Figure 7 4 Status code 10 Interrupted Stroke An interrupted stroke occurs when the press has been emergency stopped be...

Page 409: ...e a lockout message below appears on SmartPAC s display This message indicates that a serious error condition has occurred Correct the problem before continuing PRESS CONTROL IS IN LOCKOUT MODE The stroke selector must be turned to the off mode and then back to the desired operating mode to reset the lockout condition Figure 7 5 Lockout Message To clear the lockout condition 1 Correct the problem ...

Page 410: ...he condition of the brake to ensure that it is not wearing and or defective before you adjust the stop time limit Brake Monitor Stop Time Exceeded DANGER INCORRECT SAFETY DISTANCE DUE TO INCORRECT STOP TIME Perform a 90 Stop Test any time you change the stop time limit See Performing the 90 Stop Test page 346 Recalculate the safety distance based on the new stop time limit and adjust or reinstall ...

Page 411: ...an actual reading for your press s stop time Compare these results to the last time that you performed the test and make sure you record the current results Decide if the stop time limit that you had set is realistic or needs to be changed slightly See Chapter 4 to determine and set the correct Stop Time Limit See Chapter 6 Brake Monitor to calculate the correct stop time and Stop Time and Stop An...

Page 412: ...ned message with status code number SmartPAC 2 displays equipment name you set in Initialization mode Figure 7 7 User Input Status Code Message Description of Status Codes and How to Correct SmartPAC 2 with WPC provides status codes that tell you that something is wrong with the press or WPC including its internal components peripheral equipment setup or press operation When there is a problem wit...

Page 413: ...ontrol and operator safety Both of these processor systems function independently of each other and provide separate information to the operator Therefore error conditions will be detected from either or both of the two processors resident in the system As with F series status codes after you correct the malfunction you can press SmartPAC s RESET key or the EMERGENCY STOP RESET button on the opera...

Page 414: ...ctions for shorts breaks or loose connections See Chapter 2 Mounting the resolver for complete information about resolver wiring If the wiring is not the problem the resolver is probably bad and will have to be replaced If necessary contact Wintriss Tech Support for assistance or replacement Problem The resolver position is different from when the unit was turned off This message will only appear ...

Page 415: ...nce in making the Two Hand setting refer to Chapter 6 of this manual Problem 2 This means that the main motor has been turned off by WPC to save energy The only way that you will get this message if is the lockout relay is physically wired as discussed in Chapter 2 Also you would have had to set the number of minutes for WPC to shut down the motor see Chapter 4 Press Parameters for more informatio...

Page 416: ...ed into the Top Stop string Correct the problem Reset at that equipment then reset at WPC and restart F17 Problem This error occurs when the pair of cross checked inputs 8 9 disagree for longer than 100 msec Disagree means that one input is open and the other is closed See page 400 and Table 7 1 Remedy Correct the problem Reset at the equipment the input is connected to then reset at SmartPAC and ...

Page 417: ... refer to Chapter 6 of this manual 22 Problem This means that the operating mode was changed with the press running Remedy Reset Run the press after you have made the operating mode selection Consult Chapter 6 for the correct operating mode to select 23 Problem This means that the operating mode you selected is not a valid one Remedy Reset Consult Chapter 6 to determine the correct operating mode ...

Page 418: ... of 0 zero Refer to the section Setting Shutdown and Flywheel Timer Limits in Chapter 4 for more information 26 Problem This means that the flywheel turned too fast potentially creating an unsafe barring condition more than an equivalent of 6 SPM while the press was in Bar mode Remedy After clearing the error bar the press more slowly 28 Problem This means that the flywheel was still in motion whe...

Page 419: ... No reply received from second processor to reset error message F37 No reply received from second processor to compare input buffers message H38 The second processor did not receive the power up information correctly H39 The second processor did not receive the mode information correctly Remedy Try to reset If errors persist contact Wintriss Tech Support for assistance Input buffer test failures 4...

Page 420: ...hat the counterbalance air pressure is outside the sensor limits set in SmartPAC s Programming mode This error can also be generated by the second processor Remedy Check the level of your press s counterbalance air pressure If necessary refer to Chapter 4 to reset the limits NOTICE TO RAMPAC USERS This error should not appear if you use RamPAC to monitor the counterbalance pressure If this error d...

Page 421: ...n into the DSV You may need to rebuild the valve Regarding 48 the air pressure may be turned off or set too low If you are using the Air Pressure sensor instead of the Air Pressure switch 48 will occur if you have not wired terminal 8 to ground see Chapter 2 F47 Dual Safety Valve DSV monitor switch input open F48 Main system air pressure switch input open Remedy Reset and correct the problem If th...

Page 422: ...You can display the status of the user interlocks from Initialization mode See Using the WPC Input Status Display page 420 50 through 58 Problem These error codes indicate failures that have occurred to auxiliary equipment that you connected to WPC such as lubrication systems Codes 50 and 58 are related to the cross checked user input pairs see table below and also refer to codes 17 and 18 which a...

Page 423: ...4 GROUND 56 User 7 73 GROUND 57 User 8 paired with 9 ESTOP or ESTOP LOCKOUT 85 GROUND 58 17 User 9 paired with 8 ESTOP or ESTOP LOCKOUT 74 GROUND User 10 paired with 11 ESTOP or ESTOP LOCKOUT 86 GROUND 50 18 User 11 paired with 10 ESTOP or ESTOP LOCKOUT 18 GROUND These inputs have changed function with WPC firmware version 3 91 and later Be sure to wire these inputs correctly according to the need...

Page 424: ...Check the auxiliary equipment that signaled the stop Correct the problem Reset SmartPAC If the error does not go away contact Wintriss Tech Support for assistance Light Curtain faults 60 or 61 Problem These errors indicate that the light curtain s failed the internal light curtain test conducted by WPC There may be a problem with the wiring of either the first or second light curtain connected to ...

Page 425: ...r indicates that the first light curtain A is blocked at the start of or during the stroke Remedy Check to see that light curtain A is clear 64 Problem This error indicates that the second light curtain B is blocked at the start of or during the stroke It could also indicate that you have dual light curtain selected at the program select switches in WPC but only one set of light curtains is wired ...

Page 426: ...ne for your application Emergency stop circuit driver failure 66 Problem The driver circuitry which controls the emergency stop E Stop input circuitry has a failure This error can also be generated by the second processor Remedy Reset Check the E Stop wiring If the error persists contact Wintriss Tech Support for immediate assistance or replacement Top stop circuit driver failure 67 Problem The dr...

Page 427: ...ther F72 or H72 The DSV control flip flop not functioning properly F73 or H73 The DSV missing pulse detector window not functioning properly F74 or H74 The DSV relay driver did not close properly at the start of the stroke F75 or H75 The DSV relay driver did not open properly at the end of the stroke F76 or H76 The Lockout relay driver did not open properly at the end of the stroke F77 or H77 The ...

Page 428: ...ning even though the press crankshaft is turning Also you may have low air pressure to the clutch or a bad clutch so the crankshaft and therefore the resolver did not move even though the clutch control valve has been activated An internal WPC problem could also have occurred or the resolver could be defective Reset Check the resolver and resolver drive Check and repair the clutch If these solutio...

Page 429: ...h the other timing signals such as auto carry up and top stop If WPC detects more than one on off occurrence it generates the following error message NOT ALL OF THE TIMING SIGNALS WERE SEEN IN SEQUENCE Remedy Review Install the Overrun Limit Sensor Magnetic Switch page 44 Install Magnet for Overrun Limit Sensor page 116 and Switches 1 and 2 Overrun Limit Switch Settings page 242 and see LED map Fi...

Page 430: ...totally at high RPMs Also the resolver or overrun limit switch may be defective or not installed properly Check the wiring and installation of the resolver and overrun sensor and magnet For more information about the overrun limit switch see Install the Overrun Limit Sensor Magnetic Switch page 44 Install Magnet for Overrun Limit Sensor page 116 Overrun Limit Switch Setting Fault 89 Problem These ...

Page 431: ...artPAC 2 After you have corrected the problem press RESET If the problem is corrected you will be able to run the press again If not you will get the same fault message Loss of rotation detected Explanation The resolver did not start rotating within the start time limit that is preset in Initialization mode Or the resolver could have stopped turning while the press was running SmartPAC 2 knows whe...

Page 432: ...will not work Input check circuit failure Explanation The resolver turned five times in other words the press was running but SmartPAC 2 received no signal into the input check circuit Remedy The input check circuit has not been connected or wired properly If this message occurs when the press stops your press is taking more than five revolutions to stop after the brake is activated You should che...

Page 433: ... could be because your limit is not large enough to account for normal wear A more serious situation could be that the brake is excessively worn and needs to be serviced by your maintenance personnel If this is the case a dangerous safety problem may exist and needs to be corrected immediately It is assumed that you were pre warned by the brake warning LED which illuminates whenever the stopping t...

Page 434: ...for the problem below contact Wintriss Tech Support for assistance After you have corrected the problem press RESET If the problem is corrected you will be able to run the press again If not you will get the same fault message No tool number has been loaded Explanation A tool number is not presently loaded You will see this message if you try to go into Run mode without a tool number loaded A tool...

Page 435: ...ile you were in the middle of programming or adjusting settings for a tool It will also happen if the stored tool number settings got damaged due to an internal SmartPAC 2 malfunction Go back into programming and review the tool number setup in question Make sure that all the information you programmed is correct then reload this tool number If the problem was caused because the system was turned ...

Page 436: ...te Explanation A green or green quick check turned on late after its ready signal was completed That is it turned on within 50 milliseconds after the end of the ready signal If a green or green quick check sensor does not come on during its ready signal SmartPAC 2 continues to look for the sensor signal If it saw the sensor come on within 50 milliseconds after the ready signal the angle where the ...

Page 437: ...upposed to detect part ejection problem misfeed etc Check for a part wedged against the sensor a shorted sensor a pinched wire or other cause that would keep the sensor on or cause it to go on outside its ready signal Make sure the ready signal is set correctly Green special fault Explanation A green special sensor did not actuate within the maximum number of strokes set in Program mode SmartPAC 2...

Page 438: ...set at SmartPAC 2 Remedy After clearing the error either run the press at a slower speed or adjust the maximum limit set at SmartPAC 2 Refer to Chapter 4 Minimum press speed exceeded Explanation This message is generated when the press is running at a speed less than the minimum limit set at SmartPAC 2 Remedy After clearing the error either run the press at a higher speed or adjust the minimum lim...

Page 439: ... occur since SmartPAC 2 does not let you enter a value greater than 24 However it could appear if there is a problem with the internal workings of SmartPAC 2 Remedy First press RESET If the message reappears contact Wintriss Tech Support Loss of Communication at Address X Explanation SmartPAC 2 detects that it cannot communicate with one of the option modules X refers to one of the addresses shown...

Page 440: ... occurred and the crankshaft angle when the stop occurred When you stop the press to load a new tool the error log shows the tool number The log retains this information for the 100 most recent errors To see the error log select Error Log from the Run menu The display shows a list of errors and events with the most recent error first Use the cursor keys to scroll through the list The complete text...

Page 441: ...tion to Wintriss Tech Support When troubleshooting your SmartPAC 2 system you can easily e mail the error log list of installed options and other useful information to Wintriss Tech Support Go to Send E mail to Wintriss Tech Support page 362 F1 F2 F3 F4 F5 F6 F7 F8 Figure 7 9 E mailing Error Log to Wintriss Tech Support ...

Page 442: ...nd of Chapter 4 1 Enter the Initialization mode as described in Chapter 4 The Main Initialization menu appears 2 Select Press Control The WPC Initialization menu next figure appears WPC INITIALIZATION MENU USE THE CURSOR KEYS USER INTERLOCKS TO SELECT THE ITEM PRESS PARAMETERS YOU WISH TO SEE PRESS OPTIONS PRESS ENTER TO INPUT STATUS ACCESS IT PRESS RESET WHEN DONE USER INTERLOCKS Figure 7 10 WPC ...

Page 443: ... HAND N O 3 ON WPC BUTTONS PALM B N C 2 ON AND SWITCHES PALM B N O 12 ON INPUT STATUS FOOT N C 4 ON FOOT N O 14 ON EXT ACT N C 15 ON EXT ACT N O 5 ON BAR MODE 6 ON BAR ACT 16 ON OFF SEL S248 OFF INCH SEL S249 OFF S S SEL S250 OFF CONT SEL S251 OFF OP STA 1 S253 OFF OP STA 2 S254 OFF WPC LOCK S255 OFF REM RESET S257 OFF ON ON ON ON ON ON ON ON ON ON ON Figure 7 12 Display of Buttons Switches Input ...

Page 444: ...ECK ON ON ON ON ON ON ON ON ON ON ON ON ON ON Figure 7 13 Display of Estops Top Stops Input Status NAME TERM STATUS LOW OIL LEVEL 21 ON LOW OIL PRESS 82 ON DIE NITROGEN 71 ON WPC INTER MOTOR OVLD 83 ON LOCK INPUT USER 5 72 ON STATUS USER 6 84 ON USER 7 73 ON USER 8 85 ON USER 9 74 ON USER 10 86 ON USER 11 18 ON DSV MONITOR 20 OFF MAIN AIR 8 OFF SPEC 1 26 OFF SPEC 2 13 OFF SPEC 3 75 OFF SPEC 4 19 O...

Page 445: ...INGS BEFORE INSTALLING NEW WPC FIRMWARE Before you install new WPC firmware use the WPC Parameter Setup Sheets at the end of this manual to record your WPC settings including top stop angle auto carry up angle stop time limit micro inch timing and ON OFF cam settings You must re enter these settings after you install the new firmware chips Also record the counter reading if needed NOTICE To instal...

Page 446: ...ts holder Orient it so that the notch faces the same direction as the notch on the chip you removed If you plug the chip in backward it will be destroyed 8 Plug the chip into its socket by starting to plug in one row of pins and then aligning the other row of pins over the socket and pushing straight in 9 If the two rows of pins are spread too far apart to plug easily into the socket A Hold the ch...

Page 447: ...enever you initialize your WPC Use the stop time measured in the 90 stop time test to calculate the safety distance When you initialize your WPC the stop time limit is reset to its factory setting of 500 ms Failure to comply with these instructions will result in death or serious injury 12 Re initialize the system according to the instructions in Chapter 2 Initialize Press Parameters page 101 Then...

Page 448: ...1126800 SmartPAC 2 with WPC Integration Page 426 Chapter 7 SmartPAC 2 Fault Messages ...

Page 449: ...aining to the use of presence sensing devices for point of operation guarding on mechanical power presses Portions from the text of the OSHA regulations are presented in the left hand column of the pages in this section Additionally an interpretation provided by the Precision Metalforming Association PMA is presented in the right hand column Honeywell makes no claim regarding the accuracy or effec...

Page 450: ...uccessive stroke until the failure is corrected The failure shall be indicated by the system When failure occurs the best indication is the press won t run d Muting bypassing of the protective function of such device during the upstroke of the press slide is permitted for the purpose of parts ejection circuit checking and feeding Top of stroke is the point at which muting shall cease as it is not ...

Page 451: ...ed by the presence sensing device 3 iii f Great care must be taken to assure that no access to the die area exists unguarded OSHA 1910 217 c 3 5 5 Additional requirements for safe guarding Where the operator feeds or removes parts by placing one or both hands in the point of operation and a two hand control presence sensing device of Type B gate or movable barrier on a part revolving clutch is use...

Page 452: ...ary equipment and safeguards are in safe operating condition and adjustment The employer shall maintain records of these inspections and the maintenance work performed Records of clutch and brake will be weekly Other inspections are periodic subject to time factor determined by employer ii Each press shall be inspected and tested no less than weekly to determine the condition of the clutch brake m...

Page 453: ...wo hand controls Both the ANSI standard and its interpretation are part of ANSI standard B11 1 2001 To get a complete copy of the ANSI standard write to ANSI 1430 Broadway New York NY 10018 Extracts from ANSI B11 1 2001 8 5 3 Standard Requirements Explanatory Information 8 5 3 Presence sensing safeguarding device 8 5 3 1 A presence sensing point of operation device when used for safeguarding shall...

Page 454: ...y as the presence sensing device itself A simple cam operated limit switch wired in parallel with the device s output is inadequate as its failure can remain undetected 8 5 3 8 The device shall have an identifiable minimum object sensitivity so that an obstruction of an equal or greater size will be detected anywhere within the sensing field regardless of the plane of intrusion E8 5 3 8 The device...

Page 455: ...ts of 6 8 and 8 7 in the event of a power failure to the device the device shall initiate a stop command to the press control system 8 5 3 14 The interface of the presence sensing device to the press control shall conform to the requirements of 6 8 and 8 7 8 5 3 15 The sensitivity of the device to intrusion shall not be adversely affected by changing conditions around the press E8 5 3 15 Some devi...

Page 456: ...ct sensitivity is stated by the manufacturer If beam blankouts or floating window features are used these figures should be added to the object sensitivity figure before using the chart NOTE Ts Tc are usually measured by a stop time measuring device See also Annex C Whenever the press cycle stroke STOP command or stopping performance monitor time or angle setting is changed the safety distance sho...

Page 457: ...ards safety mats light curtains or other devices Operator controls for each operator located outside of the sensing field of the presence sensing device may be used 8 5 3 18 The device shall not be affected by ambient light or by light source decay so that the increase in response time or object sensitivity is greater than the value used to calculate the safety distance E8 5 3 18 Examples of ambie...

Page 458: ...e stroke E8 5 2 1 5 The total stopping time of the press should include the total response time of the control system and the time it takes the press to cease slide motion The following formula should be used when calculating the safety distance Ds Ds K Ts Tc Tbm Where K 63 inches second hand speed constant Ts the stop time of the press measured from the final de energized control element usually ...

Page 459: ...ng when a period of time has passed Consequently the entire stamping process is monitored automatically and maintenance is alerted only when equipment requires attention Comparison with Traditional Preventive Maintenance Equipment used on or around the press need to be checked at regular intervals such as daily weekly or number of strokes Traditional preventive maintenance programs are based upon ...

Page 460: ...lighted until the alert is cleared and the item is reset The PM monitor continues to track alerted items until they are reset Please note that SmartPAC does not stop the press when an item is in alert status SmartPAC s PM schedule is password protected to keep unauthorized personnel from clearing an alert Examples of How to Use the PM Monitor Here are some examples to help you properly set up your...

Page 461: ... press control faults 45 59 3 press overloads4 1 For SmartPAC without WPC run hours refers to the length of time that SmartPAC is on For SmartPAC with WPC it means how long the motor is on The version of SmartPAC that you currently have is without WPC Contact Wintriss Tech Support if you require WPC 2 Ch cycles 1 through 16 can be used only if you have a 16 channel ProCamPAC Only ch cycles 1 throu...

Page 462: ... TOOL INFORMATION RAM POSITION RAM TONNAGE ERROR LOG LOAD NEW TOOL USE THE CURSOR KEYS TO MAKE SELECTIONS PRESS ENTER TO ACCESS SELECTION TOOL NUMBER 6160 PART CNTR 0 CHAIR BRACKET ENABLE SENSORS ENTER RESET PROG RUN OFF INCH SINGLE STROKE CONT POWER BRAKE WARNING HELP 1 2 3 4 5 6 9 8 7 0 CLEAR SmartPAC 2 F1 F2 F3 F4 F5 F6 F7 F8 CAMBIE AL ESPANOL USE THE CURSOR KEYS ENABLE SENSORS TO MAKE SELECTIO...

Page 463: ...are found in Chapter 2 of this manual After this has been completed proceed to the section Using the PM Monitor in Initialization mode and you will be instructed to access and initialize this option NOTICE PM Monitor must be initialized before you can use it see page 443 Using the PM Monitor in Initialization Mode How to Get into SmartPAC Initialization and PM Monitor NOTICE SELECT HIGHLIGHT ENTER...

Page 464: ...ization menu Figure A 1 A screen will appear asking for your password NOTICE The password prompt will appear EVERY time that you select PM Monitor from the Initialization mode ENTER THE PASSWORD USE THE KEYPAD TO ENTER NUMBERS USE THE UP DOWN CURSOR KEYS TO INCREMENT DECREMENT PRESS ENTER WHEN DONE PRESS RESET TO CANCEL 0 65535 Figure B 3 PM Password Screen 3 At this point consider the applicable ...

Page 465: ...ge your password Proceed to the section Assigning a new PM password number to change your password skip Initializing the PM Monitor altogether After you have done that you can use the PM Monitor For Existing Systems If you ordered the PM Monitor options separately you must initialize this option before you can actually use it Complete all the steps in this section to initialize the PM Monitor NOTI...

Page 466: ... Controls by using the number keypad This will take you to the PM Screen see below Don t worry if erroneous information appears on the screen as it will disappear when you have completed step 5 ITEM ALERT EVERY USE THE CURSOR KEYS TO MAKE SELECTION PRESS ENTER TO SELECT RESET WHEN DONE INIT F6 YOUR PRESS NAME PM MONITOR NEW ITEM Figure B 5 PM Entry Screen 4 Press the function key F6 which is label...

Page 467: ...you press Clear you will briefly see the confirming message INITIALIZING PM MONITOR 7 Next press RESET to exit from the Initialize PM screen You will be returned to the PM entry screen Proceed to the next section to assign a new password number Assigning a New PM Password Number Before you can actually set up and use the PM Monitor you may want to assign a new password number The default password ...

Page 468: ...cribes its function SmartPAC provides about 35 names If there is a function for which you cannot find a suitable name you can create a new name using the Custom feature This procedure is explained in step 5 below 1 Select New item from this display You may be asked for a password before getting to this screen If so enter it ITEM ALERT EVERY USE THE CURSOR KEYS TO MAKE SELECTION PRESS ENTER TO SELE...

Page 469: ...en suggests see the next illustration certain keys enable you to custom name the item The name you select can be any combination of alpha numeric characters symbols etc Pressing the CLEAR key clears the text To create a custom name do the following a To select letters or symbols Use the up down left and or right cursor keys to highlight the desired letter then press ENTER b To select numbers Use t...

Page 470: ... Figure B 11 Selecting Tracking Unit of Measure 7 Next the number display appears superimposed over the previous display see the next illustration Use the number keys or cursor keys to set the tracking frequency for the PM item ENTER A MAINTENANCE FREQUENCY FOR AIR ROTARY SEALS USE THE KEYPAD TO ENTER NUMBERS USE THE UP DOWN CURSOR KEYS TO INCREMENT DECREMENT PRESS ENTER WHEN DONE PRESS RESET TO C...

Page 471: ...otor and set it to alert at 100 die changes YOUR PRESS NAME PM MONITOR SLIDE ADJ MOTOR Figure B 13 Example 9 To set more PM items repeat steps 1 through 8 When you are completely done initializing the PM items press RESET to return to the main Initialization mode 10 You can now go to the Run mode to view the PM Monitor status conditions There is no PM information to set in SmartPAC s Program mode ...

Page 472: ...ow the press to run If you try to switch to Run mode without a tool number loaded you will get this error message on your screen NO TOOL NUMBER HAS BEEN LOADED If so turn the Program Run key to Program Press RESET to clear the error message Then load a tool number Now set the Program Run key to Run The Run menu shown below is the first display you see in Run mode From this display you can access t...

Page 473: ...CT RESET WHEN DONE CLUTCH VALVE ALERT AT CURRENT 2000 STARTS STOPS 1001 STARTS STOPS YOUR PRESS NAME STATUS IS NORMAL PM MONITOR SLIDE ADJ MOTOR ALERT AT CURRENT 100 DIE CHANGES 75 DIE CHANGES GIBS ALERT AT CURRENT 1000000 STROKES 458239 STROKES MORE notice that alert status is normal CLEAR ALERT F3 CHANGE VALUE F4 Figure B 15 Display Showing PM Monitor in Normal Status Mode NOTICE You may notice ...

Page 474: ... or may not be in alert status use the cursor keys If more than three PM items were set in Initialization they will not all appear on the screen To view them simply use the cursor keys to scroll down the list 5 To clear the alert first highlight that item press the appropriate function key designated on your screen and enter the PM password NOTICE When you clear the alert condition for a certain i...

Page 475: ...pendix C page 453 SmartPAC 2 with WPC Integration 1126800 Appendix C Update SmartPAC 2 Firmware NOTICE This Appendix will be shipped to you later NOTICE To install new firmware into WPC see Install Revised Firmware into WPC page 423 ...

Page 476: ...1126800 SmartPAC 2 with WPC Integration page 454 Appendix C Updating SmartPAC 2 Firmware ...

Page 477: ...martView Remote Viewing Appendix D page 455 and E mail Setup SmartPAC 2 with WPC Integration 1126800 Appendix D SmartView Remote Viewing and E mail Setup NOTICE This Appendix will be shipped to you later ...

Page 478: ...1126800 SmartPAC 2 with WPC Integration page 456 Appendix D SmartView Remote Viewing and E mail Setup ...

Page 479: ...ade from Original SmartPAC Appendix E page 457 to SmartPAC 2 SmartPAC 2 with WPC Integration 1126800 Appendix E Upgrade from Original SmartPAC to SmartPAC 2 NOTICE This Appendix will be shipped to you later ...

Page 480: ...1126800 SmartPAC 2 with WPC Integration page 458 Appendix E Upgrade from Original SmartPAC to SmartPAC 2 ...

Page 481: ...Replacing SmartPAC 2 PC Board Appendix F page 459 SmartPAC 2 with WPC Integration 1126800 Appendix F Replacing SmartPAC 2 PC Board NOTICE This Appendix will be shipped to you later ...

Page 482: ...1126800 SmartPAC 2 with WPC Integration page 460 Appendix F Replacing SmartPAC 2 PC Board ...

Page 483: ...advance per 100 RPM increase in press speed auto advance equal to the number of degrees of advance per 100 RPM increase in press speed Auto Carry up another name for operator station mute bypasses the operator station during the non hazardous portion of the stroke when the operator releases his hands from the palm buttons the press automatically completes the stroke and stops at TDC see Chapter 4 ...

Page 484: ... settings that have been programmed for a sensor and or cam channel communications ability to send and receive data from a computer running PACNet computerized pressroom reporting and or RSR Remote Storage Retrieval Control Component Failure another name for Control Reliability control reliability as per ANSI B11 1 1988 and OSHA 1910 217 regulations de mands that a single component failure in a cl...

Page 485: ...ual Safety Valve controls the air flow that operates the clutch and brake of the press dwell duration time how long the cam channel and or sensor are expected to stay activated emergency stop signal sent to the press as soon as a malfunction occurs should be used when the operator wants the press to stop immediately enable mode ability to activate or deactivate sensors connected to the die protect...

Page 486: ...on to the flow of electric current some die protection controls have inputs with different impedances for electromechanical sensors as a rule of thumb use a high impedance input if the part is dirty or covered with a non conductive lubricant use a low impedance input if the part is covered with a water based or conductive lubricant Interrupted Stroke occurs when the press has been emergency stoppe...

Page 487: ...nd make proper connections to ensure NEMA 12 protection with the enclosure ninety 90 stop time test test that is required in order to set the proper safety distance for personnel guarding devices including light curtains two hand controls and type B movable barriers This test is done at the press s most critical stopping point the worst case scenario occurs halfway on the down stroke at 90 while t...

Page 488: ...allation of the overrun limit switch and is a function of the stopping time of the press provides a backup for top stop timing and is influenced by the condition of the brake linings and the press speed should the top stop output relay fail overrun will provide the signal to stop the press if the overrun limit switch has not been properly installed overrun timing in WPC will not work pinch point h...

Page 489: ...side of which the light curtains two hand controls and type B movable barriers must be mounted determined by using a precise formula set by OSHA regulations and or ANSI standards critical for proper machine guarding security access ability to prevent or allow personnel access to programming and operating functions in the control selection bar a box that appears on menu displays used to indicate wh...

Page 490: ...l programming easier Program the Tool Template with the programming items that are the same on several tools Then use the Tool Template as the basis for programming new tools Any tool that you name Tool Template will serve as the template top stop signal which allows the press to stop at top of stroke 0 used when an emergency stop setting might cause the press to stick on bottom and when one hit a...

Page 491: ...USB connector J117 on the SmartPAC 2 PC board It is not actually a disk drive but computers treat it as if it were voltage selector switch enables the setting of the power supply from 115V to 230V located on the power supply board yellow sensors normally open to ground a stop command is sent to the press as soon as the sensor actuates closes to ground ...

Page 492: ...1126800 SmartPAC 2 with WPC Integration page 470 Glossary ...

Page 493: ...2 on off setting 305 Program mode 302 select names 211 set timing 195 timed output 309 timed output setting 309 timing 10 view summary 305 view summary Run mode 344 view timing 341 cam outputs enclosure dimensions 85 installing 83 cam switch See cam channels capture screen 199 checkout See also testing checksum 413 462 circle diagram 311 334 462 See also crank angle clock ready angle 298 clear cou...

Page 494: ...onitor 391 409 E stop circuit driver failure 404 E stop error messages 410 F Series 391 F17 394 F18 394 green constant 415 green quick check sensor 415 green quick check sensor fault 415 green sensor actuated late 414 green sensor missed 414 green special 415 green special fault 415 H Series 391 input buffer test failures 397 internal memory failures 409 internal timing input failures 406 loss of ...

Page 495: ...ey 177 cursor keys 179 ENTER key 181 HELP key 178 number keys 176 RESET key 182 selecting an item 187 stroke select key switch 175 using cursor keys 179 using function keys 184 using Hot keys 185 using the Program Run key switch 183 keyboard computer entering names with 270 keylock switch secure WPC settings 257 L LED mute 5 palm time 5 left right select switch one hand 6 light curtain break mode ...

Page 496: ...ower Precision Metalforming Association 50 427 preset reached See also counters good parts counter 332 message 385 total hits 287 288 presets setting and clearing 287 press control 233 236 237 353 Initialization mode 225 Program mode 314 Run mode 353 press functions 439 press name 210 press option switches 241 See also switch es press option switches 1 and 2 overrun limit 242 3 one hand or foot mo...

Page 497: ...ode select 365 foot operation 372 one hand operation 369 test with light curtains 142 testing 142 145 two hand operation 370 slave See resolver See resolver slow RPM 214 467 Smart Stop 18 467 critical angle 296 die protection 296 SmartPAC 2 display 186 enclosure installation 70 input check and stop circuit wiring 167 mounting dimensions enclosure 71 mounting dimensions panel mount 73 panel mount 7...

Page 498: ...p constant 468 top stop in inch disabling 367 total hits counter 10 287 468 clearing 288 tracking frequency 438 tracking units 438 troubleshooting 383 on power up 98 two hand only 250 two hand mode select 365 operation in single stroke 370 two hand control 3 as safety device 47 50 U USB disk saving to 267 user inputs 52 226 status codes 390 testing 157 user interlocks 52 227 V voltage See specific...

Page 499: ...vofeed Interface CWP Wintriss 1108100 Servofeed Interface DiPro 1096300 Servofeed Interface Electrocraft Wintriss 1109200 Servofeed Interface Indramat Wintriss 1104500 Servofeed Interface ProCam 1069100 Servofeed Interface SmartPAC 1102500 Servofeed Interface Waddington Wintriss 1102700 Shadow I II IV Safety Light Curtain 1069100 Shadow V Safety Light Curtain 1087300 Shadow VI Safety Light Curtain...

Page 500: ..._____ms TOP STOP TOGGLE PULSE FOR _______ms Increment mode circle one STROKES GOOD PARTS STROKES GOOD PARTS STROKES GOOD PARTS Increment angle degrees This tool should be serviced when the TOTAL HITS count reaches _____________ Strokes Part _____________ OR Parts Stroke _____________ Tool Information Item Value Units Tool Memo box text 30 characters total __ __ __ __ __ __ __ __ __ __ __ __ __ __ ...

Page 501: ...V ON Time to shut off after press stops in seconds Arc Normally 1 arc per channel can be up to 4 ON angle OFF angle Arc 1 Arc 2 Arc 3 1 _____ _____ms ____sec Arc 4 Arc 1 Arc 2 Arc 3 2 _____ _____ms ____sec Arc 4 Arc 1 Arc 2 Arc 3 3 _____ _____ms ____sec Arc 4 Arc 1 Arc 2 Arc 3 4 _____ _____ms ____sec Arc 4 Arc 1 Arc 2 Arc 3 5 _____ _____ms ____sec Arc 4 Arc 1 Arc 2 Arc 3 6 _____ _____ms ____sec Ar...

Page 502: ...o shut off after press stops in seconds Arc Normally 1 arc per channel can be up to 4 ON angle OFF angle Arc 1 Arc 2 Arc 3 9 _____ _____ms ____sec Arc 4 Arc 1 Arc 2 Arc 3 10 _____ _____ms ____sec Arc 4 Arc 1 Arc 2 Arc 3 11 _____ _____ms ____sec Arc 4 Arc 1 Arc 2 Arc 3 12 _____ _____ms ____sec Arc 4 Arc 1 Arc 2 Arc 3 13 _____ _____ms ____sec Arc 4 Arc 1 Arc 2 Arc 3 14 _____ _____ms ____sec Arc 4 Ar...

Page 503: ...G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP OFF ON 8 G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP OFF ON 9 G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP OFF ON 10 G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP OFF ON 11 G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP OFF ON 12 G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP OFF ON 13 G R Y ...

Page 504: ...P STOP OPTION Press Control Option Switches and Other Mode Settings INITIALIZATION PRESS CONTROL PRESS OPTIONS These are set to OPEN when you initialize press parameters Circle current setting Switch 1 OPEN CLOSED Switch 2 OPEN CLOSED Switch 3 OPEN CLOSED Switch 4 OPEN CLOSED Switch 5 OPEN CLOSED Switch 6 OPEN CLOSED Switch 7 OPEN CLOSED Switch 8 OPEN CLOSED Circle current setting DUAL OPERATORS S...

Page 505: ...ERNET LEDS LINK ACTIVITY USB INPUT CHECK LED DS103 E STOP LEDS COMPACT FLASH ACCESS LED K101 K102 F101 F102 F103 INPUT CHECK FUSE E STOP FUSE TOP STOP FUSE 224 225 226 227 228 229 230 231 232 233 234 245 246 247 248 249 250 251 252 253 254 212 213 214 215 216 217 218 TB107 235 236 237 238 239 240 241 242 243 244 205 206 207 208 209 210 PS 2 ZERO CAM LED DS102 TOP STOP RELAY BATTERY Tx6 Rx6 Tx5 Rx5...

Page 506: ...nd 78 Light curtain B 1 input 33 Analog 1 input 77 Light curtain A 1 input 32 13 5 VDC out 76 24 VDC out 31 Ground 75 Unused 30 Ground 74 User input 9 paired with User input 8 29 Aux 3 out 73 User input 7 28 Aux 1 out 72 User input 5 27 Light curtain 1 enable 71 User input 3 26 Unused 70 Remote reset input 25 Ground 69 Estop string in connects internally to 45 24 Overrun limit switch input 68 Esto...

Page 507: ...BLK RED OFF RED GRN BLK WHT 45 46 47 48 10 49 50 51 52 53 54 11 12 13 14 15 16 17 18 19 20 21 22 55 56 57 58 59 60 61 62 63 64 66 23 24 25 26 27 28 29 30 31 32 33 34 67 68 69 70 71 72 73 74 75 76 77 78 35 36 37 38 39 40 41 42 43 44 79 80 81 82 83 84 85 86 87 88 65 ON D 1 2 3 4 5 6 7 8 9 B A CONNECT TO THE ENCLOSURE CONNECT TO THE ENCLOSURE CONNECT TO THE ENCLOSURE FIGURE 1 SMARTPAC 2 SYSTEM WIRING...

Page 508: ... TOPSTOP OUTPUT OUTPUT INPUT 79 80 81 49 1 N C A OP STA BLUE VIOLET GREY RED ORG BLACK W RED BRN GREEN WHITE W BLK YEL 3 ONE HAND A W YEL WPC INPUT LED WPC INPUT LED TOP STOP A TOP STOP B 52 60 WPC INPUT LED WPC INPUT LED ESTOP A ESTOP B 48 57 W ORG 24 VDC WPC OUTPUT GROUND 53 54 WPC OUTPUT WPC OUTPUT PRIOR ACT LAMP MUTE LAMP 66 WPC OUTPUT PALM TIME LAMP 65 64 WPC INPUT LED PRIOR ACT IN 63 W BRN G...

Page 509: ... 84 85 86 87 88 65 MAIN BOARD CONNECTORS RESOLVER RESOLVER CABLE RED GRN BLK 92 R1 93 S2 94 S1 95 GND 89 S4 90 R2 91 S3 RESOLVER CONNECTOR ON EDGE OF MAIN BOARD YEL ORG BRN SHOWN FOR CW ROTATION FACING SHAFT FOR CCW ROTATION SWAP THE BLACK AND YELLOW WIRES 24V N C CONTACTS OF BAR CONTROL ON OFF SWITCH SO THAT MAIN MOTOR TURNS OFF WHEN BAR MODE IS SELECTED WINTRISS CLUTCH BRAKE CONTROL EXTERNAL WIR...

Page 510: ...D ADB HIGH NEU GND CHASSIS GND 24V FRONT SET OF SHADOWS SET A REAR SET OF SHADOWS SET B 24V PACTRON PACTRON WIRE TO THE MOTOR STARTER STOP START CIRCUIT SO THAT MAIN MOTOR TURNS OFF WHEN LOCKOUT RELAY IS OPEN WPC POWER SUPPLY 121 L1 122 L2 123 GND 124 CHAS 126 L2 125 L1 127 GND 128 L1 129 L2 130 GND 131 DSVA C 132 DSVA N O 133 DSVB C 134 DSVB N O 135 LKOUT C 136 LKOUT N O 137 LKOUT N O WINTRISS CL...

Page 511: ... BLACK 1 W RED 1 ORG 1 W YEL 1 RED 1 GREY 1 W ORG 1 BLUE 1 1 1 2 3 4 45 46 47 48 5 6 7 8 9 10 49 50 51 52 53 54 11 12 13 14 15 16 17 18 19 20 21 22 55 56 57 58 59 60 61 62 63 64 66 23 24 25 26 27 28 29 30 31 32 33 34 67 68 69 70 71 72 73 74 75 76 77 78 35 36 37 38 39 40 41 42 43 44 79 80 81 82 83 84 85 86 87 88 65 MAIN BOARD CONNECTORS YELLOW 1 GREEN 1 BROWN 1 VIOLET 1 GREEN 2 YELLOW 2 BROWN 2 VIO...

Page 512: ...T OF SHADOWS SET A REAR SET OF SHADOWS SET B 24V PACTRON PACTRON 9 8 7 6 2 1 4 3 5 ROSS SERPAR WITH EP MONITOR DUAL SAFETY VALVE JUMPERS REQUIRED REMOVE ALL OTHERS 24V DSV RESET SWITCH SUPPLIED BY USER SHADOW V AND ROSS EP DSV WIRING WIRE TO MOTOR STARTER CIRCUIT SO THAT MOTOR TURNS OFF WHEN RELAY OPEN WPC POWER SUPPLY 121 L1 122 L2 123 GND 124 CHAS 126 L2 125 L1 127 GND 128 L1 129 L2 130 GND 131 ...

Page 513: ... Reverse FIGURE 7 SENSING AND CONTROL CODE IDENT NO DRAWING NUMBER APPROVALS HONEYWELL FILENAME DRAWN TITLE SHEET SCALE DATE CHK ENG MFG SIZE REV REL OF any part thereof any information contained therein or any physical article or thereof confers or transfers any right to reproduce or disclose the document device or to practice any method or process except by written permission or PROPRIETARY RIGH...

Page 514: ...3 44 79 80 81 82 83 84 85 86 87 88 65 MAIN BOARD CONNECTORS RUN RUN ONE HAND EMERGENCY STOP TOP STOP PRIOR ACT 24 VDC 24 VDC 24 VDC Red Yellow PALM TIME MUTE Green 24 VDC 24 VDC 24 VDC 24 VDC For no One Hand Button just connect Run button N C directly to terminal 1 WPC OEM OPERATOR STATION WITH SEPARATE ONE HAND CONTROL FIGURE 8 CODE IDENT NO DRAWING NUMBER APPROVALS HONEYWELL ACTON MA FILENAME DR...

Page 515: ...11 12 13 14 15 16 17 18 19 20 21 22 55 56 57 58 59 60 61 62 63 64 66 23 24 25 26 27 28 29 30 31 32 33 34 67 68 69 70 71 72 73 74 75 76 77 78 35 36 37 38 39 40 41 42 43 44 79 80 81 82 83 84 85 86 87 88 65 MAIN BOARD CONNECTORS BLUE GREY CUT THE GREY WIRE OFF AND TAPE IT SO THAT IT WILL NOT SHORT OUT GREY WIRE IS NOT CONNECTED 11 12 13 14 ONE HAND CONTROL BUTTON WPC WITH SEPARATE ONE HAND CONTROL WI...

Page 516: ...sor 6 Sensor 7 Sensor 8 4 N C 24 VDC 24 VDC L1 24V OUTPUT 5 VDC INPUT POWER DSI 2 Grd Grd Grd Grd TB2 TB4 TB3 GND 10 L2 11 12 10 11 1 2 3 4 5 6 7 8 9 1 2 3 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 1 2 3 4 1 Sensor Power 3 Sensor Input SENSOR STATUS 2 Ground Sensor 1 Sensor 2 Sensor 3 Sensor 4 Sensor 5 Sensor 6 Sensor 7 Sensor 8 Sensor 1 Sensor 2 Sensor 3 Sensor 4 Sensor 5 Sensor 6 Sensor 7 Sensor 8 4 N C...

Page 517: ...4 305 Aux 2 306 Aux 1 DiProPAC 8 291 Grd 1 1 12 VDC SOLID STATE INPUT INPUT OUTPUT OUTPUT RELAY DiProPAC to RCB Wiring Diagram CUSTOMER SUPPLIED any part thereof any information contained therein or any physical article or thereof confers or transfers any right to reproduce or disclose the document device or to practice any method or process except by written permission or PROPRIETARY RIGHTS This ...

Page 518: ...rocess except by written permission or PROPRIETARY RIGHTS This document discloses subject matter in which HONEYWELL has proprietary rights Neither receipt nor possession written agreement with HONEYWELL CAMS 1 8 8 CHANNEL CAM I O ASSEMBLY N C C N O N C C N O N C C N O N C C N O N C C N O N C C N O N C C N O N C C N O 5 VDC TB301 TB303 TB302 CH 8 CH 7 CH 6 CH 5 CH 4 CH 3 CH 2 CH 1 CH 1 CH 2 CH 3 CH...

Page 519: ...D3 237 TXD1 243 TXD2 244 TXD2 246 Pos 247 Grd CONNECTOR 315 Grd 326 Grd 229 Grd 240 Grd 250 Grd 201 L1 202 L2 213 S1 214 S2 215 R1 216 S3 245 V 217 R2 218 S4 205 A 206 B AUX I O CONT S S INCH GRD OFF TB103 TB104 TB106 TB105 TB101 TB102 TB107 GND 1 1 1 1 1 1 1 Wintriss SmartPAC 2 SPARE 2 PORT 8 SPARE 3 PORT 7 SPECIAL PORT 3 SPARE 1 PORT 5 MODULE PORT 2 PacNET PORT 4 253 OP STA 2 254 OP STA 1 RESOLV...

Page 520: ...CH SWITCH SHOWN IN KEY IN POSITION 3 BLUE 1 BRN 2 WHT 4 BLK HONEYWELL GKB SERIES INTERLOCK SWITCH SWITCH SHOWN IN KEY IN POSITION 22 21 11 12 Figure 14 11 30 01 SENSING AND CONTROL CODE IDENT NO DRAWING NUMBER APPROVALS HONEYWELL FILENAME DRAWN TITLE SHEET SCALE DATE CHK ENG MFG SIZE REV REL OF any part thereof any information contained therein or any physical article or thereof confers or transfe...

Page 521: ... 2 2 2 SHADOW VI CONTROL BOX SHADOW VI RECEIVER UNIT SHADOW VI TRANSMITTER UNIT TO WPC 125 TO WPC 126 TO WPC 127 CHAS WINTRISS CLUTCH BRAKE CONTROL SHADOW VI FIGURE 15 CONNECT TO THE ENCLOSURE CONNECT TO THE ENCLOSURE TB3 TRANSMITTER 1 CONNECTOR TB3 TRANSMITTER 2 CONNECTOR TB 1 MAIN POWER CONNECTOR TB2 RECEIVER 1 CONNECTOR TB2 RECEIVER 2 CONNECTOR TB4 AUXILIARY CONNECTOR TB4 OUTPUT CONNECTOR TB5 L...

Page 522: ...TCH BRAKE CONTROL SHADOW VI RECEIVER UNIT INTEGRATED SHADOW VI WIRING SHADOW VI WPC INTERFACE BOARD CODE IDENT NO DRAWING NUMBER APPROVALS HONEYWELL FILENAME DRAWN TITLE SHEET SCALE DATE CHK ENG MFG SIZE REV REL OF CONNECT THE SHIELD TO THE ENCLOSURE NEAR THE POINT OF ENTRY TB3 TRANSMITTER 1 CONNECTOR TB3 TRANSMITTER 2 CONNECTOR TB2 RECEIVER 1 CONNECTOR TB2 RECEIVER 2 CONNECTOR TB1 MAIN POWER CONN...

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