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1128600

SmartPAC 2 with WPC 2000 Integration User Manual

6-24

Run Mode

ANSI and OSHA Safety Distance Formulas

Occupational Safety and Health Administration (OSHA) regulations and American National 
Standards Institute (ANSI) standards mandate that all machine safeguarding devices, 
including Shadow light curtains, be located at the correct safety distance from the pinch point.

OSHA regulation 1910.217 governs the mounting of infrared light curtains to protect 
mechanical power presses.  Wintriss recommends, however, that you use the formula in ANSI 
standard B11.1-2009 when calculating safety distance.  The ANSI formula has been 
developed specifically for guarding of mechanical power presses and includes more factors, 
such as brake monitor setting, object sensitivity, and depth penetration factor, than the OSHA 
formula.  The B11.1-2009 formula represents a new consensus among manufacturers on the 
proper installation of light curtains.

ANSI and OSHA formulas are documented in the following sections.  For complete 
information on OSHA regulation 1910.217 and ANSI standards B11.1-2009 and 
B11.19-2003, see Appendix A.

The ANSI Safety Distance Formula

PRESS MAY NOT STOP BEFORE OPERATOR REACHES PINCH POINT

• Calculate the safety distance carefully according to the instructions below.
• Mount your light curtain heads at least the safety distance from the hazardous area.  If a light 

curtain is too close to the hazard, there may not be enough time for the press to stop before the 
operator’s hand (or another object) reaches the hazard.

• Mount your Two-hand Control, if you are using it as a safety device, at least the safety distance 

from the hazardous area.  If the Two-hand Control is too close to the hazard, there may not be 
enough time for the press to stop before the operator’s hand (or another object) reaches the 
hazard.

• Call Wintriss Tech. Support if you are not sure how to calculate the safety distance.

Failure to comply with these instructions will result in death or serious injury.

OBSERVE THE CORRECT SAFETY DISTANCE

• Calculate the safety distance carefully according to the instructions below, and mount your light 

curtain heads at least the calculated distance from the hazardous area.

• Mount your light curtain heads at least 7.5 in. (191 mm) from the hazardous area, regardless of 

the calculated safety distance.

• Be sure your value for Ts (i.e., stopping time) includes the response times of all devices that 

react to stop the press. If your measurement for stopping time does not include the response 
times of the press control, light curtain, and any other devices that react to stop the press, the 
safety distance will be too short.

Failure to comply with these instructions will result in death or serious injury.

DANGER

!

DANGER

!

Summary of Contents for SmartPAC 2

Page 1: ... com includes optional DiPro PAC and ProCam PAC 1128600 Rev P January 2018 Press Automation Control with WPC 2000 Clutch Brake Control Wintriss Controls Group LLC 100 Discovery Way Unit 110 Acton MA 01720 USA Phone 800 586 8324 Fax 978 263 2048 PRINTED IN USA DA70482 ...

Page 2: ......

Page 3: ...e returning We ask that you either fax us a PO for that amount or enclose the PO with the returned item This will enable us to ship the item back to you as soon as the repair has been completed If the item cannot be repaired or there are additional charges you will be contacted for approval Please be sure to carefully pack all returned items and ship to our Acton MA location Expedited Repair Progr...

Page 4: ......

Page 5: ...to downloadable product documentation Throughout manual updated with Shadow 9 light curtain information including addition of wiring diagrams Figures 26 27 and 28 at the end of the manual In Chapter 7 Fault Messages added notes about finding error numbers 120 or higher in WPC 2000 Option 2 User Manual 1130700 and WPC 2000 Option 2 Additional Inputs Only Instruction Sheet 1141900 In Appendix A revi...

Page 6: ......

Page 7: ...o Terminal Block Connectors 2 5 Terminating Cable Shields 2 6 Checking the Press 2 7 Installing WPC 2000 2 7 Mounting the Control Enclosure 2 7 Wiring the Control Enclosure 2 8 Connecting AC Wiring 2 9 Installing WPC 2000 without Enclosure 2 11 Installing a Dual Safety Valve 2 12 Installing Air Pressure Sensors or Switches 2 13 Installing Operator Station s 2 16 Wiring a User built Operator Statio...

Page 8: ...rtPAC 2 and WPC 2000 2 71 Problems at Startup 2 73 Verifying Installation of DiProPAC and ProCamPAC 2 74 Initializing WPC 2000 Parameters 2 75 Creating and Loading a Test Tool 2 76 Checking and Setting the Direction of Resolver Rotation 2 77 Zeroing the Resolver 2 78 Setting the Top stop On Angle and Installing the Overrun Magnet 2 78 Installing Revised Firmware in WPC 2000 2 85 Performing Checkou...

Page 9: ...ain Versions Earlier than V 5 3 1 3 23 Screen Capture in SmartPAC 2 Main Versions V 5 3 1 and Later 3 25 Chapter 4 SmartPAC 2 Initialization Mode 4 1 Entering and Exiting Initialization Mode 4 2 Initializing WPC 2000 Parameters 4 3 RESOLVER ZERO 4 3 Moving the Ram to Top Dead Center TDC 4 3 Setting the Resolver Zero Position 4 4 POSITION SENSOR 4 5 Position Sensor Mode 4 5 Resolver Motion Mode Nor...

Page 10: ... SETUP NETWORK 4 56 E MAIL FUNCTION 4 57 SMARTVIEW FUNCTION 4 58 SETUP E MAIL 4 58 CHANGE NETWORK SETTINGS 4 60 PRESS TYPE 4 60 DIAGNOSTICS 4 61 COMMUNICATIONS 4 62 SET CLOCK 4 64 SAVE TO USB DISK 4 65 UPDATE FIRMWARE 4 65 Using SmartPAC 2 with a Link motion Press 4 65 Setting Link Motion 4 66 Using a ServoFeed Interface with Link Motion 4 66 Using a Computer Keyboard to Enter Names 4 68 Chapter 5...

Page 11: ...TATUS Optional 5 52 Viewing Sensor Status 5 52 Enabling or Disabling All Sensors 5 53 Turning a Sensor Off or On 5 53 Chapter 6 SmartPAC 2 Run Mode 6 1 Entering and Exiting Run Mode 6 2 Loading a Tool 6 2 Programming Hot Keys 6 3 Settings Locked or Password Required 6 4 Displaying Multiple Faults 6 5 Opening the Crankshaft Angle Window 6 6 DISABLE ENABLE SENSORS 6 6 COUNTERS 6 8 DIE PROTECTION Opt...

Page 12: ... the Press in Bar Mode 6 53 Multiple Operator Stations 6 54 Chapter 7 Fault Messages 7 1 Responding to Fault Messages 7 2 Lockout Message 7 3 Brake Monitor Faults 7 3 Brake Warning LED 7 3 Stop Time Exceeded 7 3 Messages for Press Control Problems 7 5 Resolver Faults 7 6 Operational Faults 7 7 Inter processor Failures 7 12 Input Buffer Test Failures 7 13 Air Pressure Limits Exceeded 7 13 Component...

Page 13: ...onitor Optional C 1 About SmartPAC PM Monitor C 1 Comparison with Traditional Preventive Maintenance C 1 How the PM Monitor Works C 2 Examples of How to Use the PM Monitor C 2 Installing the PM Monitor C 3 For New Systems from the Factory C 3 For Existing Systems C 3 Using the PM Monitor in Initialization Mode C 4 How to Get into SmartPAC Initialization and PM Monitor C 4 Initializing the PM Monit...

Page 14: ...AC 2 F 1 Backing Up Tools on Original SmartPAC F 1 Removing SmartPAC 1 and Mounting SmartPAC 2 F 3 Wiring the SmartPAC 2 F 4 AC Wiring on SmartPAC 2 F 12 Restoring Tools to SmartPAC 2 F 12 System Checkout F 14 Appendix G Replacing SmartPAC 2 PC Board G 1 Unpacking the Replacement Board G 1 Installing the Replacement Board G 2 Appendix H Reporting Downtime and Scrap to SFC H 1 Machine States to Whi...

Page 15: ...ing I 2 Putting the Press Back on Line I 3 Forced Error Dialog Mode I 4 Persist Dialog Mode I 5 Single stroke Mode I 6 Reset Strokes Counters I 6 Setting up SmartPAC 2 to Report Downtime I 6 Making Downtime Reporting Settings I 7 Programming Downtime Reasons I 11 Documenting Downtime on the Dialog Menu I 14 Documenting Downtime in Response to the Forced Dialog Message I 14 Documenting Downtime in ...

Page 16: ...2000 Herion DSV Wiring Figure 17 WPC 2000 Ross DSV Wiring Figure 18 WPC 2000 Operating Mode Output Wiring Figure 19 WPC 2000 and SmartPAC 1 System Wiring Figure 20 WPC 2000 and Shadow VII Wiring Diagram Figure 21 Shadow VII DIN Control WPC 2000 Wiring Diagram Figure 22 WPC 2000 Ross DM2 DSV Wiring Figure 23 WPC 2000 and Shadow 8 Control Box Wiring Diagram Figure 24 WPC 2000 and Shadow 8 Wiring Dia...

Page 17: ...minal Block Inside Enclosure Top Right 2 53 Figure 2 27 Input Check Switch S101 2 55 Figure 2 28 DiProPAC and ProCamPAC Boards Installed on SmartPAC 2 Board 2 57 Figure 2 29 DiProPAC Boards 8 16 and 32 Sensor Location of Components 2 58 Figure 2 30 ProCamPAC Boards 8 and 16 Channel Location of Components 2 58 Figure 2 31 ProCamPAC Output Assembly 2 65 Figure 2 32 Cam Outputs Board 2 66 Figure 2 33...

Page 18: ...Names Screen 4 17 Figure 4 13 Die Protection Mode Selection Menu 4 18 Figure 4 14 Tool Information Setup Screen 4 20 Figure 4 15 Tool Information Name Screen 4 20 Figure 4 16 Tool Information Units Selection Screen 4 21 Figure 4 17 Tool Information Setup Screen with Sample Entries 4 23 Figure 4 18 WPC Initialization Menu 4 23 Figure 4 19 Press Control User Interlock Menu 4 24 Figure 4 20 Select St...

Page 19: ...Programming for a Green Constant Sensor 5 19 Figure 5 20 Enter Your Password Screen 5 21 Figure 5 21 Die Protection Sensor Menu with Auto Enable by Tool Counter 5 21 Figure 5 22 Sensor Names Screen 5 22 Figure 5 23 Custom Sensor Names Screen 5 23 Figure 5 24 Auto Enable by Sensor Counter Screen 5 23 Figure 5 25 Sensor Type Screen 5 24 Figure 5 26 Sensor Stop Type Screen 5 25 Figure 5 27 Critical A...

Page 20: ...ayed on Main Run Menu 6 6 Figure 6 8 Main Run Menu with SENSORS ENABLED Display 6 7 Figure 6 9 Disable Sensors Confirmation Message 6 7 Figure 6 10 Counters Screen 6 8 Figure 6 11 Counters Screen with Reload Batch Counters Function 6 9 Figure 6 12 Die Protection Menu Run Mode 6 10 Figure 6 13 Sensor Turned Off Message 6 10 Figure 6 14 Ready Signal Programming Screen 6 11 Figure 6 15 Sensor Status ...

Page 21: ...D 5 Firmware Load Menu with RELOAD CURRENT FIRMWARE Highlighted D 10 Figure D 6 Firmware Load Menu with Yellow Status Window D 10 Figure D 7 SmartPAC 2 Display with Loading Firmware Message D 11 Figure E 1 Internet Explorer Window with Internet Options Selected E 6 Figure E 2 Internet Options Screen E 7 Figure E 3 Security Tab with Custom Level Button E 7 Figure E 4 SmartView Introductory Page E 8...

Page 22: ...ain Initialization Menu I 7 Figure I 5 Set Communications Menu I 7 Figure I 6 Dialog Fixed Name Choice Menu I 11 Figure I 7 Dialog Special Choice Name Menu I 13 Figure I 8 SmartPAC 2 Run Mode Main Menu with Forced Dialog Message Displayed I 15 Figure I 9 Dialog Menu I 15 Figure I 10 Dialog Menu with F2 F3 Option Window Displayed I 16 Figure I 11 SmartPAC 2 Run Mode Main Menu with DIALOG MENU Item ...

Page 23: ...28 WPC 2000 Power Supply TB105 Wiring Connections 2 115 Table 2 29 WPC 2000 Aux E stop Relay Board Wiring Connections 2 115 Table 2 30 WPC 2000 DSV Lockout Relay Board Wiring Connections 2 115 Table 2 31 WPC 2000 AC Power Wiring Connections 2 115 Table 2 32 SmartPAC 2 SFI Port 1 and Module Port 2 TB103 Wiring Connections 2 115 Table 2 33 SmartPAC 2 Special Port 3 and PACNet Port 4 TB104 Wiring Con...

Page 24: ... Wiring Changes Position Sensor If Used F 7 Table F 6 SmartPAC 1 to SmartPAC 2 Wiring Changes DiProPAC 8 Channel F 7 Table F 7 SmartPAC 1 to SmartPAC 2 Wiring Changes DiProPAC 16 Channel F 8 Table F 8 SmartPAC 1 to SmartPAC 2 Wiring Changes ProCamPAC 8 Channel F 8 Table F 9 SmartPAC 1 to SmartPAC 2 Wiring Changes ProCamPAC 16 Channel F 9 Table F 10 SmartPAC 1 to SmartPAC 2 Wiring Changes WPC Port ...

Page 25: ...taining to the use of presence sensing devices for point of operation guarding on mechanical power presses Appendix B provides the safety standards you must meet when building your own Operator Station Appendix C shows you how to use the optional PM Preventative Maintenance Monitor available with SmartPAC 2 Appendix D shows you how to upgrade SmartPAC 2 firmware Appendix E shows you how to install...

Page 26: ...ous situation which if not avoided will result in death or serious injury A WARNING symbol indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION symbol indicates a potentially hazardous situation which if not avoided may result in property damage A NOTICE symbol indicates important information that you should remember including tips to a...

Page 27: ...at its factory or facility any products which shall within the applicable period after shipment be returned to Wintriss Controls freight prepaid and which are after examination disclosed to the satisfaction of Wintriss to be defective This warranty shall not apply to any equipment which has been subjected to improper installation misuse misapplication negligence accident or unauthorized modificati...

Page 28: ...1128600 SmartPAC 2 with WPC 2000 Integration User Manual xxii Table of Contents ...

Page 29: ...can be linked to Wintriss s ShopFloorConnect Asset Utilization Software SFC or Line Efficiency Tracking Software LETS for data collection analysis and reporting WPC 2000 and Control Reliability WPC 2000 Wintriss Clutch Brake Control is an easy to use dual microprocessor based system that controls part revolution mechanical power presses Housed in a single modular enclosure both microprocessors fun...

Page 30: ...to SmartPAC 2 via the local network or mailed to you on a USB disk WPC 2000 Standard Features WPC 2000 provides the following capabilities as standard features Interrupted Stroke provision When the press is the Emergency stopped before the completion of a stroke by either the operator or an automatic device for personnel or equipment protection the message Interrupted Stroke flashes on the SmartPA...

Page 31: ...cam channels enabling SmartPAC 2 to control cam timing for feed pilot release air blow off lubricator and other press equipment ProCamPAC also includes global cams for press operation functions DSV ON channel delay timing and multiple on off cycles for a single cam AutoSetPAC or WaveFormPAC Provides two or four channel load monitoring protecting your press and dies from overloads and underloads Yo...

Page 32: ...ch and brake Wintriss provides 3 4 in and 1 in Ross DM2 DSVs See Installing a Dual Safety Valve page 2 12 for further details System Air Pressure Sensor or Switch This sensor or switch monitors the system air pressure See Installing Air Pressure Sensors or Switches page 2 13 for additional information Shadow Light Curtain The Shadow light curtain is a presence sensing device that places an infrare...

Page 33: ... designed specifically for variable speed presses See Switch 4 Enabling Auto Compensated Top Stop ACTS page 4 37 for additional information about this feature Multiple Operator Stations Two Operator Stations can be connected directly to WPC 2000 If you wish to install more than two Op Stations contact Wintriss Tech Support see Installing Multiple Operator Stations page 2 21 Display Configuration O...

Page 34: ...is provided below Display Used with the keyboard to make and adjust settings load tool numbers and view diagnostic messages The display which measures 10 4 in 264 mm diagonally is a color liquid crystal display LCD Program Run key switch Allows Program mode to be locked so settings cannot be changed by the press operator Key must be set to Run to operate the press Minor adjustments including loadi...

Page 35: ...rator that it is time to schedule maintenance on the brake Detailed instructions on how to use the keyboard and display are provided in Chapter 3 Figure 1 1 SmartPAC 2 Front Panel PRESS 14 TOOL NUMBER 6160 PART CNTR 449 FLANGE B TWO HAND S S PRESS ANGLE 270 CAMBIE AL ESPANOL USE THE CURSOR KEYS ENABLE SENSORS TO MAKE SELECTIONS COUNTERS PRESS ENTER TO DIE PROTECTION ACCESS SELECTION CAM SWITCH BRA...

Page 36: ... Stops the press immediately when you push it The switch is not spring loaded so you must pull it back to its original position to clear the emergency stop F13 fault see page 7 8 Top Stop Switch Stops the press at the top of its stroke when pressed during Continuous operation Palm Time Lamp Illuminates when one Run Inch palm button is depressed turning off after the 1 2 second palm time synchronou...

Page 37: ...pping time and the press reaches that stop time limit the brake monitor disables the press alerting you that your brake requires service In addition the Brake Warning LED on the SmartPAC 2 front panel see Figure 1 1 page 1 7 for location flashes when press stopping time approaches within 10 milliseconds of the stop time limit allowing you to schedule brake maintenance before the press has to be di...

Page 38: ...ed All types of NPN electronic sensors e g proximity photoelectric and fiberoptic sensors can be used as can simple contact sensors and probes If you have questions about whether a certain sensor will work with SmartPAC 2 contact Wintriss Controls Wintriss makes or sells a wide range of sensors Those that can be used with SmartPAC 2 with DiProPAC are shown below Detailed application information is...

Page 39: ...the resolver global cams auto advance constants etc Initialization settings generally only need to be made once Initialization mode is discussed in detail in Chapter 4 Program Mode Used to create modify and load settings that control SmartPAC 2 operation for a specific tool e g sensor and cam timing counter presets etc You cannot use this mode while the press is running Instructions for using Prog...

Page 40: ...lb axial 200 lb radial Operator Station NEMA 12 Includes two palm buttons Top stop Emergency stop and Prior Act buttons and palm time and mute lamps Pre wired unwired version also available Dual Safety Valve DSV Available in 0 75 in 19 mm or 1 in 25 mm Ross DM2 models Air Pressure Switch or Sensor Switch 12 150 PSI Sensor 0 200 PSI 1 6 Vdc excitation 24 Vdc Monitors clutch air supply pressure Elec...

Page 41: ...000 Inputs Motor Forward and reverse contacts Shadow Light Curtains 2 Checks proper functioning at every stroke initiation and stop Customized Status Codes Seven for E stop Top stop or E stop Lockout Two cross checked pairs one for E stop or E stop Lockout the other for E stop Lockout only WPC 2000 Outputs DSV Two monitored relays rated 4 A 120 Vac for E stopping and Top stopping press Lockout One...

Page 42: ... 14 x 4 3 in 312 x 356 x 109 mm Provides up to 16 analog NPN or PNP inputs Ability to store high low and repeatability setpoints with tool number Display and adjust manual or auto setpoints and display actual values Monitor in die dimensions and other process parameters SBR Provides capability to back up tool settings to a Windows laptop PC Requires purchase of SBR software USB Disk Backup Enables...

Page 43: ...ous on demand on off to slave the press to an external device Operator station select for either of two operator stations or both operator stations Auxiliary E Stop Output Relays Two monitored relays rated 4 A 120 Vac for up to three auxiliary devices e g feed transfer etc which can be stopped or prevented from starting if any E stop button is depressed any light curtain is interrupted or any cros...

Page 44: ...1128600 SmartPAC 2 with WPC 2000 Integration User Manual 1 16 Introduction ...

Page 45: ... after any modification or repair of the WPC 2000 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 instructions for use of the WPC 2000 clutch brake control Disconn...

Page 46: ...PAC 2 with WPC 2000 system you may include the DiProPAC die protection and or ProCamPAC programmable cam switch option This manual includes instructions for installing and using both modules Remember that they are options and might not be included in your system If you ordered SmartPAC with other optional modules such as AutoSetPAC load monitor or ProPAC process monitor refer to the user manual fo...

Page 47: ...voltage wiring Run a high voltage conduit for DSV wiring and a a low voltage conduit for the resolver to knockouts on the bottom left of WPC 2000 Run a low voltage conduit for resolver and communications wires from the lower right of WPC 2000 to the lower left of SmartPAC 2 The AC power supply wires to SmartPAC 2 should be run separately from the DC control wires going to the ProCamPAC Output Asse...

Page 48: ...ty Valve DSV Air pressure switch Motor Control Resolver overrun limit sensor and air pressure switch wiring Operator Station Wintriss Clutch Brake Control AC power E stop Top stop input check cirucit wiring Resolver and communications wiring AC high voltage wiring from customer control transformer DSV wiring Connections to option modules cam outputs DSI 2 etc SmartPAC 2 ...

Page 49: ...le See Figure 2 34 page 2 69 Never install a suppressor across relay contacts If you do the suppressor may fail shorted and the equipment controlled by that relay remain energized In some cases suppressors are required in the Top stop and Emergency stop circuits Additional suppressors part number 2238801 can be obtained from Wintriss Connecting Wires to Terminal Block Connectors Connect wires to t...

Page 50: ... wrap at least once around the nearest grounding stud Loosen the nut on the stud wrap the drain wire clockwise around the stud and tighten down the nut 3 Connect the rest of the wires in the cable to the terminal block Figure 2 2 Correct Way to Attach Wires to Terminal Block Connectors TERMINATE BOTH ENDS OF SHIELD Be sure to terminate cable shields at both ends for example at SmartPAC 2 and DSI 2...

Page 51: ...e 2 4 page 2 8 for mounting dimensions so that it can be easily reached to make wiring connections and perform necessary maintenance The enclosure does not have to be mounted to the press but can be installed on a free standing pedestal pendant or column For easy access to the interior of the enclosure make sure that there is enough room to open the control enclosure door at least 120 Plastic cabl...

Page 52: ...icable Power to WPC 2000 should be provided by a step down control transformer capable of handling 75 VA at 115 Vac 10 Most of the original controls on the press will be replaced during rewiring except the disconnect motor starter and control transformer Make sure to rewire so that the motor starter operates properly Figure 2 4 WPC 2000 Enclosure Mounting Dimensions 12 00 304 8 14 68 372 8 17 62 4...

Page 53: ...t of the enclosure see Figure 2 5 page 2 10 No 16 wire No 14 if local codes require it is recommended for these circuits with a minimum 75 C temperature rating To make AC power wiring connections perform the following steps 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 fuse...

Page 54: ...o ensure NEMA 12 protection 4 Connect the ground wire to the set screw terminal on the roof of the enclosure referring to Figure 2 5 and to Figure 16 Herion DSV Figure 17 Ross Serpar DSV or Figure 22 Ross DM2 DSV at the back of the manual 5 Connect the power wires For 115 Vac power connect the black wire to the LINE terminal and the white wire to NEUT For 230 Vac connect the black wire to the LINE...

Page 55: ...n clearance on top bottom and both sides of the plate and above the power supply and Main Processor board Allow at least 2 1 2 in clearance on the right side of the plate for making wiring connections to terminal blocks TB101 TB104 Figure 2 6 WPC 2000 Mounting Plate Mounting Dimensions TB105 TB104 TB103 TB102 TB101 TB 109 312 7 92 ID 4 places 45o x 125 3 18 4 places TB 106 Dimensions inches mm All...

Page 56: ...with a red LED indicator visible inside You install this connector on the Reset solenoid at one end of the DSV The Reset solenoid connector is the only connector at this end of the DSV The other two connectors are installed on the two valve solenoids at the other end of the DSV USER SUPPLIED DUAL SAFETY VALVE NOT SUITABLE FOR SAFETY USE Ensure that your dual safety valve meets the applicable safet...

Page 57: ...reset switch See Figure 17 at the end of this manual Also all jumpers except those shown in the wiring diagram must be removed otherwise the WPC 2000 Main Processor board may be damaged Herion XSZ Make sure that you wire the Herion DSV monitor between pin 20 and a 24 Vdc output See Figure 16 at the end of the manual Installing Air Pressure Sensors or Switches Your SmartPAC 2 with WPC 2000 requires...

Page 58: ...PSI or the pressure recommended by the press manufacturer Installing a Counterbalance Air Pressure Sensor Install and wire a counterbalance air pressure sensor as follows if there is a counterbalance 1 Install a filter regulator and lubricator in line before the counterbalance air pressure sensor if they are not already present 2 Connect shop air to the counterbalance air pressure sensor input por...

Page 59: ...ounterbalance air pressure switch as follows if there is a counterbalance 1 Install a filter regulator and lubricator in line before the counterbalance air pressure switch if they are not already present 2 Connect shop air to the counterbalance air pressure switch input port 3 Run the cable through flexible liquid tight conduit observing NEMA 12 requirements 4 Wire the normally open terminals of t...

Page 60: ...s an operator from leaving the station and reaching the pinch point before the press stops If you are installing a light curtain the Operator Station must be placed outside the area guarded by the light curtain You do not need to calculate a specific safety distance for your Operator Station since the light curtain now prevents access to the pinch point You must not however mount the Operator Stat...

Page 61: ...ify the mute lamp wiring If your mute lamp wiring looks like panel E in Figure 2 9 page 2 18 i e the black wire is connected the red and white wire not connected the wiring is correct If your mute lamp wiring looks like panel A follow steps A through E in Figure 2 9 to disconnect the white and red wires and connect the black wire 4 When the mute lamp wiring is correct connect the Operator Station ...

Page 62: ...the cable into the Operator Station Figure 2 9 Wiring Steps to Modify Operator Station for WPC 2000 B Free the black wire Disconnect the pair of white and red wires C Connect the black wire where you just disconnected the pair of white and red wires Bend the white and red wires back on themselves Ty wrap them in place Insulate connector lug with electrical tape D E Black wire with connector lug no...

Page 63: ...lating the correct safety distance Refer to Figure 2 10 and Figure 2 11 for mounting dimensions Figure 2 10 Pre wired Operator Station with Side Run Buttons Mounting Dimensions Figure 2 11 Pre wired Operator Station with Top Run Buttons Mounting Dimensions MUTE PALM TIME PRIOR ACT INTRISS W TOP STOP 5 8 148 REF 4 69 119 1 16 75 425 5 R U N I N C H R U N I N C H 5 50 139 7 21 25 539 8 Dimensions in...

Page 64: ...igure 2 12 for mounting dimensions OPERATOR STATION MAY NOT MEET SAFETY REQUIREMENTS Ensure that the Operator Station is wired correctly Run all necessary tests to verify that each Operator Station is wired correctly and provides proper anti tie down and anti repeat protection Test procedures are provided at the end of this chapter see page 2 87 Failure to comply with these instructions will resul...

Page 65: ...tation is wired correctly Ensure that on any non Wintriss Operator Station the Run buttons are placed so that two hands are required to push them at the same time and that buttons cannot be pushed simultaneously with one hand or with one hand and one elbow Ensure that on any non Wintriss Operator Station the Run buttons comply with the requirements specified in Table B 2 page B 2 Ensure that on an...

Page 66: ...ain must be guarded by mechanical barriers To determine the Stopping Time of the press refer to page 6 21 To calculate the correct safety distance see page 6 23 PREVENT OPERATOR FROM STANDING BETWEEN LIGHT CURTAIN AND HAZARDOUS AREA Ensure that the operator cannot position himself between the light curtain and the hazardous area Use another pair of light curtains or a mechanical barrier at knee to...

Page 67: ... board see Figure 2 14 page 2 28 to the positions shown in Table 2 3 Wiring diagrams are provided in figures 20 Shadow VII control box 21 Shadow VII DIN controller 23 Shadow 8 optional control 24 Shadow 8 wired directly to WPC 2000 26 WPC 2000 and Shadow 9 Control Box Wiring Diagram 27 WPC 2000 and Shadow 9 Wiring Diagram and 28 Dual Shadow 9 WPC 2000 Wiring Diagram at the end of the manual Instal...

Page 68: ... keyed or pinned The resolver shaft has a standard key Wintriss stocks a spring loaded base with a hole pattern to match the resolver When designing the drive for the resolver observe the following precautions Do not use a chain more than three feet in length Do not use gears right angle joints or shafts with universal joints which will develop either too much backlash or too much play RESOLVER OU...

Page 69: ... page 2 26 4 Keeping the keyway aligned with the arrow attach the chain or drive mechanism Wiring the Resolver To wire the resolver perform the following steps 1 If the resolver cable is not already connected locate the cable plug the molded connector into the resolver it only goes one way and twist the locknut so the connection is tight 2 Run the resolver cable through conduit from the resolver t...

Page 70: ...tion in which your resolver will rotate clockwise or counterclockwise Refer to Installation Overview page 2 4 if you need help wiring the TB 106 connector Figure 2 13 Resolver Mounting Dimensions 2 75 69 9 1 06 26 9 1 75 44 5 2 00 50 8 3 4 dia shaft 19 05 standard key Electrical connector for cable 3 62 91 9 0 34 8 6 dia holes 2 places 9 16 232 7 RESOLVER IS AT ZERO WHEN KEYWAY IS ALIGNED WITH ARR...

Page 71: ...rotation see procedure above 3 Rezero the resolver following the instructions in Zeroing the Resolver page 2 78 Table 2 4 WPC 2000 Resolver TB 106 Wiring Pin Signal Wire Color 104 S4 Return Brown 105 R2 Ground Orange 106 S3 Return Yellow 107 R1 Drive Red 108 S2 Cosine Green 109 S1 Sine Black 110 Shield Shown for clockwise rotation facing shaft For counterclockwise swap black and yellow wires CONNE...

Page 72: ...ssor LED DS149 Light curtain B output type jumper JP121 Light curtain A test mode jumper JP124 5V B processor LED DS151 Option switches S101 Option switches S102 Green Orange Green Green Green Orange TB102 Green Orange LO HI INT EXT PNP NPN RAM chip U102 A pro cessor chip U111 ON 8 7 6 5 4 3 2 1 ON 8 7 6 5 4 3 2 1 B pro cessor chip U134 INT EXT PNP NPN LED 1 45 2 3 4 5 6 7 8 9 10 46 47 48 49 50 51...

Page 73: ...ust be no connection between the overrun limit sensor and the resolver to ensure that the overrun sensor continues to operate if the resolver or its drive mechanism fails To obtain an adequate overrun signal at high speeds the magnet should be mounted so that it can be sensed by the switch for 15 to 25 of the stroke The interval during which the magnet is sensed called the dwell decreases as the d...

Page 74: ...et Placement Dwell as a Function of Shaft Diameter INSTALL MAGNET AFTER MOUNTING SWITCH Install the overrun magnetic switch as instructed in this section Refer to page 2 82 for instructions on installing the overrun magnet Figure 2 16 Overrun Sensor Magnetic Switch Installation Example 10 Actuating Magnet 5 127 mm diameter 23 of dwell o 10 254 mm diameter 11 of dwell o Crankshaft 5 23o 11o Optimum...

Page 75: ...ring Connections WPC 2000 Main Processor Bd Pin Signal Wire Color 23 24 Vdc Red 24 Overrun input to WPC 2000 White 25 Ground Black USER INPUTS 1 THROUGH 7 NOT SUITABLE FOR SAFETY USE DO NOT use inputs 1 through 7 as part of any personnel protection system These inputs are not control reliable Failure to comply with these instructions will result in death or serious injury USER INPUTS ADD DELAY TO ...

Page 76: ...ct critical safety problems such as the removal of die receptacle blocks E Stop Lockout and Top Stop Lockout stop types not only issue a Stop command and display the appropriate fault code but also simultaneously open the Lockout relay and display the Lockout message on the SmartPAC 2 display To clear the Lockout message turn the Stroke Select switch to OFF and then back to INCH see Wiring the Loc...

Page 77: ...hecked user inputs to your WPC 2000 by purchasing the Option 1 daughter board which you install on the WPC 2000 Main Processor board If you are interested in this product contact your local Wintriss representative or call Wintriss Tech Support To install wire program monitor and troubleshoot the Option 1 board refer to Appendix J You can display the status of all user inputs in SmartPAC Initializa...

Page 78: ... manual for specific wiring schematics Use customized status code wiring see Wiring WPC 2000 User Inputs page 2 31 when the auxiliary equipment that you are connecting does not have its own self explanatory displays as are available in DiPro 1500 or AutoSet load analyzers Installing WPC 2000 Options Wiring the Lockout Relay The Lockout relay which is designed to be wired to critical press function...

Page 79: ...essor board Switch settings are shown in Table 2 9 NON SAFETY OUTPUT USED FOR SAFETY FUNCTIONS Use Auxiliary outputs 1 2 and 3 for non safety functions only such as convenience in automation They cannot protect personnel from a moving hazard Failure to comply with these instructions will result in death or serious injury Table 2 8 Auxiliary Output Wiring Connections and Change Conditions Output Pi...

Page 80: ... Output 2 can be connected to the Setup Mode inputs of DiPro 1500 and AutoSet 1500 1504 Plus The output is used to disable green sensors in DiPro 1500 or repeatability setpoints in AutoSet 1500 1504 Plus whenever the press is switched to Inch mode or an interrupted stroke or fault condition occurs A customer supplied output relay can be wired into this circuit Refer to the applicable manuals for w...

Page 81: ... Single stroke Wiring schematics for all operator mode outputs is provided in Figure 18 at the end of the manual Figure 2 17 WPC 2000 Operator Mode Outputs Wiring Example Pin Pin Designation 121 24 VDC Power 122 Ground 123 ON in Foot Continuous 124 ON in Two hand Continuous 125 ON in Automatic Single stroke 126 ON in Foot Single stroke 127 ON in One hand Single stroke 128 ON in Two hand Single str...

Page 82: ... shown in Table 2 10 and Figure 3 at the end of the manual Refer to page 4 37 for Foot Switch settings UNGUARDED HAZARDS When using a foot switch ensure that light curtains and other safeguards are properly installed and operating to protect operators Failure to comply with these instructions will result in death or serious injury IMPROPER FOOT SWITCH Ensure that any foot control switch complies w...

Page 83: ...e mode used for One hand Control is determined by the setting on option switch 3 see page 4 36 When switch 3 is set to OPEN One hand Control operates in Normal mode When switch 3 is set to CLOSED One hand Control operates in Light Curtain Break mode INSTALL SAFEGUARDS TO PREVENT ACCESS TO HAZARDOUS AREA Follow all applicable OSHA and ANSI regulations for safeguarding your press system Point of ope...

Page 84: ...e 2 19 page 2 41 for mounting dimensions DO NOT MOUNT OPERATOR CONTROL TOO CLOSE TO HAZARD Mount the One hand Control outside the area protected by the light curtain DO NOT mount the One hand Control between the light curtain and the point of operation Failure to comply with these instructions will result in death or serious injury Figure 2 18 One hand Control Switch Mounting Dimensions DANGER ...

Page 85: ...ed to make connections to both the Operator Station and to the WPC 2000 Main Processor board To do so perform the following steps 1 Turn off power to the press and to the WPC 2000 Figure 2 19 One hand Control Switch Base Mounting Dimensions ELECTRIC SHOCK OR HAZARDOUS ENERGY Disconnect main power before installation Remove all power to the press press control and other equipment used with the pres...

Page 86: ...ure wires to fit before cutting then make the appropriate wiring connections referring to Table 2 11 below and Figure 8 at the end of the manual Refer to Figure 2 20 above 6 Fasten the switch cover onto the base with the screws provided 7 Tighten all conduit connections that may have been loosened during installation 8 Close and latch the cover of the Operator Station and WPC 2000 9 Make sure that...

Page 87: ...To install the LMCS do the following 1 Select a mounting location that allows the sensor to detect the magnets as they rotate on the flywheel The magnets should be mounted approximately 180 apart to ensure that the LMCS transitions from Off to On once per revolution 2 Fabricate a bracket to position the LMCS 3 8 in to 1 2 in from the face of the magnets If possible make the bracket adjustable 3 In...

Page 88: ...ion that is convenient to the operator while he is releasing the machine s brake and barring the press Make sure that the operator will not block a light curtain while pressing the Bar control Operate button Refer to Figure 2 22 page 2 45 for mounting dimensions To wire the Bar Control connect the Bar selector switch input to pin 6 on the WPC 2000 Main Processor board and the Bar actuator input to...

Page 89: ... Wiring Connections WPC 2000 Main Processor Bd Pin Bar Control Contacts 16 Bar actuator input 6 Bar selector switch input 24 Vdc e g 37 Common BAR CONTROL OPERATE SELECT OFF ON DATA INSTRUMENTS Wintriss Controls Group 6 23 158 2 7 49 190 2 3 13 79 5 3 24 82 3 4 60 116 8 5 02 127 5 6 70 170 2 0 312 7 9 4 places 2 00 50 8 4 40 111 8 Dimensions inches mm ...

Page 90: ... using this operating mode PRESS STARTING UNEXPECTEDLY Ensure that light curtains and other safeguards are properly installed and operating to protect operators when using Automatic Single stroke Since the external trigger starts the stroke a stroke can occur unexpectedly Ensure that guarding is properly installed to prevent access to the machine over under or around any guarding device Failure to...

Page 91: ... convenient height for all users Ideally the top edge of the unit should be approximately at chin level Experiment to determine a good height for all users before mounting Figure 2 23 SmartPAC 2 Mounting Dimensions Enclosure NOTICE NOTICE Enclosure depth approx 5 5 inches 140 mm However you must allow clearance of approximately 18 inches 460 mm from mounting surface to fully open the enclosure s d...

Page 92: ...ing SmartPAC 2 as a Panel Mount If you have received the panel mount configuration of SmartPAC 2 follow the steps below to install the panel mount in your enclosure The panel mount is usually installed from the outside of the enclosure Be sure to allow at least 6 in 152 mm of clearance behind the panel mounting plane to leave enough room for the electronics 1 Determine a convenient location within...

Page 93: ...1 F2 F3 F4 F5 F6 F7 F8 NOTE SmartPAC and SmartPAC 2 both use the same size cutout 9 5 x 11 inches The top 9 holes are in the same location If you are replacing a SmartPAC with a SmartPAC 2 drill three additional holes at the locations shown for the bottom three holes 10 65 270 5 11 00 279 4 11 30 287 0 12 30 312 4 0 35 8 9 TYP 8 65 105 4 9 00 228 6 10 35 261 6 5 50 139 7 0 35 8 9 TYP Allow 6 inche...

Page 94: ...age 2 4 Both WPC 2000 and SmartPAC 2 are 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 3 Remove the resolver connector TB106 from the WPC 2000 Main Processor board it is already wired to the resolver and connect wiring from the 6 conductor cable to terminals 104 through 110 matching brown wire to brown ...

Page 95: ...wise rotation facing shaft For counterclockwise swap black and yellow wires Figure 2 25 SmartPAC 2 Board Location of Components TB101 RESOLVER S101 TB105 TB106 TB102 TB107 TB104 TB103 AUX I O A B JP101 MASTER SLAVE JP102 SPEED LOW HIGH INPUT CHECK SWITCH 1 1 1 1 1 1 1 ProCam DiPro PACNET SPECIAL MODULE SFI E STOP RELAYS POSITION SENSOR LED TX RX TX RX TX RX TX RX USB PORT LEDS TOP STOP LED POWER L...

Page 96: ...ting AC Wiring Run the AC power wires through a high voltage conduit see Installation Guidelines page 2 3 along with the wiring for Emergency stop Top stop and Input Check circuits No 16 wire No 14 if local codes require it with a minimum 75 C temperature rating is recommended for these circuits Bring the conduit from the top left of WPC 2000 to the top right of SmartPAC 2 Then to wire the AC inpu...

Page 97: ... the press control transformer at the press control For 115 Vac you need three wires high black neutral white and ground green For 230 Vac wires are black and red with green or green yellow for ground 3 Connect the AC input wires and ground wire as shown in Figure 2 26 Make your ground connection as follows SmartPAC 2 Enclosure Connect your ground green or green yellow wire to the set screw termin...

Page 98: ...t the wires for stop and input check circuits to TB102 pin locations as shown in Table 2 17 below and Figure 1 at the end of the manual Plug the connector back into TB102 when you are done 3 Locate connectors TB103 and TB104 on the WPC 2000 Main Processor board see Figure 2 14 page 2 28 and unplug them from their sockets Connect the wires for stop and input check circuits to the appropriate pin nu...

Page 99: ...age 2 51 Figure 2 27 Input Check Switch S101 HOW THE INPUT CHECK CIRCUIT DETECTS RESOLVER CHAIN BREAKAGE When the dual safety valve relay is energized by the press control to start the press voltage is produced in the input check circuit This signals SmartPAC 2 to initiate a stroke at the press If SmartPAC 2 gets no signal from the resolver within the specified start time limit resolver not turnin...

Page 100: ...ations shown in Figure 2 28 page 2 57 If you install a board in the wrong location SmartPAC 2 will not recognize that the option is installed Eight 16 and 32 channel configurations of the same option are interchangeable When a board is installed in the correct location SmartPAC 2 recognizes whether it is an 8 16 or 32 channel version of DiProPAC or an 8 or 16 channel version of ProCamPAC DIPROPAC ...

Page 101: ...chips by touching a large metal object such as the press Static electricity can destroy electronic components Failure to comply with these instructions could result in property damage TB101 S101 60 250 12 60 TB105 TB106 TB102 TB107 TB104 TB103 AUX I O 15V POS SEN GND Z CAM REM RST GND LOCKOUT IN SETUP OP STA 2 OP STA 1 SPARE 1 WPC A B E STOP T STOP JP101 JP102 SPARE 2 SPARE 3 1 1 1 1 1 1 1 PACNET ...

Page 102: ...98 299 300 301 282 283 284 285 286 287 288 289 290 291 180 181 182 183 185 186 187 188 189 184 190 191 192 193 194 195 196 197 198 199 DiProPAC 8 DiProPAC 16 DiProPAC 32 Wiring connector for auxiliary outputs also DiProPAC 16 and 32 Wiring connector for sensor inputs 1 8 also DiProPAC 16 and 32 LEDs for sensor inputs 1 8 also DiProPAC 16 and 32 Wiring connector for sensor inputs 9 16 also DiProPAC...

Page 103: ...k s Terminal block assignments for the different boards are as follows see Figure 2 29 and Figure 2 30 DiProPAC 8 Sensors 1 8 to TB554 upper DiProPAC 16 Sensors 1 8 to TB554 upper sensors 9 16 to TB554 lower DiProPAC 32 Sensors 1 8 to TB554 upper sensors 9 16 to TB554 lower ProCamPAC 8 Cam channels 1 8 to TB401 ProCamPAC 16 Cam channels 1 8 to TB451 channels 9 16 to TB452 10 If you have installed ...

Page 104: ...16 to TB554 lower sensors 17 24 to TB555 upper and sensors 25 32 to TB555 lower ProCamPAC 8 Cam channels 1 8 to TB401 ProCamPAC 16 Cam channels 1 8 to TB451 channels 9 16 to TB452 5 Wire the connector s to the appropriate component s For the DiProPAC board wire the connector s to the DiPro Sensor Interface following the instructions starting on page 2 61 For the ProCamPAC board wire the connector ...

Page 105: ...al for more information DSI 2 NOT COMPATIBLE WITH LOW IMPEDANCE SENSORS If any of your sensors are low impedance types they must be wired directly to DiProPAC Low impedance sensors cannot be wired to DSI 2 Table 2 18 DiPro Sensor Interface DSI 2 to SmartPAC 2 Wiring Sensors 1 8 Wire color 1st DSI 2 TB2 DiProPAC TB554 Pin Pin Designation Pin Pin Designation Brown 1 SENSOR 1 282 SENSOR 1 Red 2 SENSO...

Page 106: ...ection 11 5 VDC No connection Shield Terminate drain wire to ground stud Terminate drain wire to ground stud Your colors may be different Table 2 20 DiPro Sensor Interface DSI 2 to SmartPAC 2 Wiring Sensors 17 24 Wire color 3rd DSI 2 TB2 DiProPAC TB555 Pin Pin Designation Pin Pin Designation Brown 1 SENSOR 1 180 SENSOR 17 Red 2 SENSOR 2 181 SENSOR 18 Orange 3 SENSOR 3 182 SENSOR 19 Yellow 4 SENSOR...

Page 107: ...98 Sensor power Black 9 GND 199 GND 10 GND No connection 11 5 VDC No connection Shield Terminate drain wire to ground stud Terminate drain wire to ground stud Your colors may be different If there are extra wires in the cable cut them off close to the end of the cable jacket PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE Use SmartPAC 2 s programmable cam switch to control auxiliary functions only The ...

Page 108: ...e relays in channel locations 5 8 For example if you plug a solid state relay into channel 5 location K306 you cannot plug a standard relay into location K305 See Figure 2 32 Example Say you wish to use three standard relays and one solid state relay You would install the three standard relays in channels 1 through 3 and the solid state relay in channel 5 skipping the channel 4 output for all wiri...

Page 109: ...s for connecting wires to equipment 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 channels 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...

Page 110: ... Connection to press control Relay 1 K301 Relay 2 K302 Relay 3 K303 Relay 4 K304 Relay 5 K305 Relay 6 K307 K309 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 Connect to loads to be controlled Cam 1 Cam 3 Cam 2 Counter on 200 off 250 o o ...

Page 111: ...dc 4 Tan Ch 8 267 Ch 8 5 Pink Ch 7 266 Ch 7 6 Gray Ch 6 265 Ch 6 7 Blue 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 23 ProCamPAC to Cam Output Assembly TB301 Wiring Cams 9 16 Wire 16 cam ProCamPAC TB452 9 16 Pin 2nd Cam Output Board TB301 Pin CHAS 1 White Relay Pwr 281 A...

Page 112: ...hen you use SmartPAC 2 to turn it on Use the N C terminal only if it is more practical to do the reverse All solid state relays work only when the C and the N O terminals are connected Polarity must be correct for DC solid state relays refer to Table 2 24 Figure 2 33 Connector TB302 and TB303 for Wiring Relays to Equipment Table 2 24 Connections to Relays Module How To Connect Type Relay One wire ...

Page 113: ...load or as close to the load as possible Attach suppressors by connecting leads across existing terminals or junction points b DC loads Install a diode across each DC load such as relays solenoids and PLC inputs see Figure 2 35 Figure 2 34 Installing Suppressors Across an AC Load Figure 2 35 Installing a Diode Across a DC Load RIGHT WRONG ACCEPTABLE not recommended c n o Power in Power Return Supp...

Page 114: ... TB107 for wiring a remote Reset switch Connect a wire from terminal 249 on TB107 on the SmartPAC 2 board to a normally open switch see Figure 2 25 page 2 51 Table 2 25 below and Figure 1 at the end of the manual Connect another wire from the switch to terminal 250 on TB107 SmartPAC 2 and WPC 2000 are reset with a momentary connection to ground Wiring a Sensor Disabled Output Optional You can wire...

Page 115: ... from the press during setup Be sure there is no die or other tooling in the press during setup Failure to comply with these instructions will result in death or serious injury PREVENT DAMAGE TO PRESS AND OR DIE Ensure that no die is mounted in the press during setup procedures Failure to comply with these instructions could result in property damage For help in using the SmartPAC 2 keyboard and d...

Page 116: ...tPAC 2 Main Program Menu If the Program Run key switch is set to RUN when you power up the message PRESS CONTROL IS IN LOCKOUT MODE is displayed on the screen To clear the message turn the Stroke Select key switch to OFF then to one of the other operating modes If another error message displays when SmartPAC 2 starts up press RESET If the error message continues to appear after you press RESET fin...

Page 117: ...one of the following problems occurs at startup perform the accompanying instructions to solve it SmartPAC 2 Display Remains Off If the green Power LED on the SmartPAC 2 front panel does not illuminate Turn off power to SmartPAC 2 and WPC 2000 and recheck all power connections Check to make sure that the connectors at both ends of the cables between the SmartPAC 2 board and the display are correct...

Page 118: ...e right side of the board If both LEDs are blinking SmartPAC 2 and WPC 2000 are communicating Check the Main Initialization Menu again for the presence of the PRESS CONTROL item If PRESS CONTROL is displayed in the menu go to the next applicable section to continue setting up your system If PRESS CONTROL is not displayed contact Wintriss Tech Support If the green Rx6 LED is not blinking power down...

Page 119: ... 2 with WPC 2000 or when you install new WPC 2000 firmware initialize press parameters on the Press Control Parameter Menu see page 4 34 for instructions Figure 2 39 Installed Options Screen INITIALIZE WPC 2000 PARAMETERS BEFORE PROGRAMMING SMARTPAC 2 WPC 2000 When you set up a new SmartPAC 2 with WPC 2000 initialize the WPC 2000 press parameters before you start programming your unit RECORD WPC 2...

Page 120: ...w Tool page 5 3 TOOL NAME or TOOL ID page 5 8 and COUNTERS page 5 9 If you are not familiar with how to use the SmartPAC 2 keyboard and displays see Chapter 3 2 Load the tool number see Loading a Tool page 5 5 and enter Run mode see Entering and Exiting Run Mode page 6 2 To access the Press Control Parameter Menu 1 Turn the Program Run key on the SmartPAC 2 front panel to PROG 2 Press the 1 and CL...

Page 121: ...ng direction and wiring is incorrect Correct resolver wiring by swapping the black and yellow wires at both the WPC 2000 resolver connector TB106 and the SmartPAC 2 resolver connector TB101 referring to Wiring the Resolver page 2 25 4 Inch the press again and observe the crankshaft angle display If the crankshaft angle increases go to the next section If the crankshaft angle decreases contact Wint...

Page 122: ...Keep all personnel away from the press during setup Be sure there is no die or other tooling in the press during setup Failure to comply with these instructions will result in death or serious injury PRESS MUST BE AT TDC WHEN ZEROING RESOLVER Verify that the press is at top dead center i e 0 2 before you zero the resolver If the press is not at TDC your timing settings may be wrong PREVENT INJURY ...

Page 123: ...1 2 and 4 on switch block S101 on the WPC 2000 Main Processor board should be set to OPEN see page 4 35 for instructions When switches 1 and 2 are open you can set any Top stop Angle between 211 and 355 When switch 4 is open the Auto Compensated Top Stop ACTS feature is disabled ACTS compensates for increases in press speed by adjusting the Top stop Angle backward i e decreasing the angle Pin 13 o...

Page 124: ...ure 2 40 page 2 81 11 Repeat step 9 at least two more times and record the angle at which the press top stops in the Trial 2 and Trial 3 boxes in the Overrun Sensor Magnet Installation Worksheet 12 Calculate the average angle at which the press top stops from the three trials and record this value in the box in step 2 in the Overrun Sensor Magnet Installation Worksheet 13 If the average angle read...

Page 125: ...late the average of the three trials and record Avergage angle at which press top stops 3 Does the average angle at which the press top stops occur before or after TDC Calculate the Top stop On Angle as follows a or b a Angle at which press top stops occurs before TDC 181 through 357 b Angle at which press top stops occurs after TDC 3 through 180 360 Top stop Angle Setting Stopping Angle Stopping ...

Page 126: ...orrect angle at which to mount the overrun magnet based on your Top stop On Angle calculations in the previous section Determine the setting for option switches 1 and 2 based on your Top stop On Angle calculations Install the magnet Since the Top stop cam stays on for 20 the magnet must be mounted at an angle at least 20 greater than the Top stop On Angle you calculated and set in the previous pro...

Page 127: ...ld be OPEN for switch 1 and CLOSED for switch 2 3 Set option switches 1 and 2 to the positions you determined in step 2 referring to page 4 35 for instructions 4 If you are using the Auto Compensated Top Stop feature return option switch 4 to its CLOSED setting to enable it see step 1 of the Setting the Top stop On Angle procedure 5 Power down then power back up SmartPAC 2 to enable the new option...

Page 128: ...RESET and run the press again for a few strokes If the press stops and the same error code displays call Wintriss Tech Support If another fault code displays look up the fault in Chapter 7 and follow the suggested remedy After correcting the problem press RESET and run the press again for a few strokes checking for faults If you need assistance contact Wintriss Tech Support 11 Permanently install ...

Page 129: ...direction as the notch on its socket MACHINE MALFUNCTION AFTER INSTALLING REVISED SOFTWARE Perform the final checkout see page 2 87 tests after performing the firmware installation Failure to comply with these instructions could result in death or serious injury ELECTRIC SHOCK OR HAZARDOUS ENERGY Disconnect main power before installation Remove all power to the press press control and other equipm...

Page 130: ...e units up again If WPC 2000 continues to malfunction call Wintriss Tech Support Each new WPC 2000 firmware chip must be installed with the notch facing in the same direction as the chip it is replacing If you use a screwdriver be careful not to insert the screwdriver under the socket or you may damage the board Failure to comply with these instructions could result in property damage CHIP INSTALL...

Page 131: ... other tooling in the press during testing Failure to comply with these instructions will result in death or serious injury INCORRECT INSTALLATION Perform the necessary checkout procedures according to the instructions in this manual Correct any malfunctions before running the press Ensure that all procedures are performed by qualified personnel Failure to comply with these instructions will resul...

Page 132: ...now how to operate the press in Inch Single stroke and Continuous modes using Two hand One hand or Foot control Refer to the instructions starting on page 6 39 if you need help running the press using these settings Many of the tests ask you to check the state of LEDs on the WPC 2000 Main Processor board and status indicators on the screens available from the Display WPC Input Status screen see In...

Page 133: ...ser input 1 G R O U P 3 66 Mute lamp 1 output DSV B contact check 88 Light curtain B 2 input DSV A contact check DSV B drive check Lockout drive check Lockout contact check DSV A drive check G R O U P 5 24 Overrun limit switch 75 Unused input 74 User input 9 73 User input 7 72 User input 5 71 User input 3 70 Remote reset 26 Unused input G R O U P 6 24 VDC Serial port Display bus Receive Transmit T...

Page 134: ... ENCLOSURE WITH POWER ON DO NOT touch electrical connections or circuit boards Use test equipment only on the terminals specified in the instructions Ensure that this test is performed by qualified personnel Failure to comply with these instructions could result in death or serious injury DO NOT USE NON SAFETY INTERLOCK SWITCHES IN SAFETY APPLICATIONS Ensure that all interlock switches used on saf...

Page 135: ...ould stop immediately If the press stops go to the next step If the press does not stop check the wiring of the light curtain and correct any problems Repeat the test If the press still doesn t stop call Wintriss Tech Support 2 Run the press in Inch mode Keeping hands outside the guarded area have someone else open one of the moveable guards just enough to open the interlock switch The press shoul...

Page 136: ... the press is in Inch mode and push both Run Inch buttons Observe what happens If the ram does not move and the SmartPAC 2 display shows F79 or one of the DSV faults the DSV is operating properly Go to the next step If the ram moves and or the SmartPAC 2 display shows a fault other than F79 or one of the DSV faults check the wiring of the DSV and correct any problems then repeat step 6 If the ram ...

Page 137: ...ress top stops repeat this test for every Top Stop button on the press If the press top stops every time go to the next applicable test If the press does not top stop check the wiring of your Top stop circuit correcting any problems and run the test again If the press still does not top stop call Wintriss Tech Support Do not continue with this checkout procedure until the press top stops correctly...

Page 138: ... is still OFF call Wintriss Tech Support 4 Press the Emergency Stop button on the Operator Station 5 Check to see whether fault code F13 appears on the SmartPAC 2 display If F13 displays go to the next step If F13 does not display check to see whether the E stop A input and E stop B input LEDs on the WPC 2000 Main Processor board turn off when the Emergency Stop button is pressed If the two LEDs d...

Page 139: ...erbalance pressure switch is connected to normally F54 for User 4 Input should display If the ram does not move and the appropriate fault code appears restore the counterbalance air press RESET and go to the next step If the ram moves and or the appropriate fault code does not display check the wiring of the counterbalance air pressure switch input and correct any problems Push both Run Inch palm ...

Page 140: ...s Tech Support 3 Remove both hands from the Run Inch buttons 4 Press and hold down both Run Inch buttons to cycle the press through one stroke When the press top stops continue to hold down the right button and remove your hand from the left button then after a moment replace your hand on the left button and continue to hold down both buttons If the press does not initiate the stroke the test has ...

Page 141: ...C 2000 is operating correctly Go to the next applicable test If the press cycles again after making one stroke check the wiring of the Operator Station and correct any problems then repeat the test If the press still cycles after it makes one stroke call Wintriss Tech Support INJURY DURING TESTING Keep all personnel away from the press during testing Be sure there is no die or other tooling in the...

Page 142: ...wer fuse The fuse is located in the Shadow V receiver or in the Shadow VI Shadow VII Shadow 8 or Shadow 9 optional control box The Shadow VII DIN controller has no fuse Rewire power connections and or replace the fuse if necessary Power up again On Shadow V and Shadow VI units if there is still no power turn off the transmitter and try replacing the amber indicator Power up again If there is still...

Page 143: ...ne of these remedies corrects the problem call Wintriss Tech Support 4 Block the light curtain On the receiver the green indicator should turn off and the red indicator should illuminate If the receiver s green indicator goes off and the red indicator comes on go to the next step If the receiver s green indicator stays on when the curtain is blocked check receiver wiring and repeat step 4 If the g...

Page 144: ...step If the ram moves but does not make a complete stroke or does not stop at top dead center and a fault code between F80 and F89 or between H80 and H89 displays there is a problem with the overrun limit switch Try the remedies suggested for overrun limit switch faults starting on page 7 21 then inch the ram to the top of the stroke and repeat this test If the ram still does not make a complete s...

Page 145: ... using one light curtain and the ram stops immediately and the Interrupted Stroke message flashes on the SmartPAC 2 display go to the next step If you are using two light curtains and the ram stops immediately and the Interrupted Stroke messages displays inch the ram to the top of the stroke and repeat the test by interrupting the second light curtain starting with step 6 When you have successfull...

Page 146: ...there is a problem with the overrun limit switch Try the remedies suggested for overrun limit switch faults starting on page 7 21 then inch the ram to the top of the stroke and run the test again starting with step 2 If the ram still does not make a complete stroke or does not stop at top dead center call Wintriss Tech Support If the SmartPAC 2 display shows no error or an error other than an over...

Page 147: ...rupted Stroke message does not display call Wintriss Tech Support 6 Complete the stroke by pressing and holding the Run Inch palm buttons 7 Go to the next applicable test Continuous Mode Test with Light Curtain s IMPROPER SAFEGUARDING Install safeguarding devices as needed to ensure operator safety Follow the machine guarding requirements of OSHA regulation 1910 217 and any other regulations and s...

Page 148: ...e light curtain is obstructed 3 Press the Prior Act button on the Operator Station The Prior Act lamp should illuminate then turn off after eight seconds If the Prior Act lamp turns off after eight seconds go to step 4 If the Prior Act lamp does not turn off after eight seconds stop Do not go any further Call Wintriss Tech Support 4 Press the Prior Act button and before the indicator lamp goes out...

Page 149: ... Interrupted Stroke message displays go to the next step If your WPC 2000 has the muting option and the ram stops as soon as it reaches the non muted i e downward portion of the stroke go to the next step If your WPC 2000 has the muting option and the ram does not stop in the non muted portion of the stroke check the wiring of the light curtain correcting any problems and run the test again starti...

Page 150: ...econds If the Prior Act lamp turns off after eight seconds go to the next step If the Prior Act lamp does not turn off after eight seconds stop Do not go any further Call Wintriss Tech Support 3 Press the Prior Act button and before the indicator lamp goes out press both Run Inch palm buttons releasing them after bottom dead center on the first stroke The press should continue running If the press...

Page 151: ... does not stop at TDC check the wiring of the Operator Station particularly the top stop wiring and correct any problems Rerun this test from step 6 If the ram still does not top stop call Wintriss Tech Support 8 If the die space is safeguarded with doors or gates with interlocking circuits open a door gate and try starting the press The press should not start and an F13 see page 7 8 or F17 or F18...

Page 152: ... OPEN its default setting see Enabling Foot Control in a Foot Switch page 4 37 3 Power down then power back up the WPC 2000 if necessary to enable the settings change The WPC 2000 is now in Foot Trip mode the press stroking each time the Foot Switch is depressed INJURY DURING TESTING Keep all personnel away from the press during testing Be sure there is no die or other tooling in the press during ...

Page 153: ... should complete the stroke stopping at Top stop If the press completes the stroke go to the next step If the press does not complete the stroke check the wiring of the Foot Switch and the setting of switch 3 it should be CLOSED Make any necessary corrections and repeat step 7 If the press still does not stroke call Wintriss Tech Support 8 Press and hold the Foot Switch again but release it before...

Page 154: ...ss Tech Support 13 If you want to repeat testing of the Foot Switch in Continuous mode make sure to press the Prior Act button before attempting to initiate another stroke 14 Go to the next applicable test One hand Control Test This test which should be run only if you have an optional One hand Control verifies that your One hand Control is operating properly To perform the test do the following r...

Page 155: ...rrect check the wiring of the One hand Control the setting of switch 3 it should be OPEN and the selection on the Mode Select Menu ONE HAND should be selected Make any necessary corrections and repeat step 4 If the press still fails to make a complete stroke or input status is still incorrect contact Wintriss Tech Support 5 Set option switch 3 to CLOSED 6 Power down then power back up WPC 2000 to ...

Page 156: ...ating properly To perform the test do the following referring to Input Status page 4 44 for instructions in how to access the Input Status screens 1 On the SmartPAC 2 front panel Make sure the Program Run key switch is set to RUN Turn the Stroke Select key switch of OFF Select TWO HAND on the Mode Select Menu see page 6 40 Turn the Stroke Select key switch to INCH 2 Set the Select switch on the Ba...

Page 157: ...puts go to the next test If the press does not stop and or the appropriate fault code does not display check the wiring of that input referring to Wiring WPC 2000 User Inputs page 2 31 and rerun the test If the press still does not stop and or the correct fault code does not display call Wintriss Tech Support Checking Cam Channels ProCamPAC Only Create some test settings for your cam channels in P...

Page 158: ...3 26 Unused input 70 Remote reset input 25 Ground 69 E stop string input connects internally to 45 24 Overrun limit switch input 68 E stop string center loop connection 23 24 Vdc output 67 E stop string drive output TB102 Top TB102 Bottom 22 Top stop limit switch input 66 Mute lamp 1 output 21 User input 1 65 Palm time lamp output 20 DSV monitor input 64 Prior act lamp output 19 Unused input 63 Pr...

Page 159: ...put 102 DSV B relay input 101 DSV A relay output 100 DSV A relay input 99 Lockout relay output 98 Lockout relay output 97 Lockout relay input Table 2 31 WPC 2000 AC Power Wiring Connections Pin Signal L1 Hi L2 Neutral Ground Table 2 32 SmartPAC 2 SFI Port 1 and Module Port 2 TB103 Wiring Connections Pin Signal Port 235 RXD1 SFI PORT 1 236 RXD1 237 TXD1 238 TXD1 239 TXD1 240 GND 241 RXD2 MODULE POR...

Page 160: ...324 TXD5 323 TXD5 322 RXD5 321 RXD5 Table 2 35 SmartPAC 2 Spare 3 Port 7 and Spare 4 Port 8 TB106 Wiring Connections Pin Signal Port 320 TXD8 SPARE 2 PORT 8 319 TXD8 318 TXD8 317 RXD8 316 RXD8 315 GND 314 TXD7 SPARE 3 PORT 7 313 TXD7 312 TXD7 311 RXD7 310 RXD7 Table 2 36 SmartPAC 2 Aux I O TB107 Wiring Connections Pin Signal 245 15 V 246 POSITION SENSOR 247 GND 248 ZERO 249 REMOTE RESET 250 GND 25...

Page 161: ... the next step This chapter covers the following topics Comparing SmartPAC 2 with Original SmartPAC next section SmartPAC 2 Keyboard page 3 3 SmartPAC 2 Display Layout in Run Mode page 3 13 SmartPAC 2 Operating Modes page 3 15 Screen Capture page 3 23 Figure 3 1 SmartPAC 2 with WPC 2000 Front Panel PRESS 14 TOOL NUMBER 6160 PART CNTR 449 FLANGE B TWO HAND S S PRESS ANGLE 270 CAMBIE AL ESPANOL USE ...

Page 162: ...of display Indicator light on front panel 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 SELECTIONS COUNTERS PRESS ENTER TO CAM SWITCH ACCESS SELECTION BRAKE MONITOR TONNAGE WAVEFORM PROCESS MONITOR FEED CONTROL PM MONITOR TOOL INFORMATION SHUTHGT CNT...

Page 163: ... is also used to clear the Lockout message when it appears on the SmartPAC 2 display see page 7 3 To do so turn the key to the OFF position then back to the operating mode you want Users can be prevented from changing the operating mode by removing the key Figure 3 3 SmartPAC 2 Keyboard Figure 3 4 Stroke Select Key Switch OFF INCH SINGLE STROKE CONT Stroke Select Key Switch CLEAR key Cursor keys H...

Page 164: ...nter information on these entry screens see Cursor Keys page 3 6 The CLEAR key is used to delete entered information see CLEAR Key next To cancel a numeric entry operation press RESET see RESET Key page 3 11 CONTINUOUS MODE USED ON PRESS NOT GUARDED PROPERLY FOR CONTINUOUS Disconnect the Continuous position on the Stroke Select switch to prevent your press from being run in Continuous mode if it i...

Page 165: ...h a prominent crankshaft angle display is useful such as angle adjustment screens for cams and die protection sensors These keys and their functions are summarized in Table 3 1 CLEAR Key The CLEAR key shown in Figure 3 8 is used to delete digits or characters in a SmartPAC 2 entry window see Figure 3 6 and Figure 3 7 You also use the CLEAR key as directed in other procedures such as deleting a too...

Page 166: ...trol the movement of the highlight bar that you use to select items on a SmartPAC 2 screen such as the CAM SWITCH item on the SmartPAC 2 Run Menu shown in Figure 3 10 Pressing the Up or Down cursor key moves the highlight bar up or down the list of items When the highlight bar rests on the item you want to select press ENTER The highlight bar moves one item up or down for each depression of the ap...

Page 167: ...ease the value press the Up cursor to decrease the value press the Down cursor The displayed value increases or decreases one unit for each depression of the appropriate key If you hold the key down the value continues to increase or decrease until you release it Using Cursor Keys to Highlight Letters in Entry Windows You can use Up Down Left and Right cursor keys to move the highlight box from on...

Page 168: ... for a cam channel On and Off crankshaft angles are both 0 as shown in Figure 3 11 The dwell i e the number of degrees during which the channel is On is 0 2 To set the On angle you use the Left and Right cursor keys Press and hold down the Right cursor key to move the On cursor clockwise around the crank angle diagram until you reach 239 The On angle is shown in the window in the center of the cra...

Page 169: ... Down cursor key and hold it down until the Off cursor moving counterclockwise reaches 270 as shown in the window inside the crank angle diagram The channel timing display should look like the one shown in Figure 3 13 If you overshoot the desired Off angle press the Up cursor key to move the Off cursor clockwise Figure 3 12 Cam Channel Timing On 239 Off 0 Figure 3 13 Cam Channel Timing On 239 Off ...

Page 170: ...ng the ENTER key displays the SmartPAC 2 screen for that item You also use the ENTER key for other functions such as to accept a number you have keyed in to start loading settings for a tool etc Figure 3 14 HELP Key Figure 3 15 ENTER Key SELECT HIGHLIGHT ENTER When this manual instructs you to select an item you should highlight the item and press ENTER Cursor arrow keys HELP key HELP ENTER RESET ...

Page 171: ... disappears and you can once again run the press Program Run Key Switch The Program Run key switch shown in Figure 3 17 is used to move between Program and Run modes see SmartPAC 2 Operating Modes page 3 15 When you turn the key switch to PROG SmartPAC 2 enters Program mode When you turn the key switch to RUN SmartPAC 2 enters Run mode Figure 3 16 RESET Key Figure 3 17 Program Run Key Switch RESET...

Page 172: ...u can program function keys as Hot keys to give you quick access to frequently used screens See Hot Keys next for more information Hot Keys Hot keys shown in Figure 3 19 page 3 13 are function keys you program to take you directly to screens you use frequently in Run mode When a function key is programmed as a Hot key a description of the screen to which the key is linked appears in the label to t...

Page 173: ...nd other elements Along the right edge of the display are the eight function keys with descriptive labels shown for active keys If any function keys have been programmed as Hot keys see page 3 12 their labels have a red border You progress from menu to menu in Run mode by use of the ENTER and RESET keys as instructed on the display You navigate in the same way in Initialization and Program modes F...

Page 174: ... to proceed on each display Figure 3 20 SmartPAC 2 Display Run Mode Figure 3 21 Main Run Menu with CAM SWITCH Highlighted PRESS 14 TOOL NUMBER 6160 PART CNTR 51635 FLANGE TWO HAND S S PRESS ANGLE 270 CAMBIE AL ESPANOL USE THE CURSOR KEYS ENABLE SENSORS TO MAKE SELECTIONS COUNTERS PRESS ENTER TO DIE PROTECTION ACCESS SELECTION CAM SWITCH BRAKE MONITOR TONNAGE WAVEFORM PRESS CONTROL FEED CONTROL TOO...

Page 175: ...s more detail about what you can do in each mode instructs you in how to enter and exit the mode and refers you to other sections of the manual To exit any mode be sure you are in the Main menu as shown in Figure 3 22 If you are not in the Main menu press RESET repeatedly until the Main menu appears Initialization Mode Chapter 4 white text on dark blue display settings for the press Program Mode C...

Page 176: ...display From Run mode Turn the Program Run key to PROG _________________________ From Initialization mode Go to the Main Initialization Menu and Press RESET or Turn the Program Run key to RUN and then back to PROG To switch to Run mode Turn the Program Run key to RUN _________________________ To switch to Initialization mode Press the 1 and CLEAR keys simultaneously and hold down a few seconds unt...

Page 177: ... you install a new SmartPAC 2 but you will likely use it only occasionally after SmartPAC 2 is set up and the press is running The Main Initialization Menu is shown in Figure 3 23 Figure 3 24 page 3 18 shows you how to navigate through the SmartPAC 2 menus in Initialization mode See Chapter 4 for detailed instructions on how to use SmartPAC 2 in Initialization mode Figure 3 23 Initialization Mode ...

Page 178: ...F4 COUNTERBALANCE SETUP F5 CUSHION SETUP menu item Function Key PROGRAM ON OFF ANGLES PROGRAM TIMED OUTPUT PROGRAM AUTO ADVANCE PROGRAM DSV ON DELETE CHANNEL SETTINGS POSITION SENSOR MODE RESOLVER MOTION MODE TOOL NUMBER MODE COUNTER SETUP MODE F2 CALIBRATE F3 SHOW CALFACTORS F4 ZERO OFFSETS select input F1 CHANGE PASSWORDS set access privileges ANGLE WHEEL ROTATION UPDATE FIRMWARE RESOLVER COMMUN...

Page 179: ...e or disable sensors The Main Program Menu is shown in Figure 3 25 Figure 3 26 page 3 20 shows you 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 Figure 3 25 Program Mode Main Menu For help with an item on the Main Program Menu press the HELP key when that screen is displayed NOTICE ...

Page 180: ... 1 BATCH 2 BATCH 3 TOTAL HITS F2 SET COUNTER MODES PARTS STROKE STROKES PART AUTO ENABLE COUNTER select sensor F6 VIEW SENSOR SUMMARY SENSOR NAME SENSOR TYPE STOP TYPE READY WINDOW select cam channel F5 VIEW GLOBAL CAM SUMMARY F6 VIEW CAM SUMMARY PROGRAM ON OFF ANGLES PROGRAM TIMED OUTPUT PROGRAM AUTO ADVANCE PROGRAM DSV ON DELETE CHANNEL SETTINGS OPERATING MODE HIGH PERCENTAGE LOW PERCENTAGE REPE...

Page 181: ...ter of the clock diagram When the press is stopped or running in Inch or Single stroke the crankshaft angle is displayed inside the clock If security access settings in Program mode permit you may be able to adjust cam timing and perform other operations in Run mode see CAM SWITCH Optional page 6 18 Figure 3 28 page 3 22 shows you how to navigate through the SmartPAC 2 menus in Run mode See Chapte...

Page 182: ...STATUS F5 VIEW GLOBAL CAM SUMMARY F6 VIEW CAM SUMMARY F7 SHOW CAM TIMING SHOW WAVEFORMS SHOW PLAN VIEW SHOW BARGRAPHS ADJUST SETPOINTS TONNAGE HISTORY RECALCULATE SETPOINTS SHOW REVERSE TONNAGE CURRENT TO STORED WAVEFORM CURRENT TO HELD WAVEFORM HELD TO STORED WAVEFORM CURRENT TO CRITICAL CURVE SET THE PRESS STROKES MIN F2 HIGH SETPOINT F3 LOW SETPOINT F4 REP SETPOINT F5 SAMPLE PERIOD F6 RECALC SE...

Page 183: ...he following 1 On the SmartPAC 2 front panel access the screen you want to capture 2 Press the 8 and 0 zero keys simultaneously for a second or two until the message Capturing Screen in very small letters appears at the top right of the display The captured screen remains in SmartPAC 2 memory until the next screen capture is performed the new screen capture overwriting the old one E Mailing a Scre...

Page 184: ...tialization Menu see Figure 4 1 page 4 1 select DIAGNOSTICS and when the Diagnostics Menu see Figure 4 40 page 4 61 displays select SAVE TO USB DISK The following messages appear in succession PLEASE WAIT WHILE THE DATA IS BEING TRANSFERRED TO THE USB DISK THIS MAY TAKE UP TO ONE MINUTE TO COMPLETE THE USB DISK TRANSFER HAS FINISHED AND WAS SUCCESSFUL PRESS THE RESET KEY AND THEN REMOVE THE USB DI...

Page 185: ... the screens you want to capture 6 Press the 8 and 0 zero keys simultaneously for a second or two until the message USB Capturing Screen in very small letters appears at the top right of the display 7 Repeat steps 5 and 6 for additional screens The number of screens you can capture is limited only by the capacity of your disk 8 When you are finished open the enclosure or console and remove the USB...

Page 186: ...1128600 SmartPAC 2 with WPC 2000 Integration User Manual 3 26 Keyboard Displays Etc ...

Page 187: ...ting communications parameters and other operations The chapter also covers programmable cam and die protection functions such as entering custom cam channel and sensor names and setting global cams If you have SmartPAC 2 options installed you will also make Initialization settings for them Refer to the user manuals for the options you have purchased for instructions INITIALIZE WPC 2000 PARAMETERS...

Page 188: ...Initialization Mode To Exit Initialization Mode 1 Turn Program Run key to PROG 2 Press the 1 and CLEAR keys simultaneously and hold down a few seconds until the Main Initialization Menu appears To switch to Program mode Press RESET ____________________________________ To switch to Run mode Turn the Program Run key to RUN If you turn the key and nothing happens press RESET repeatedly until SmartPAC...

Page 189: ...ro Position procedure Moving the Ram to Top Dead Center TDC If the ram is not at TDC you must first inch the press to 0 2 before you can zero the resolver You must load a tool in order to inch the press To move the ram to TDC do the following 1 With a test tool loaded see Creating and Loading a Test Tool procedure page 2 76 turn the Program Run key to RUN and inch the press to 0 2 Initializing pre...

Page 190: ... shaft by hand either direction is acceptable until the arrow on the shaft is aligned with the keyway see Figure 2 13 page 2 26 indicating a resolver position of 0 Continue to adjust the position of the resolver shaft until the reading in the CURRENT RESOLVER ANGLE field is as close to 0 as you can get it Then tighten the drive mechanism making sure not to change the resolver angle reading 3 Press...

Page 191: ...set on the screen shown in Figure 4 3 The following sections show you how to set each parameter Position Sensor Mode INITIALIZATION POSITION SENSOR To operate SmartPAC 2 with WPC 2000 you must disable the POSITION SENSOR MODE setting To do so follow these instructions 1 With the cursor resting on the POSITION SENSOR MODE field press ENTER until the DISABLED entry displays 2 Press RESET to save you...

Page 192: ...ith the ANGLE WHEEL ROTATION item selected and CW DIRECTION displayed The setting changes to CCW DIRECTION Tool Number Mode INITIALIZATION POSITION SENSOR This item enables you to select which format Numeric or Alphanumeric is used to enter tool numbers in SmartPAC 2 In Numeric mode tool numbers are limited to 7 digits and contain only numbers Alphanumeric tool numbers can contain 20 characters in...

Page 193: ...e tool number mode to Alphanumeric 2 If a tool does not have a tool name go to Program mode and enter a unique name for it 3 If more than one tool has the same name change the duplicate name or names to unique ones When you have completed these changes you can set tool number mode to Alphanumeric Table 4 2 Numeric and Alphanumeric Tool Number Modes Numeric Tool Number Mode Alphanumeric Tool Number...

Page 194: ...here is an Interrupted Stroke 2 When the setting you want is displayed press RESET Counter Increment Mode INITIALIZATION POSITION SENSOR This item which is provided for SFC see Appendix H and LETS see Appendix I customers allows you to specify whether the Good Parts counter increments during a fault condition The default setting NO INC FAULT prevents the counter from incrementing when there is a f...

Page 195: ...u have ordered the alternate language option this screen provides a function key F3 Select Language that allows you to select the language in which SmartPAC 2 screens are displayed When you press F3 the screen shown in Figure 4 5 displays To select a language highlight one of the three items and press RESET You are returned to the Installed Options screen Figure 4 4 Installed Options Screen Your s...

Page 196: ...use the numeric keypad then press ENTER 2 To accept your entry press F6 To cancel your selection press RESET SELECT CAM NAMES Optional INITIALIZATION SET CAM NAMES This item which appears on the Main Initialization Menu only if your SmartPAC 2 is equipped with ProCamPAC allows you to assign descriptive names to each of your cam channels You can name up to 16 channels depending on your SmartPAC 2 c...

Page 197: ...ames the name that best describes the function of the selected cam channel You are returned to the Cam Channel Name Menu with the name you selected displayed to the right of the selected channel To view names that appear below the MORE NAMES line press the Down cursor key A new name appears each time you press the Down cursor When you have cycled through the complete list the highlight bar returns...

Page 198: ...selection press RESET 6 When you are finished naming channels press RESET to return to the Main Initialization Menu AUTO ADVANCE and Slow RPM Optional INITIALIZATION AUTO ADVANCE This item which appears on the Main Initialization Menu only when ProCamPAC is installed enables you to set parameters that control the timing for up to two cam channels that are programmed as Auto Advance You make these ...

Page 199: ...ield on the Auto Advance Menu The Auto Advance Menu allows you to adjust your Auto Advance and Slow RPM settings while the press is running When the press is stroking the press speed in SPM is displayed in the upper right corner of the screen under the caption PRESS SPEED When an Auto Advance cam is turned on the press angle is displayed in the same location under the caption PRESS ANGLE see Figur...

Page 200: ...RPM To set the auto advance constants and slow RPM value do the following 1 Select AUTO ADVANCE on the Main Initialization Menu to access the Auto Advance Menu see Figure 4 9 2 With the highlight bar on ADVANCE CONST 1 press ENTER The Numeric Entry window see Figure 3 6 page 3 4 displays 3 Key in a value maximum is 500 in the Numeric Entry window using the numeric keypad or the Up and Down cursor ...

Page 201: ...OR SAFETY USE Use SmartPAC 2 s programmable cam switch to control auxiliary functions only The SmartPAC 2 programmable cam capability should never be used to provide timing signals for any safety use including clutch brake control or muting of light curtains Failure to comply with these instructions will result in death or serious injury Set as global cams only cam channels that perform identicall...

Page 202: ...ng you want to program for this channel referring to CAM SWITCH Optional page 5 38 for instructions 4 When you have finished programming the global cam press RESET Figure 4 10 Global Cams Menu Asterisk Indicates Global Cams Figure 4 11 Global Cam Timing Type Screen If you set or change global cams while a tool is loaded you must reload the tool to make the global cams take effect F1 F2 F3 F4 F5 F6...

Page 203: ...nsor Names screen displays 2 Select the item for which you want to create a custom name e g CUSTOM 1 CUSTOM 2 etc The Alphabetic Entry window see Figure 4 6 page 4 10 displays 3 Key in the custom name following the directions in the Alphabetic Entry window then press F6 to accept your entry You are returned to the Custom Sensor Names screen with You can use a separate computer keyboard to enter cu...

Page 204: ...ke these settings on the Die Protection Mode Selection Menu see Figure 4 13 Selecting Sensor Enable Mode You can select one of three modes for enabling die protection sensors MANUAL ENABLE When this option is selected sensors are not automatically re enabled after the press is restarted following a setup or other procedure in which the sensors have been temporarily disabled You must enable or disa...

Page 205: ...uring setup You enable Setup mode by selecting one of two settings IN INCH Press operates in Setup mode whenever the Stroke Select switch is set to INCH IN INCH INT STRK Press operates in Setup mode whenever the Stroke Select switch is set to INCH or an Interrupt Stroke occurs To enable Setup mode do the following 1 Select SENSOR ENABLE MODE on the Main Initialization Menu The Die Protection Mode ...

Page 206: ...14 displays 2 Highlight the NAME 1 item and press ENTER The Tool Information Name screen shown in Figure 4 15 displays 3 Move the highlight bar to the name you want using the cursor keys and press ENTER You are returned to the Tool Information Setup screen with the name you selected displayed This feature is not available if you have the optional PLC interface installed Figure 4 14 Tool Informatio...

Page 207: ... Units Selection screen shown in Figure 4 16 displays 7 Move the highlight bar to the abbreviation for the unit you want using the cursor keys and press ENTER See Table 4 3 page 4 22 for an explanation of abbreviations You are returned to the Tool Information Setup screen with your Units selection displayed 8 If you want to specify a unit that is not in the list select the CUSTOM item When the Alp...

Page 208: ...illimeters 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 Table 4 4 Decimal Places and Formats No of Places Example Digits to Left of Decimal Point Digits to Right of Decimal Point Range 0 Whole numbers press speed SPM Up to seven 7 None 0 0 to...

Page 209: ...Figure 4 17 11 When you are finished press RESET to return to the Main Initialization Menu PRESS CONTROL INITIALIZATION PRESS CONTROL The PRESS CONTROL item on the Main Initialization Menu gives you access to the WPC Initialization Menu see Figure 4 18 which allows you to make settings specific to the WPC 2000 clutch brake control Figure 4 17 Tool Information Setup Screen with Sample Entries Figur...

Page 210: ... result in death or serious injury INPUT PAIRS 8 9 AND 10 11 ARE CONTROL RELIABLE ONLY IF WIRED CORRECTLY User input pairs 8 9 and 10 11 are control reliable only if wired correctly in a pair according to the instructions in this section Failure to comply with these instructions will result in death or serious injury USER INPUTS ADD DELAY TO STOPPING TIME DO NOT connect light curtains or other pre...

Page 211: ... or both inputs in a pair are open or the inputs in a pair disagree for longer than 100 msec i e one input is open and the other is closed 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 6 As a help to troubleshooting and installation you can also display the status of t...

Page 212: ... next to the appropriate user input If you want to enter a name that does not appear in the list select CUSTOM NAME and when the Alphabetic Entry window displays see Figure 4 6 page 4 10 key in the name following the directions in the window then press F6 to accept your entry You are returned to the Select Stop Name screen If you are not using the input select UNUSED If you have SmartPAC 2 firmwar...

Page 213: ... you access to the Press Control Parameter Menu see Figure 4 21 on which you can make the following WPC 2000 settings Top stop Angle Auto Carry up Angle Micro inch Time and Angle Main Air Pressure Limit and Counterbalance Air Pressure Offset Stop time Limit Start time Limit Shutdown Time Flywheel Timer ACTS Angle You can also select the units that are used to display pressure on this and other Pre...

Page 214: ...ops at its slowest speed and with the shortest stopping angle time BEFORE YOU SET THE TOP STOP ANGLE MAKE SURE THAT The press ram has been mechanically set to top dead center TDC see NOTICE on page 2 3 The resolver has been aligned as close as possible to TDC i e 0 2 see Mounting the Resolver page 2 25 The resolver has been zeroed see page 2 78 INCORRECT AUTO CARRY UP ANGLE Ensure that the Auto Ca...

Page 215: ...g as the Run Inch palm buttons are depressed When Micro inch is enabled the clutch remains engaged only for the length of time specified in the MICRO TIME setting on the Press Control Parameter Menu unless the operator releases the Run Inch palm buttons before the period has expired You enable Micro inch via the MICRO ANGLE setting on the Press Parameter Control Menu The Micro Angle default settin...

Page 216: ...am mode and counterbalance pressure readings and the Counterbalance Setpoint will not display in Run mode Setting the Stop time Limit This item enables you to set the limit for your press s stopping time The stopping time is the time that it takes the crankshaft to stop once the dual safety valve DSV has been de energized The Brake Monitor checks the stopping time of the press on every top stop an...

Page 217: ...0 of 175 i e 0 20 x 175 35 and add the result to 175 i e 35 175 210 Your calculated Stop time Limit is 210 mS Setting the Start time Limit The starting time of your press is the time it takes for the crankshaft to start turning after the DSV has been energized More specifically it is the interval between the closing turning on of the output relays on the DSV Lockout Relay board which provides the ...

Page 218: ... motor may still be on even though the press is not actually running WPC 2000 uses the Shutdown Time value to turn off the press motor if the DSV is not re energized after the specified length of time An F10 fault code see page 7 7 is displayed on the SmartPAC 2 LCD when the press has been stopped You can set the Shutdown Time to any value between 0 and 100 minutes Setting Flywheel Timer Optional ...

Page 219: ... Press Control Option Switch Menu see page 4 37 for instructions and for additional details about the ACTS feature The ACTS Angle setting allows you to specify the angle at which you want the press to stop In most variable speed applications the ACTS angle should be set to 0 the default value However in top knock out applications the angle might be set after 0 while in some high speed applications...

Page 220: ...ess or Press RESET to cancel the Initialize Parameters process The warning message disappears and you are returned to the Press Control Parameter Menu INITIALIZE WPC 2000 PARAMETERS BEFORE PROGRAMMING SMARTPAC 2 WPC 2000 When you set up a new SmartPAC 2 with WPC 2000 initialize WPC 2000 press parameters before you start programming your unit See page 2 75 RECORD WPC 2000 SETTINGS BEFORE INITIALIZI...

Page 221: ...on the WPC 2000 Main Processor board Switches can be set to OPEN or CLOSED To set one of these items do the following 1 On the Press Control Option Switch Menu move the highlight bar to the setting for the switch you want 2 Press ENTER until the setting you want is displayed 3 Repeat steps 1 and 2 for each switch you want to set 4 Press RESET when you are finished to save your settings and return ...

Page 222: ...er which a One hand Control see Installing a One hand Control page 2 39 is active as shown in Table 4 6 When switch 3 is set to OPEN the One hand Control is continuously active allowing you to initiate a stroke any time you push the One hand Control switch When switch 3 is set to CLOSED the One hand Control is active only during the window within which the operator breaks the light curtain to feed...

Page 223: ... in press speed ACTS is designed specifically for variable speed presses As the speed of the press increases the stopping angle increases pushing the point at which the press actually top stops past 360 or TDC ACTS senses when the press has not stopped at TDC and compensates for this lengthening of the stopping angle by moving the Top stop Angle back an equivalent number of degrees The Top stop An...

Page 224: ... increases to 5 minutes for Automatic Single stroke and 10 minutes for Automatic Continuous On demand Wiring instructions for Automatic Single stroke are provided on page 2 46 operating procedures on page 6 49 For information on wiring and operating Automatic Continuous On demand call Wintriss Tech Support Switch 6 Enabling Dual Light Curtains Switch 6 controls whether WPC 2000 recognizes dual lig...

Page 225: ...nal stroke before it top stops if the error occurs after 210 When switch 8 is set to CLOSED the press top stops on the current stroke if an F or H fault occurs at any angle CHANGES TO SWITCH 8 SETTING AFFECT BOTH SWITCH FUNCTIONS When you change the option switch 8 setting for either the Top stop or Auxiliary Output 1 function the new setting will affect operation of the other function PRESS MAKES...

Page 226: ...HAND ONLY items allow you to make settings that control operator interaction with the WPC 2000 To set one of these items do the following 1 On the Press Control Option Switch Menu move the highlight bar to the operator mode item you want 2 Press ENTER until the setting you want is displayed 3 Repeat steps 1 and 2 for each operator mode you want to set NON SAFETY OUTPUTS USED FOR SAFETY FUNCTIONS U...

Page 227: ...ing you must wire a remote selector switch You can order such a switch from Wintriss part no 4256601 Automatic Mode This item allows you to enable Automatic Single stroke or Automatic Continuous On demand operating mode if you have installed one of these options Refer to page 2 46 for wiring instructions and pages 6 49 and 6 52 for operating procedures There are two options DISABLED Default Automa...

Page 228: ...y when your WPC 2000 has optional Shadow muting firmware which disables the light curtain during the portion of the stroke after the Auto Carry up Angle has been reached see Setting the Auto Carry up Angle page 4 28 When switch 2 is set to OFF its default setting muting of the Auxiliary E Stop Output Relay board is disabled and penetration of the light curtain at any point in the stroke causes a s...

Page 229: ...6 is set to ON and more than two Operator Stations are connected to WPC 2000 palm switches on all connected Operator Stations must be pressed within a 5 second concurrent time window to start the press All Op Stations connected to the B inputs must contain a Two hand Control module to provide the required 1 2 second palm or synchronous time You should only change this switch from its default setti...

Page 230: ...es E stops Top stops interlocks and transducers Input status screens for these items which are displayed when you press the appropriate function key are provided as an aid to installation and troubleshooting When you press F2 Buttons Switches the WPC Buttons and Switches Input Status screen displays see Figure 4 26 page 4 45 Figure 4 25 Display WPC Input Status Screen The LEDs on the WPC 2000 Main...

Page 231: ...lays see Figure 4 27 When you press F4 Interlocks the WPC Interlock Group 1 Input Status screen displays see Figure 4 28 page 4 46 Input Status screens for additional user inputs are available if you have installed the Option 1 daughter board see Appendix J Figure 4 26 WPC Buttons and Switches Input Status Screen Figure 4 27 WPC Estop and Top Stop Input Status Screen ...

Page 232: ...gration User Manual 4 46 Initialization Mode When you press F5 Transducers the WPC Transducer Input Status screen displays see Figure 4 29 Figure 4 28 WPC Interlock Group 1 Input Status Screen Figure 4 29 WPC Transducer Input Status Screen ...

Page 233: ... to change settings only after they have entered a password This access type is the most secure The following items on the Security Access Menu allow you to select other access options see Table 4 15 page 4 48 for a complete list of security access settings CHANGE COUNT and CHG GOOD PRTS CNT These items allow you to specify NO CHANGES ALLOWED which prevents changes to actual counter values for str...

Page 234: ...RAM MODE ONLY PASSWORD REQUIRED NO CHANGES ALLOWED RESET MODE PROGRAM AND RUN MODES PROGRAM MODE ONLY PASSWORD REQUIRED CHG TOOL TEMPLATE 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 T...

Page 235: ... 5 digit number from the bottom of the Enter your password display CHECK YOUR PASSWORDS Make sure to check your passwords before changing any security access settings Record the passwords in a safe place Refer to Changing Passwords page 4 50 DO NOT ENABLE INIT PASSWORD UNTIL YOU HAVE CHECKED YOUR PASSWORDS Field upgraded SmartPAC 2s may have different passwords than those listed in this manual If ...

Page 236: ...With security access set in this way the cams cannot be adjusted without the user entering the correct password Changing Passwords SmartPAC 2 allows you to set up to four different passwords General Password Provides access to all SmartPAC 2 menus and settings unless one or more of the following specific passwords is also required Init Password Provides access to the Main Initialization Menu PM Pa...

Page 237: ...ct the password you want to change The screen shown in Figure 4 33 displays 3 Key in the new password following the instructions in the window and press ENTER You are returned to the Set Passwords Menu DEFAULT PASSWORDS Your SmartPAC 2 comes from the factory with all passwords set to the default password 1234 If you have upgraded your SmartPAC 2 in the field your passwords may be different Figure ...

Page 238: ...B disk inserted in the SmartPAC 2 board You can back up as many as 200 tools per SmartPAC 2 as well as SmartPAC 2 Initialization parameters Instructions for backing up tools to a network drive are provided on the SmartPAC2 com Web site Click on See a Demo then on Backup Setup Online Manual Instructions for backing up tools to a USB disk are provided below Backing Up Tools to a USB Disk The USB dis...

Page 239: ... displays with the message Please wait Checking SmartPAC 2 tools appearing briefly at the top of the screen followed by a message displaying the number of tools that have been programmed on that SmartPAC 2 see Figure 4 34 3 To begin the backup process press the F6 Backup function key The message Please wait appears briefly at the top of the screen and the following message displays near the bottom...

Page 240: ...own in Figure 4 35 page 4 55 If the SmartPAC 2 detects that the USB disk does not have enough free space to store the tool and initialization backup information a message like the following displays There is NOT enough space available on USB Disk Please remove and free up approx nnn nK then try again Press RESET to clear this message The variable nnn n is the number of kilobytes KB of free space r...

Page 241: ... when firmware for Wintriss data collection software is installed allows you to set communications parameters for a Wintriss data collection software product Communications settings are made on the Set Communications Menu which is shown in Figure 4 36 This screen is fully documented starting on page H 7 for SmartPAC 2 users with the SFC firmware option If you have the LETS firmware option refer to...

Page 242: ... network You make these settings on the Network Setup Utility screen which is shown in Figure 4 37 page 4 57 Figure 4 36 Set Communications Menu Your network administrator must connect SmartPAC 2 to your computer network before you can use e mail messaging or the SmartView remote viewing utility For e mail your network must have a valid SMTP mail server If your network requires static IP addresses...

Page 243: ...wing to enable this function 1 Select SETUP NETWORK on the Main Initialization Menu to display the Network Setup Utility screen 2 With the highlight bar on E MAIL FUNCTION press ENTER to toggle the setting to ENABLED 3 Press RESET to return to the Main Initialization Menu If you don t plan to use E mail set the E MAIL FUNCTION item to DISABLED Figure 4 37 Network Setup Utility Screen Consult with ...

Page 244: ... the setting to ENABLED 2 Press RESET to return to the Main Initialization Menu If you don t plan to use SmartView set the SMARTVIEW FUNCTION item to DISABLED SETUP E MAIL INITIALIZATION SETUP NETWORK SETUP E MAIL If you have enabled the SmartPAC 2 E mail function you should use the SETUP E MAIL item on the Network Setup Utility screen to enter E mail settings Settings are made on the Setup E mail...

Page 245: ...ministrator Figure 4 39 Alphanumeric Entry Window with Default Mail Server Displayed Table 4 16 Setup E mail Items Item Description Examples Mail Server The name or IP address of the SMTP mail server on your network server yourcompany com 124 15 62 53 Mail Port The port on the server used for mail Usually 25 25 Use Secure Login Indicates whether a username and password are required to log in to th...

Page 246: ...pe of press i e straight side or gap frame on which SmartPAC 2 is installed This graphic appears in the press information summary on the SmartView Main Page To set the press type do the following 1 With the highlight bar in the PRESS TYPE field press ENTER to toggle between GAP FRAME and STRAIGHT SIDE until the option you want is displayed 2 Press RESET to return to the Main Initialization Menu E ...

Page 247: ...ou are working with Wintriss Tech Support for initial setup or troubleshooting This section documents only the following items COMMUNICATIONS which allows you to run a communications loopback test SET CLOCK which allows you to set SmartPAC 2 s internal clock to local time SAVE TO USB DISK which allows you to save screen captures and other items to a USB disk UPDATE FIRMWARE which allows you to upl...

Page 248: ...r resting on one of the communications ports e g PORT 1 SFI the Transmit and Receive Data screen for that communications port displays see Figure 4 42 You can view communications data in two screen formats combined and split Press ENTER with the F1 key label showing COMBINED TX AND RX to view the combined format Press ENTER with F1 showing SPLIT TX AND RX to view the split format To toggle between...

Page 249: ... you can perform a loopback test To do so you connect or jumper the TXD transmit and RXD receive lines and then press F1 Send Loopback Message to check communications In effect you are receiving the communications data that you are transmitting This test is useful when verifying the accuracy of Transmit and Receive hardware and wiring To perform a loopback test follow these steps 1 Wire loopback j...

Page 250: ... The Numeric Entry window see Figure 3 6 page 3 4 displays 2 Key in a value using the numeric keypad or the Up and Down cursor keys and press ENTER You are returned to the Set the Clock screen with your entry displayed in the date or time segment you selected in step 1 3 Repeat steps 1 and 2 for other date time segments 4 Press RESET when you are done to return to the Diagnostics Menu Figure 4 43 ...

Page 251: ...ICS and when the Diagnostics Menu see Figure 4 40 displays select SAVE TO USB DISK The following messages appear in succession PLEASE WAIT WHILE THE DATA IS BEING TRANSFERRED TO THE USB DISK THIS MAY TAKE UP TO ONE MINUTE TO COMPLETE THE USB DISK TRANSFER HAS FINISHED AND WAS SUCCESSFUL PRESS THE RESET KEY AND THEN REMOVE THE USB DISK DEVICE 3 When the second message appears press RESET to return ...

Page 252: ...bar to the RESOLVER MOTION MODE item and press ENTER to display the LINK MOTION setting 3 Press RESET to return to the Main Initialization menu Turn the Program Run key to RUN and run the press to observe the behavior of the Press Speed value Using a ServoFeed Interface with Link Motion If you have a link motion press and are using a servofeed with a Wintriss Servofeed Interface SFI you can compen...

Page 253: ...he Main Initialization Menu select FEED CONTROL and increase the SETTLING TIME value by 3 mS Then return to Program mode and use Feed Advisor to calculate a new value with this setting see steps 3 and 4 Load the tool number and run the press to observe the feeding again Continue to increase the settling time by 3 mS increments until feeding is complete at the correct time If feeding is completed t...

Page 254: ...by 3 and calculate a new value with this setting see steps 2 and 3 Load the tool number and run the press to observe the feeding again Continue to decrease Press Speed in the Feed Advisor by 3 increments until feeding is complete at the correct time Using a Computer Keyboard to Enter Names When entering the name for your press and custom names for cams and sensors you can use a computer keyboard c...

Page 255: ...sensors press control parameters and other SmartPAC 2 options Once you have programmed and loaded a tool you can switch to Run mode to run that tool on your press refer to Chapter 6 In Run mode you can also make some adjustments to tool settings If you need help using the SmartPAC 2 keyboard to input information on Program mode displays refer to Chapter 3 Entering and Exiting Program Mode Follow t...

Page 256: ...d press the appropriate function key i e F8 Copy Tool F6 Delete Tool F4 Edit Tool or F5 Load Tool To create a new tool press F7 New Tool Table 5 1 Instructions for Entering and Exiting Program Mode To Enter Program Mode To Exit Program Mode From Run mode Turn the Program Run key to PROG _________________________ From Initialization mode Go to the Main Initialization Menu Press RESET or Turn the Pr...

Page 257: ...ions displayed in the applicable window 3 Press ENTER after keying in a numeric tool number or F6 after keying in an alphanumeric tool number The window shown in Figure 5 4 page 5 4 displays Figure 5 2 Tool Manager Screen The Tool Manager screen sorts the tool list based on the setting for TOOL NUMBER MODE in Initialization see page 4 6 If the setting is NUMERIC tools are sorted by tool number If ...

Page 258: ... tool perform the following steps 1 On the Tool Manager screen highlight the tool whose settings you want to copy to the new tool and press F8 Copy Tool The Numeric Entry or Alphanumeric Entry window see Figure 5 3 page 5 3 displays depending on whether you selected Numeric or Alphanumeric tool number mode in Initialization 2 Key in the desired tool number following the directions displayed in the...

Page 259: ... tools Tool template is not used to run the press To copy Tool Template to a new tool do the following 1 On the Tool Manager screen highlight TOOL 9999999 TOOL TEMPLATE and press F8 Copy Tool 2 Perform steps 2 through 5 of the Copying an Existing Tool procedure starting on page 5 4 Loading a Tool PROGRAM GO TO THE TOOL MANAGER select tool F5 LOAD TOOL To load a tool perform the following steps The...

Page 260: ... see SECURITY ACCESS page 4 47 Figure 5 5 Enter Your Password Screen You can also load tool numbers in Run mode if allowed by security access as long as the press is stopped Figure 5 6 Load Tool Warning Window If an error message displays go to Chapter 7 and follow the instructions for correcting the problem If the error is not covered in Chapter 7 or you cannot fix the problem call Wintriss Tech ...

Page 261: ... you want to delete the tool 2 Press the CLEAR key to continue the deletion process A message displays indicating that the tool has been deleted and you are returned to the Tool Manager screen with the deleted tool removed from the tool list If this display appears you need to enter the general password to program the tool Security access is set in Initialization mode see SECURITY ACCESS page 4 47...

Page 262: ...EDIT TOOL TOOL NAME ID Figure 5 9 Tool Program Menu Includes some options Your display may look different For help with screens accessible from the Tool Program Menu press the HELP key with that screen displayed RELOAD CURRENTLY LOADED TOOL IF YOU CHANGE IT 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 th...

Page 263: ... F4 EDIT TOOL COUNTERS This item on the Tool Program Menu allows you to set the counters that maintain counts of press strokes and good parts and initiate various actions when a preset number of strokes has been reached Settings are made via the Counters screen see Figure 5 11 page 5 10 If you have selected alphanumeric tool number mode in Initialization see Tool Number Mode page 4 6 a tool ID is ...

Page 264: ...essage displays in the Status Box in Run mode This counter can be used to indicate when die maintenance is required Batch counters 3 Incremented by the Strokes or Good Parts counter depending on the user programmed setting Each batch counter can be set to initiate one of three actions when the programmed preset is reached Top Stop Toggle and Pulse When a Batch counter is set to TOP STOP SmartPAC 2...

Page 265: ...ESET VALUE column of the counter you want to program The Numeric Entry window see Figure 5 3 page 5 3 displays 3 Key in a preset value following the directions in the window and press ENTER The value you entered displays in the PRESET VALUE field for the counter you selected in step 2 4 Repeat steps 2 and 3 for each counter preset you want to program Changing Count Values Under some circumstances ...

Page 266: ...Total Hits counter does not reset to zero 0 when its preset has been reached you must reset the counter manually To do so perform the following steps 1 On the Counters screen select the setting displayed in the COUNT column for TOTAL HITS 2 Press the CLEAR key The Change Count Confirmation window see Figure 5 13 displays asking you to confirm that you want to change the COUNT value 3 Press the Up ...

Page 267: ...nter you want to program then press ENTER to scroll through the three options i e TOP STOP TOGGLE and PULSE until the setting you want is displayed 3 If you selected PULSE as the output mode in step 2 move the highlight bar to the PULSE TIME MSEC column and press ENTER The Numeric Entry window see Figure 5 3 page 5 3 displays PULSE and TOGGLE settings are available only when ProCamPAC is an instal...

Page 268: ...t increment angles do the following 1 On the Counter Mode Selections screen move the highlight bar to the increment angle value for the counter you want to adjust e g Batch 2 then press ENTER The Numeric Entry window see Figure 5 3 page 5 3 displays 2 Key in a new increment angle value following the directions in the window then press ENTER The value you entered is displayed on the Counter Mode Se...

Page 269: ...r each Batch counter you specify decreasing by that value the number of strokes or good parts required to reach the preset value You can reset these pre load values in Run mode when the Batch preset is reached see COUNTERS page 6 8 as long as you set the CHANGE COUNT parameter on the Security Access Menu in Initialization to PROGRAM AND RUN MODES see SECURITY ACCESS page 4 47 To set batch pre load...

Page 270: ...r sensor settings on the SmartPAC 2 display you need to be familiar with basic sensor terminology Terms that appear on sensor displays are explained below Normally Open Normally Closed A normally open N O sensor actuates signals SmartPAC 2 when the sensor circuit to SmartPAC 2 switches from open to closed to ground N O sensors are either yellow or green see page 5 18 In a normally closed N C senso...

Page 271: ...sends a stop command to the press The type of stop i e top stop emergency stop or smart stop is programmable See Setting Sensor Stop Type page 5 25 Impedance Impedance is a measure of the resistance to the flow of electric current Some die protection controls have inputs for electromechanical sensors that provide different impedances As a rule of thumb use a high impedance input if the part is dir...

Page 272: ...y every designated number of strokes Examples are part ejection stock feed and part transfer SmartPAC 2 stops the press when the green sensor closes to ground Any sensor set to green green quick check or green constant must actuate during the Ready signal Depending on the type of green sensor the Ready signal is set either a little longer or a little shorter than the actuation time The four types ...

Page 273: ...eady Signal Programming for a Green Constant Sensor 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 allowed press stops TDC BDC TDC BDC TDC BDC Sensor ON Sensor never g...

Page 274: ...nues to run However there are still five slugs in the ejection hole If the press makes five more strokes without ejecting a slug ten slugs are now stuck in the hole If this process were to continue it is conceivable that an infinite number of slugs could stack up in the hole without the press stopping Luckily the laws of physics make this scenario unlikely When slugs jam it is usually because the ...

Page 275: ...ATUS Optional page 5 52 and DISABLE ENABLE SENSORS page 6 6 To set the Auto Enable by Tool counter do the following 1 Select DIE PROTECTION on the Tool Program Menu The Die Protection Sensor Menu displays see Figure 5 21 with the AUTO ENABLE COUNTER field shown to the left of the list of sensors If this display appears you need to enter the general password to program die protection settings Secur...

Page 276: ...e of the names displayed or you can select one of the custom names set in Initialization see CUSTOM SENSOR NAMES Optional page 4 17 To name a sensor do the following 1 Select a sensor e g Sensor 1 on the Die Protection Sensor Menu The Sensor Names screen displays 2 Select from the list of names the name that best describes the function of the selected sensor To view names that appear below the MOR...

Page 277: ...to the Auto Enable by Sensor Counter screen see next section Otherwise the Sensor Type screen displays see Setting Sensor Type page 5 24 Setting the Auto Enable by Sensor Counter Value If Sensor Enable Mode is set to AUTO BY SENSOR in Initialization see page 4 18 a screen like the one shown in Figure 5 24 displays after you enter a sensor name Figure 5 23 Custom Sensor Names Screen Figure 5 24 Aut...

Page 278: ...ensor Type screen see next section Setting Sensor Type After you select a sensor name and if AUTO ENABLE BY SENSOR is the Initialization setting specify the Auto Enable stroke count the Sensor Type screen shown in Figure 5 25 displays The name you selected for the sensor is shown at the right of the Status Box beneath the sensor number You can select one of six types of sensor see Sensor Types pag...

Page 279: ... die closes Top Stop SmartPAC 2 stops the press at the top of its stroke after a sensor fault is detected You should use this setting for events that do not threaten the die or that occur between the critical angle and bottom dead center BDC A typical Top Stop application is a sensor that monitors a feed like a roll feed that takes place well into the downstroke Setting this sensor to a Top Stop e...

Page 280: ...al Sensor page 5 29 If you selected EMERGENCY STOP or TOP STOP and the sensor you are programming is a red or yellow sensor you are finished and the Sensor Settings screen displays on which all your programmed sensor settings are shown see Viewing and Changing Sensor Settings page 5 30 Setting the Critical Angle for a Sensor Set to SMART STOP When you program a sensor for a Smart Stop you must als...

Page 281: ...Changing Sensor Settings page 5 30 After you have programmed one or more Smart Stop sensors you can change the critical angle by performing these steps 1 On the Die Protection Sensor Menu select a sensor programmed as Smart Stop The Sensor Settings screen see Figure 5 30 page 5 30 displays 2 Select SMART STOP The Sensor Stop Type screen displays with SMART STOP highlighted 3 Press F5 Set Critical ...

Page 282: ...nal so that it is a little longer than the sensor s actuation time You set the Ready signal for Green Constant sensors so that it is a little shorter than the sensor s actuation time See Understanding Sensor Terminology page 5 16 for more information To set the Ready signal do the following The critical angle can only be set for values between 0 and 184 If you attempt to enter 185 as the critical ...

Page 283: ...ff cursor moves counterclockwise around the display and the Off angle decreases The precise Off angle value is displayed in the window inside the clock display 3 When you have finished setting the Ready On and Ready Off angles press RESET The Sensor Settings screen see Figure 5 30 page 5 30 displays with all your sensor settings shown 4 If you want to change any settings refer to Viewing and Chang...

Page 284: ...nu The highlight bar automatically scrolls down to the next sensor displayed on the menu Viewing and Changing Sensor Settings When you finish making settings for a sensor you are taken to a screen like the one shown in Figure 5 30 which displays all your sensor settings This screen also displays whenever you select a programmed sensor on the Die Protection Sensor Menu To change sensor settings do ...

Page 285: ...he summary do the following 1 On the Die Protection Sensor Menu press F6 View Sensor Summary The Sensor Summary screen shown in Figure 5 31 displays This screen shows the sensor name sensor type stop type and the Ready signal On and Off angles for Green Green Quick Check and Green Constant sensors or the stroke count for Green Special sensors Deleting a Sensor To delete a Die Protection sensor do ...

Page 286: ...k or green constant sensor among sensors 1 16 When programmed as green special sensors sensors 17 32 must use the same stroke count as an already programmed green special sensor among sensors 1 16 When planning the sensors to be assigned to each DiProPAC 32 input make sure to reserve sensor positions 1 16 for green sensors only Also if you are using multiple green sensors for the same function e g...

Page 287: ...am The Sensor Names screen see Figure 5 34 displays 3 Select a function for the sensor Stripper is used as an example in Figure 5 34 The Sensor Type screen see Figure 5 35 page 5 34 displays Figure 5 33 Die Protection Sensor 17 32 Menu Figure 5 34 Sensor Names Screen with Stripper Function Highlighted F1 F2 F3 F4 F5 F6 F7 F8 ...

Page 288: ...ure 5 36 displays 5 Select the stop type you want The Sensor Summary screen displays see Figure 5 37 page 5 35 with the Ready signal On and Off angles shown for each green sensor programmed in the group of sensors 1 16 Sensors are displayed in ascending On angle order Figure 5 35 Sensor Type Screen with GREEN Highlighted Figure 5 36 Sensor Stop Type Screen F1 F2 F3 F4 F5 F6 F7 F8 ...

Page 289: ...stop type and Ready signal On and Off angles you have selected The screen also shows the number of the sensor in the group of sensors 1 16 whose Ready signal is being used as the Ready signal for the sensor you are programming 7 Press RESET to return to the Die Protection Sensor 17 32 Menu Figure 5 37 Sensor Summary Screen Showing Ready Signals for Green Sensors Figure 5 38 Sensor Settings Screen ...

Page 290: ... 20 if necessary 1 Perform steps 1 and 2 of the Programming Sensors 17 32 as Green Green Quick Check or Green Constant procedure page 5 32 The Sensor Names screen see Figure 5 39 displays 2 Select a function for the sensor Slug Detection is used as an example in Figure 5 39 The Sensor Type screen see Figure 5 40 displays 3 Select GREEN SPECIAL from the Sensor Type items Figure 5 39 Sensor Names Sc...

Page 291: ...cial stroke count you want The Sensor Settings screen see Figure 5 42 displays showing the name of the sensor sensor type stop type and stroke count you have selected The screen also shows the number of the sensor in the group of sensors 1 16 whose stroke count is being used as the stroke count for the sensor you are programming 6 Press RESET to return to the Die Protection Sensor 17 32 Menu Figur...

Page 292: ...al page 4 10 PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE Use SmartPAC 2 s programmable cam switch to control auxiliary functions only The SmartPAC 2 programmable cam capability should never be used to provide timing signals for any safety use including clutch brake control or muting of light curtains Failure to comply with these instructions will result in death or serious injury MAXIMUM NUMBER OF ...

Page 293: ... Channel Menu displays 2 Select a cam channel to program The Cam Channel Program Type Menu shown in Figure 5 45 displays DO NOT USE 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 If this display appears you need to enter the general password to program cam settings Security access is set in Initialization mode see SECURIT...

Page 294: ...g the Left and Right cursor keys Refer to Using Cursor Keys to Set Timing page 3 7 if you need help As you press the Left cursor key the On cursor moves counterclockwise around the display and the On angle value decreases When you press the Right cursor key the On cursor moves clockwise around the display and the On angle value increases The precise On angle value is displayed in the window inside...

Page 295: ... 5 2 gives examples of how you might use the extra ON OFFs on an 8 channel ProCamPAC To set more than one on off cycle for a cam channel do the following 1 Make the first On Off setting as instructed in Making an ON OFF Setting page 5 40 Figure 5 47 shows the Cam Channel On Off Program screen set for an On angle of 228 and an Off angle of 259 Note the caption at the upper left of the screen indica...

Page 296: ...creen with a third arc programmed for an On angle of 14 and an Off angle of 44 5 If you want to adjust On Off settings for a previously programmed arc press F7 Select Arc one or more times until the highlighting for that arc turns green then use the cursor keys to change the On and or Off angles 6 Press RESET when you have finished to return to the Cam Channel Program Type Menu A new arc always st...

Page 297: ...do the following 1 Select PROGRAM TIMED OUTPUT on the Cam Channel Program Type Menu The Cam Channel Timed Output Program screen shown in Figure 5 50 page 5 44 displays 2 Set the On angle on the crank angle clock using the Left and Right cursor keys referring to Using Cursor Keys to Set Timing page 3 7 if you need help As you press the Left cursor key the On cursor moves counterclockwise around the...

Page 298: ...than 500 milliseconds is required do the following Program one of the batch counters to a preset of 1 set the Counter Increment Angle to the desired On angle and the Output Mode to PULSE Then program the Pulse Time to the cam On time you want e g 600 mS See Setting Batch Counter Output and Increment Modes page 5 13 You can program up to two Auto Advance output settings in Program mode The first ad...

Page 299: ...n angle on the crank angle clock using the Left and Right cursor keys referring to Using Cursor Keys to Set Timing page 3 7 if you need help As you press the Left cursor key the On cursor moves counterclockwise around the display and the AutoOn angle value decreases When you press the Right cursor key the On cursor moves clockwise around the display and the AutoOn angle value increases The precise...

Page 300: ... OUTPUT FOLLOWS RESOLVER MOTION setting which keeps the cam channel on until resolver rotation falls to 6 SPM To set the DSV delay time do the following 1 Select PROGRAM DSV ON on the Cam Channel Program Type Menu The Cam Channel DSV On Program screen displays 2 Increment or decrement the OFF DELAY TIME value maximum is 254 seconds using the Up or Down cursor key or Select the OUTPUT FOLLOWS RESOL...

Page 301: ...6 View Cam Summary on the Cam Channel Menu The Cam Summary screen shown in Figure 5 54 displays with the name program type and programmed settings shown for each programmed cam channel Global cams are not displayed on this screen see Viewing Global Cams below Viewing Global Cams Global cams which are programmed in Initialization mode see SET GLOBAL CAMS Optional page 4 15 are cam channels that can...

Page 302: ...lowing press control parameters for each tool Top stop angle Maximum and minimum press speed limits Counterbalance setpoint Settings are made on the Press Control Parameters screen which is shown in Figure 5 56 page 5 49 The top stop angle is the crankshaft angle at which the Top stop command is given on your press This value is set by default to the Initialization Top Stop Default setting see Set...

Page 303: ...nce tolerance you set in Initialization see Setting Clutch and Counterbalance Air Pressure Limits page 4 29 to specify the pressure range outside of which an F46 Counterbalance Air Outside Sensor Limits error displays on the SmartPAC 2 LCD This field will not display if the Initialization tolerance value is set to zero 0 To make settings on this screen do the following 1 Select PRESS CONTROL on th...

Page 304: ...he Tool Information screen allows you to enter up to six parameters and up to two lines of memo text The names units of measurement and number of decimal places for the parameters are set in Initialization mode see TOOL INFORMATION page 4 19 If you have installed a keylock switch to prevent changes to WPC 2000 settings the following message is displayed at the bottom of the screen THE PRESS CONTRO...

Page 305: ... 2 and 3 to enter other parameters as necessary 5 To enter text into the memo box press F5 for the first line F6 for the second line When the Alphabetic Entry window Figure 5 10 page 5 9 displays key in your entry following the directions in the window and press F6 The window closes and your entry appears on the first or second line of the memo box Figure 5 58 Tool Information Screen If this displ...

Page 306: ...rm these tasks on the Sensor On Off Status screen which is shown in Figure 5 60 Viewing Sensor Status To view the status of your sensors do the following 1 Select SENSOR ENABLE DISABLE STATUS on the Main Program Menu The Sensor On Off Status screen displays with status settings for sensors 1 through 8 displayed Sensors may have one of three status settings OFF ON or N U Not Used 2 To view sensors ...

Page 307: ...ess F5 If the SENSORS DISABLED message is displayed F5 is labelled Enable All Sensors and pressing F5 enables all the sensors If the SENSORS ENABLED message is displayed F5 is labelled Disable All Sensors and pressing F5 disables all the sensors 2 Press RESET to return to the Main Program Menu Turning a Sensor Off or On To turn a selected sensor Off or On do the following 1 On the Sensor On Off St...

Page 308: ... SmartPAC 2 with WPC 2000 Integration User Manual 5 54 Program Mode If you select a sensor with an Off status in Run mode SmartPAC notifies you with the following message Figure 5 61 Sensor Turned Off Message ...

Page 309: ...gram mode Duplicating these functions allows operators to perform essential tasks in Run mode without giving them access to Program mode Operators can be locked out of Program mode by turning the Program Run key to RUN and then removing the key To prevent unauthorized personnel from changing settings or loading tool numbers you can lock out choices on the Run menu or require a password for access ...

Page 310: ...r before entering Run mode see next section Table 6 1 Instructions for Entering and Exiting Run Mode To Enter Run Mode To Exit Run Mode From Program mode Turn the Program Run key to RUN To switch to Program mode Turn the Program Run key to PROG If you turn the key and nothing happens press RESET repeatedly until SmartPAC 2 changes modes Make sure SmartPAC 2 is in the Main or top menu for the mode ...

Page 311: ... label describing the key s function see Figure 6 3 If you program one or more function keys with dual Hot key assignments you move between the two sets of assignments by selecting the TOGGLE HOT KEYS item on the Main Run Menu see TOGGLE HOT KEYS page 6 39 When the first set of Hot keys is displayed the menu item caption is TOGGLE HOT KEYS 1 Selecting this item displays the second set of Hot keys ...

Page 312: ... To delete a Hot key do the following 1 With the Hot Keys Instruction window see Figure 6 4 displayed press CLEAR then the function key associated with the Hot key you wish to delete Settings Locked or Password Required When a Run mode setting is locked the screen shown in Figure 6 5 page 6 5 displays if the PASSWORD REQUIRED access type has been set for that item on the Security Access Menu in In...

Page 313: ...e Faults Whenever more than one fault occurs in response to a press condition the message for the first fault displays in a window on the Main Run Menu and the label Display All Errors appears to the left of function key F8 To view the multiple errors press F8 A large red message window opens as shown in Figure 6 6 with each fault listed in sequence beneath the caption ALL PENDING ERRORS To close ...

Page 314: ...dow can only be opened on the Main Run Menu Once the window is displayed it carries over to other selected Run mode screens DISABLE ENABLE SENSORS RUN DISABLE ENABLE SENSORS This item allows you to manually enable your sensors when they are disabled or disable your sensors when they are enabled When sensors are enabled the message SENSORS ENABLED is displayed at the left of the Status Box on the M...

Page 315: ...lected for Sensor Enable Mode in Initialization see page 4 18 If either of the Auto Enable options is selected you should refer to Setting the Auto Enable by Tool Counter Value page 5 21 or Setting the Auto Enable by Sensor Counter Value page 5 23 to make the appropriate setting for the tool In order to protect the tool sensors should always be enabled except during setup and troubleshooting when ...

Page 316: ... Initialization to PROGRAM AND RUN MODES see page 4 48 you can reset batch counts to the values you have programmed for batch pre loads see Setting Batch Pre Load Counts page 5 15 When the CHANGE COUNT feature is enabled for Run mode the label RELOAD BATCH COUNTERS displays to the left of the F2 function key see Figure 6 11 page 6 9 and F2 becomes active To reset batch counts to their pre load val...

Page 317: ...al sensors Adjustments are made via the Die Protection Menu see Figure 6 12 page 6 10 which displays when you select DIE PROTECTION You can also view a summary of information for all your sensors and a graphical display of sensor status from this menu Figure 6 11 Counters Screen with Reload Batch Counters Function When the Total Hits counter reaches its preset value a flashing message Total Hits P...

Page 318: ...ge 5 53 the following message displays Figure 6 12 Die Protection Menu Run Mode ARE YOU LOCKED OUT Access to items on the Die Protection Menu may be limited to Program mode or may require a password The security access settings in Initialization mode determine when changes can be made See Table 4 15 page 4 48 Figure 6 13 Sensor Turned Off Message FOR MORE INFORMATION For a detailed description of ...

Page 319: ...eady Off angles more precisely The On Off actuation angles displayed in the Sensor window are not updated on every stroke For green and green quick check sensors SmartPAC 2 displays the earliest On and latest Off angles for the current sequence of press strokes until the F5 Update the Sensor Arc function key is pressed updating the display only when the sensor turns on before the previous earliest...

Page 320: ...wing 1 On the Die Protection Menu select the desired sensor The Ready Signal Programming screen displays 2 Run the press 3 Observe the On and Off angles displayed in the Sensor window and the green actuation arc shown on the crank angle clock Pressing F5 will not properly update sensor actuations when you are using a mechanical sensor which vibrates constantly during the stroke It is better to use...

Page 321: ... Status box 2 Increment or decrement the displayed stroke count value using the Up or Down cursor key until the value you want is shown 3 Press RESET when you are finished to return to the Die Protection Menu Viewing the Sensor Summary RUN DIE PROTECTION F6 VIEW SENSOR SUMMARY You can view a summary of your die protection sensors by pressing F6 View Sensor Summary The screen that displays is ident...

Page 322: ...ed If the sensor block is dark the sensor is actuated If it is white the sensor is not actuated The Sensor Status screen is designed so that you can quickly check the status of all your sensors and correct programming or wiring mistakes When a sensor signals a fault you can use the display to see the status of all your sensors at the stroke angle at which the press stopped Figure 6 15 Sensor Statu...

Page 323: ...isplay if a sensor has been connected to that input by mistake The Sensor Status screen shows any change in the state of an input whether the input is being used or not Adjusting DiProPAC 32 Sensors You access DiProPAC 32 sensors on the SmartPAC 2 Main Run Menu via the DIPROPAC 1 16 and DIPROPAC 17 32 items as shown in Figure 6 16 When you select the DIPROPAC 1 16 item the Die Protection Sensor me...

Page 324: ... a sensor programmed as green green quick check or green constant on the Die Protection Menu for Sensors 17 32 the Run mode Ready Signal Programming screen displays with a message located underneath the status box indicating that you cannot change Ready signal timing for this sensor see Figure 6 18 If you want to change timing you must change the timing for the sensor in the group of sensors 1 16 ...

Page 325: ...ays with a message located at the bottom of the screen indicating that you cannot change the green special stroke count for this sensor see Figure 6 19 If you want to adjust the stroke count you must make this change for the green special sensor in the group of sensors 1 16 whose stroke count is being used for the sensor you are programming Figure 6 19 Green Special Sensor Stroke Count Screen Run ...

Page 326: ...CAMS Optional page 4 15 To adjust cam timings for the loaded tool do the following 1 On the Cam Switch Menu select the channel you want to adjust The Cam Channel Program screen appropriate to the program type of the selected cam channel displays PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE Use SmartPAC 2 s programmable cam switch to control auxiliary functions only The SmartPAC 2 programmable cam ca...

Page 327: ...e 6 21 Cam channels are displayed by number on the Y axis Only eight channels can be displayed at a time so if a 16 channel ProCamPAC is installed you must press ENTER to display channels 9 through 16 The X axis displays the number of degrees of crankshaft rotation from 0 to 360 at which channels turn on and off The timing for each channel is shown as a colored horizontal bar the end points of whi...

Page 328: ...n view a summary of the other cams by pressing F6 View Cam Summary The screen that displays is identical to the Cam Summary screen accessible in Program mode see Viewing the Cam Summary page 5 47 BRAKE MONITOR RUN BRAKE MONITOR This item enables you to view your press s starting and stopping times and stopping angle and perform the 90 stop time test to determine the longest stopping time of the pr...

Page 329: ...it takes more than 360 to stop The stopping angle value helps you when you set up the top stop cam For example if the stopping angle is 100 you would set the top stop cam to turn on at 260 Determining the Stopping Time of Your Press You need to determine the stopping time of your press at Top Stop in order to calculate the Stop time Limit to set in Initialization To do so perform the following ste...

Page 330: ...test 1 Install the heaviest upper die you use on your press Adjust the counterbalance for ram weight if your press has a counterbalance 2 With the Program Run key set to RUN select BRAKE MONITOR on the Main Run Menu The Stop Time Status screen displays 3 Run the press in Continuous mode If the press has a variable speed drive set press speed to the highest value you will normally use 4 Press the U...

Page 331: ...rom the pinch point PRESS MAY NOT STOP BEFORE OPERATOR REACHES PINCH POINT Calculate the safety distance according to the applicable safety regulations the instructions in this chapter and in your light curtain user manual Mount the Shadow light curtain heads at least the safety distance from the nearest pinch point or hazardous area of your press see Figure 6 23 Mount your Two hand Control at lea...

Page 332: ...instructions below Mount your light curtain heads at least the safety distance from the hazardous area If a light curtain is too close to the hazard there may not be enough time for the press to stop before the operator s hand or another object reaches the hazard Mount your Two hand Control if you are using it as a safety device at least the safety distance from the hazardous area If the Two hand ...

Page 333: ...osing velocity The response time of the control Tc is the time it takes for the control to activate the machine s brake In the 90 stop time test used by SmartPAC 2 see page 6 22 the calculated stop time includes both Ts and Tc values Response time Tr for Shadow light curtains is shown in Table 6 2 USE BRAKE MONITOR TO CHECK STOPPING TIME Use a brake monitor in light curtain applications to protect...

Page 334: ...object sensitivity of other Shadow models Based on S and ANSI B11 1 2009 Dpf 3 07 in 78 mm Shadow 8 Up to 42 in 23 mS 1 18 in Up to 85 in 32 mS Up to 128 in 41 mS Up to 171 in 50 mS Up to 202 in 59 mS Shadow 9 Standalone up to 31 5 in 800 mm 8 mS 1 18 in Standalone greater than 31 5 in 800 mm 13 mS Cascaded up to 110 in 2800 mm combined 13 mS Cascaded greater than 110 in 2800 mm combined 18 mS ANS...

Page 335: ...the ANSI formula be sure to perform the calculations in this order 1 Add Ts Tc Tr Tbm first 2 Multiply the result by 63 3 Add this result to Dpf This is Ds If you do no follow this order your safety distance calculation will be incorrect The OSHA Safety Distance Formula OBSERVE THE CORRECT SAFETY DISTANCE Calculate the safety distance carefully according to the instructions below and mount your li...

Page 336: ...mit page 4 31 for further details USE BRAKE MONITOR TO CHECK STOPPING TIME Use a brake monitor in light curtain applications 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 to make sure that the machine s stopping time does not exceed a predetermined limit Failure to comply with these instructions will...

Page 337: ...ch point When using the OSHA formula be sure to do the calculations in this order 1 Add the factors involved in the stopping time Ts first 2 Multiply the result by 63 This is Ds If you do no follow this order your safety distance calculation will be incorrect Adding to Safety Distance for Blanking Windows When using fixed or floating blanking windows with your Shadow 9 light curtain you must add a...

Page 338: ...or turns on and off see Figure 6 25 page 6 32 In addition the current Counterbalance air pressure may be displayed if the Counterbalance Tolerance is set to a value other than zero 0 in Initialization and the Main Air pressure setpoint and current Main Air pressure are shown if the Main Air Limit has been set to a non zero value in Initialization see Figure 6 24 Adjusting Program Settings The top ...

Page 339: ...ization see Setting Clutch and Counterbalance Air Pressure Limits page 4 29 to specify the pressure range outside of which an F46 Counterbalance Air Outside Sensor Limits error displays on the SmartPAC 2 LCD This field does not display if the Initialization tolerance value is set to zero 0 disabling the Counterbalance Setpoint feature To adjust one or more of these settings do the following 1 Sele...

Page 340: ...ing steps 1 On the Press Control Parameters screen press F3 Show Overrun Angles A window like the one shown in Figure 6 25 displays In addition to the Overrun Sensor On and Off angles the window displays the angle at which the Top stop cam turns off The value displayed in the Zeroed Top Stop Off field allows you to verify that the Top stop cam which normally stays on for 20 turns off before the ov...

Page 341: ...NTER INSTALLED If you have ordered Info Center as an installed option the TOOL INFORMATION item will not appear on the Main Run Menu Instead INFO CENTER will be displayed Documentation of the Info Center option is available at www smartpac2 com SmartView InfoCenterSetupHelp htm The Tool Information screen provides a convenient place to record information about the tool It does not control any aspe...

Page 342: ...or events that have occurred at the press or within SmartPAC 2 The Error Event Log is useful as a troubleshooting aid Each time the press is stopped due to a fault the log records the error message which gives the reason for the stop and the stroke count and crankshaft angle at which the stop occurred When a new tool is loaded the log displays the tool number If SmartPAC 2 is connected to a comput...

Page 343: ...wn in Figure 6 28 page 6 36 displays Figure 6 27 Error Event Log 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 LOAD NEW TOOL does not appear on the Main Run Menu if LOAD TOOL has been set to PROGRAM MODE ONLY on the Security Access Menu in Initialization...

Page 344: ...urned to the Main Run Menu with the tool you loaded shown in the Status Box Figure 6 28 Tool Manager Screen ARE YOU LOCKED OUT Loading a new tool number may be limited to Program mode or may require a password The security access settings in Initialization mode determine when changes can be made See Table 4 15 page 4 48 Figure 6 29 Load Tool Warning Window If an error message displays go to Chapte...

Page 345: ...the one shown in Figure 6 30 which lists the recipients you have set up using SmartView 2 Highlight the message recipient using the cursor keys then press F3 Select Recipient The recipient s name displays in the To field at the top of the screen 3 To add other recipients repeat step 2 4 Press F4 Select Message to display a list of messages as shown in Figure 6 31 page 6 38 5 Highlight the message ...

Page 346: ...l Support as your recipient and Error Log Files as your message you can send an e mail to Wintriss Tech Support that includes error logs a list of installed options and other useful information An example is shown in Figure 6 32 Figure 6 31 Messaging Screen List of Messages Figure 6 32 Sample E mail to Wintriss Tech Support F1 F2 F3 F4 F5 F6 F7 F8 ...

Page 347: ...ay be issued by the operator or a safety device or be the result of a fault condition When an Interrupted Stroke occurs the message Interrupted Stroke flashes in the status box at the top of the SmartPAC 2 screen see Figure 3 2 page 3 2 and WPC 2000 automatically switches to Two hand Maintained Single stroke mode To clear the Interrupted Stroke press both Run Inch palm buttons on the Operator Stat...

Page 348: ...ect switch of OFF with SmartPAC 2 in Run mode The Mode Select Menu may display up to five operating mode selections depending on the firmware and hardware options you have installed Two hand One hand Requires Two hand One hand Foot firmware and a Shadow light curtain Foot Requires Two hand One hand Foot firmware and a Shadow light curtain Micro inch Enabled Must also be enabled in SmartPAC 2 Initi...

Page 349: ... be muted on the upstroke if WPC 2000 has the muting option If no light curtain is installed select TWO HAND If you set the switch to ONE HAND WPC 2000 defaults to Two hand mode 4 Turn the Stroke Select key switch to INCH There are four different ways to operate the press in Inch mode Top stop in Inch Top stop Bypass Micro inch Dead Motor Inch IMPROPER SAFEGUARDING Ensure that the machine guarding...

Page 350: ...ess and hold them until the ram again comes to rest at the Top stop position Top stop Bypass Top stop in Inch Disabled Top stop in Inch can be disabled so that the ram continues to cycle without coming to a Top stop as long as the Run Inch buttons on the Operator Station are depressed In this alternative Inch mode called Top stop Bypass the ram stops only when one or both buttons are released Top ...

Page 351: ...nch is a feature that allows you to operate the press in Inch mode for a short time after the main motor is turned off using the energy stored in the flywheel Dead Motor Inch allows the press to be inched in smaller increments than is possible when the press is running and is useful during setup To activate Dead Motor Inch do the following 1 Turn off the press motor 2 Turn the Stroke Select switch...

Page 352: ...e One hand and Foot modes are not available OPERATOR STATION WIRED INCORRECTLY Run all necessary tests to verify that each Operator Station is wired correctly and provides proper anti tie down see page 2 96 and anti repeat see page 2 97 protection Failure to comply with these instructions will result in death or serious injury MORE OPERATORS THAN OPERATOR STATIONS Ensure that there are the same nu...

Page 353: ... employing a Shadow light curtain to guard the point of operation To run the press in this mode do the following 1 With ONE HAND highlighted on the Mode Select Menu initiate a stroke by pressing the left Run Inch palm button then releasing it The ram completes its stroke automatically stopping at Top stop The press is stopped if a system fault is detected or if a light curtain is blocked during th...

Page 354: ...nsure that proper safeguarding devices are installed and working properly Wintriss takes no responsibility if safeguarding devices are not installed or working correctly DO NOT use WPC 2000 or a One hand Control as a safeguarding device Install and operate WPC 2000 and a One hand Control in accordance with OSHA and ANSI regulations Failure to comply with these instructions will result in death or ...

Page 355: ...set for Normal operation Break the light curtain then remove your hand and press the One hand Control button within 8 seconds if option switch 3 is set for Light Curtain Break mode The press will make a complete stroke coming to rest at Top stop If the Interrupted Stroke message flashes on the SmartPAC 2 display press and hold the Run Inch palm buttons on the Operator Station to return the press t...

Page 356: ...2 With FOOT highlighted on the Mode Select Menu depress the Foot Switch to initiate a stroke releasing or holding the pedal depending on the option switch 3 setting Release the Foot Switch if option switch 3 is set for Foot Trip Hold the Foot Switch through the Auto Carry up Angle if option switch 3 is set for Foot Control The ram completes the stroke coming to rest at Top stop INCORRECT INSTALLAT...

Page 357: ...Support To run the press in Automatic Single stroke first install the sensors and other components required for this function then do the following 1 Set option switch 5 on the Press Control Option Switch Menu to OPEN to select 30 seconds as the prior act timing or to CLOSED to select 5 minutes see Switch 5 Prior Act Time for Automatic Stroke Modes page 4 38 2 Select AUTOMATIC on the Mode Select M...

Page 358: ...at step 4 Operating the Press in Continuous Mode To operate the press in Continuous mode do the following 1 Make sure the Program Run key switch is set to RUN 2 Turn the Stroke Select key switch of OFF 3 Select TWO HAND on the Mode Select Menu if you want to run the press in Two hand mode select FOOT if you want to run the press in Foot mode see page 6 40 4 Turn the Stroke Select switch to CONT In...

Page 359: ...ght curtain to guard the point of operation Option switch 3 settings which govern Foot operation in Single stroke see page 6 48 do not apply to Continuous Foot operation To run the press in Continuous Foot mode do the following You must press both Run Inch palm buttons on the Operator Station within 8 seconds after you press the Prior Act button in order to initiate Continuous mode operation Other...

Page 360: ... not start The Prior Act lamp illuminates when you press the Prior Act button and turns off after 8 seconds If the press is Emergency stopped WPC 2000 automatically changes to Two hand Maintained Single stroke mode and the Interrupted Stroke message flashes on the SmartPAC 2 display To clear the Interrupted Stroke message press and hold both Run Inch buttons on the Operator Station to complete the...

Page 361: ... ON 7 When the flywheel stops turning press the Operate button on the Bar Control enclosure 8 Bar the press using a spring loaded bar 9 If an F26 error appears in the display press the Reset Select button to clear it and continue with the barring operation INJURY WHEN USING BAR MODE Keep all personnel away from the press while it is being barred Use a spring loaded turnover bar when you bar the pr...

Page 362: ... provide the required 1 2 second palm time synchronous time in ANSI terminology If you have dual Operator Stations make sure to set the Operator Station Select Switch on the front panel of your WPC 2000 to enable either the first station the second station or both stations HAZARDS EXPOSED BY NON WORKING OPERATOR STATION Safeguard the point of operation exposed by the non working Operator Station w...

Page 363: ...nstructions will result in death or serious injury IMPROPER SAFETY SWITCHING RELAY REPAIR Replace the DSV Lockout Relay board or Auxiliary E stop Relay board see Figure 2 14 page 2 28 before placing the WPC 2000 back into operation after the first occurrence of a fused relay If a relay fuses DO NOT reset the WPC 2000 to restart the machine Remove the WPC 2000 from operation immediately and replace...

Page 364: ...ss the RESET key or Remote Reset Button if installed to clear the message If the problem has been solved you will be able to run the press Otherwise you will get the fault message again If the problem persists contact Wintriss Tech Support Do not attempt to run the press before correcting the problem E MAIL TROUBLESHOOTING INFORMATION TO WINTRISS TECH SUPPORT You can send an e mail containing the ...

Page 365: ...ases to within 10 mS of the Stop time Limit set in SmartPAC 2 Initialization see Setting the Stop time Limit page 4 30 the amber Brake Warning LED will flash Illumination of this LED often means that the brake is wearing and or defective To respond to this error do the following 1 Contact your maintenance crew immediately and have them investigate the condition of the brake 2 If the brake checks o...

Page 366: ...itch to OFF then to INCH to clear the message 4 Run the press several times to determine its Stopping Time and compare this value to the result of your last Stop time tests referring to the procedure starting on page 6 22 5 Determine whether you need to adjust the previous Stop time Limit and make adjustments if necessary PRESS MALFUNCTION Correct or repair any press malfunction or wiring error be...

Page 367: ... faults specifies the processor WPC 2000 has two processors that reported the problem as shown in Table 7 1 PRESS MALFUNCTION Correct or repair any press malfunction or wiring error before restarting the press Failure to comply with these instructions will result in death or serious injury Figure 7 3 WPC 2000 Display Showing Fault Code Table 7 1 Fault Codes Significance of Initial Letter Initial L...

Page 368: ...n the SmartPAC 2 display by doing one of the following To clear F and H faults press the RESET key on the display or a Remote Reset switch if one is installed To clear E faults power down SmartPAC 2 and WPC 2000 then power the units back up All E F and H faults are documented in numerical order in the following sections Resolver Faults Problem The press is running faster than 1000 SPM the resolver...

Page 369: ...ESS MOTOR IS OFF the main motor has been turned off by the operator or as the result of Lockout see page 7 3 This message displays following Lockout only when you have wired the lockout relay to the motor starter as instructed on page 2 34 Remedy 1 Turn the motor back on to reset the fault clearing the Lockout message first see NOTICE below if necessary If the motor won t turn on you may need to r...

Page 370: ...olver moved when the output relays to the Dual Safety Valve DSV were off i e open and the DSV was de energized Remedy Check clutch brake and DSV components for correct operation Correct or repair any malfunction Problem The Emergency Stop button on the WPC 2000 Operator Station has been depressed the E Stop circuit was open after initiation of the stroke or the E Stop relay circuits are not workin...

Page 371: ...ere in different states i e open or closed for longer than 100 mS Remedy Diagnose and correct the condition that the inputs are monitoring see Table 7 2 page 7 15 and reset the connected equipment then press RESET Problem Auxiliary E stop relay did not open properly Remedy Press RESET If the problem persists contact Wintriss Tech Support for assistance or replacement of the relay board F16 F17 F18...

Page 372: ...they should Remedy Check to make sure that the palm buttons are the correct switch type Check and correct the palm switch wiring If the error persists call Wintriss Tech Support Problem The operating mode was changed while the press was running Remedy Make your operating mode selection before running the press Problem The operating mode you selected i e One hand Two hand or Foot is not valid for y...

Page 373: ...s not turning off and on properly while the flywheel is turning Remedy Check the installation and wiring of the flywheel sensor see page 2 43 and make corrections You can disable flywheel speed sensing by setting the Flywheel Timer to 0 zero See page 4 32 for instructions Problem The flywheel turned faster than 6 SPM while the press was in Bar mode creating a potentially unsafe barring condition R...

Page 374: ...Inter processor Failures Problem One of the following processor errors has occurred Remedy Try pressing RESET If error persists contact Wintriss Tech Support F28 F29 F30 through F37 and H38 and H39 F30 Resolver angles for A and B processors disagree by more than 2 F31 No reply to Check Start request received from second processor F33 Incorrect reply to Mode Change message received from second proc...

Page 375: ...Remedy Check your Counterbalance Air Pressure level You may need to adjust the Counterbalance setting see page 4 29 for instructions F41 through F44 F41 Input buffer 1 check incorrect This test checks system air pressure and motor forward inputs and user inputs 1 and 8 F42 Input buffer 2 check incorrect This test checks remote reset motor reverse and bar mode selector inputs F43 Input buffer 3 che...

Page 376: ... errors check to see whether the air pressure is turned off or set too low and correct if necessary If you are using a pressure sensor instead of a pressure switch to monitor Clutch Air Pressure this fault will occur when pin 8 has not been wired to ground see step 5 of the Installing a Clutch Air Pressure Sensor procedure page 2 14 Customized Status Codes Problem A failure has occurred in an auxi...

Page 377: ...r both inputs are open Remedy Diagnose and correct the condition that the inputs are monitoring If the error persists after you reset the unit contact Wintriss Tech Support Problem A failure has occurred in an auxiliary press function wired to WPC 2000 cross checked input pair 8 and 9 see Table 7 2 One or both inputs are open Remedy Diagnose and correct the condition that the inputs are monitoring...

Page 378: ...urtains referring to the appropriate user manual if you have another product If you need additional assistance contact Wintriss Tech Support Problem Two pairs of light curtains are wired to WPC 2000 but only one pair has been enabled on option switch 6 on the Press Control Option Switch Menu Remedy Set option switch 6 for dual light curtains see page 4 38 Problem Light curtain A is obstructed duri...

Page 379: ...plication Emergency stop Circuit Driver Failure Problem The Emergency stop input circuit driver has failed or is about to fail Remedy Check E stop circuit wiring and correct any problems If the error persists after you reset the unit contact Wintriss Tech Support for assistance or replacement of the driver Top stop Circuit Driver Failure Problem The Top stop input circuit driver has failed or is a...

Page 380: ...PC 2000 Main Processor board if light curtain A is generating the fault or check Light curtain B1 input or Light curtain B2 input LEDs if light curtain B is generating the fault see Figure 2 41 page 2 89 If one of the two LEDs is unlit receiver wiring is bad or one of the receiver outputs may be shorted Check the wiring at the receiver and correct if necessary If the wiring is good either the rece...

Page 381: ...fore placing the WPC 2000 back into operation after the first occurrence of a fused relay If a relay fuses DO NOT reset the WPC 2000 to restart the machine Remove the WPC 2000 from operation immediately and replace the DSV Lockout relay board before operating the press again Failure to comply with these instructions will result in death or serious injury F70 DSV relay driver A was not off at start...

Page 382: ...defective Air pressure to the clutch may be low or the clutch may be bad resulting in no movement of the crankshaft and resolver even though the DSV is energized In addition an internal WPC 2000 problem could have occurred Remedy Check the Start time Limit setting and increase if necessary Check the resolver and resolver drive and replace the resolver if necessary Check the clutch and repair if ne...

Page 383: ... that the switch opens and closes only once per stroke referring to Installing the Overrun Sensor Magnet page 2 82 and the LED map on page 2 89 Check to make sure that the switch is installed correctly referring to page 2 29 and that the magnet is installed at the correct angle see page 2 82 Also check to make sure that the magnet is attached using a brass or other non ferrous screw Check the diam...

Page 384: ... switch to provide an adequate signal see Planning Your Overrun Sensor Installation page 2 29 An ideal diameter is 4 in to 6 in If the shaft is larger than this mount the magnet on a shaft with a smaller diameter Check installation of the overrun sensor and magnet and wiring of the overrun sensor referring to Installing the Overrun Limit Switch page 2 29 and Installing the Overrun Sensor Magnet pa...

Page 385: ...ET to clear the message If your part run is complete you need to change tooling material etc before you re start the press F90 through F98 H90 through H98 F90 or H90 Program memory checksum 1 is incorrect F91 or H91 Program memory checksum 2 is incorrect F95 or H95 Angle table memory checksum is incorrect F96 or H96 RAM memory failed memory test F97 or H97 No angle setup is loaded F98 or H98 The o...

Page 386: ...s running brake monitor faults and internal problems with SmartPAC 2 Loss of rotation detected Problem The resolver did not start rotating within the start time limit set in Initialization see page 4 31 or stopped rotating while the press was running SmartPAC 2 knows when the Dual Safety Valve DSV is energized If it sees that the DSV is energized but the resolver is not turning this message appear...

Page 387: ...turned five times indicating that the press was running but SmartPAC 2 received no signal from the input check circuit The input check circuit may not have been connected or wired properly If this message occurs when the press stops the brake may be worn Remedy Check the wiring of the input check circuit and rewire if necessary following the instructions in Connecting Stop Circuits and Input Check...

Page 388: ...riss Tech Support for assistance or replacement of the resolver Stop time exceeded Problem The stopping time of the press has exceeded the limit set in SmartPAC 2 Initialization You should have been pre warned of this condition by the brake warning LED which flashes whenever the stopping time is within 10 milliseconds of the stop time limit This message displays when the stop time limit is not suf...

Page 389: ...he older firmware does not synchronize properly with the information in the new firmware Settings can also be damaged due to an internal SmartPAC 2 malfunction SmartPAC 2 creates a checksum for every tool to check that the tool settings stored in memory are the same as the settings that are loaded with the tool The checksum value calculated when tool settings are stored in memory must be the same ...

Page 390: ...nnections between sensors and the controller Green sensor actuated late Problem A green or green quick check sensor turned on late that is 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 sees the sensor come on within 50 milliseconds after the Ready sign...

Page 391: ... the malfunction the sensor was supposed 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 Problem A green special sensor did not actuate i e there was no contact closure to gr...

Page 392: ...gram mode see PRESS CONTROL page 5 48 Minimum press speed exceeded Problem The press is running at a speed less than the minimum limit programmed for this tool Remedy After clearing the error either run the press at a higher speed or adjust the limit set in Program mode see PRESS CONTROL page 5 48 The resolver position is different from when the unit was turned off Problem This message will only a...

Page 393: ...to help them narrow down probable causes See ERROR EVENT LOG page 6 34 and Sending E mail to Wintriss Technical Support page 6 38 for more information Resetting Ross DM2 DSV Faults If your Ross DM2 DSV faults when air is first applied to the unit one or both poppets may have been jarred into a faulted position during shipment When the poppets are faulted input air can escape through the muffler po...

Page 394: ...an be supplied by the system In this case try resetting the unit with the muffler port obstructed Place your hands or a rag or plastic packaging material over the muffler to restrict the escape of air then actuate the Reset solenoid If the DSV still will not reset check to see if there are restrictions in the air supply line e g restrictive fittings quick disconnect fittings low flow filters or re...

Page 395: ...ed upon for use in any specific application The material is provided with PMA s permission for informational purposes only Refer to the most recent versions of OSHA documents To obtain copies of OSHA regulations write to OSHA s Office of Information and Consumer Affairs 200 Constitution Avenue NW Room N3647 Washington DC 20210 Tel 202 219 8151 fax 202 219 5986 REFER TO CURRENT REVISIONS OF OSHA AN...

Page 396: ... in the point of operation Presence sensing device c 3 i a Refers to the functional requirement of a presence sensing device which prevents and or stops normal stroking of the press OSHA 1910 217 c 3 iii iii A presence sensing point of operation device shall protect the operator as provided in paragraph c 3 i a of this section and shall be interlocked into the control circuit to prevent or stop sl...

Page 397: ...me stopping time increase must be accommodated due to braking system deterioration a percentage factor must be added to the measured time to obtain the factor for use in the equation for determining safety distance A percentage factor of 20 is recommended for presses with new brakes or brakes of good condition For older brakes a 10 factor is recommended Example Measured stopping time 0 190 seconds...

Page 398: ...all their parts auxiliary 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...

Page 399: ...le nationally accepted standards under the designation American National Standards The standards reflect a national consensus of manufacturers consumers scientific technical and professional organizations and governmental agencies Shown below are extracts of standards requirements and explanatory information from ANSI B11 1 2009 and B11 19 2003 for presence sensing devices light curtains and Two h...

Page 400: ...e the total response time of the control system and the time it takes hazardous motion to stop 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 the air valve Tc the response time of the control Tbm the additional time all...

Page 401: ...E8 6 3 2 The device should be located or adjusted so that the device always responds to the intrusion at or prior to the safety distance Ds Also care should be taken when installing the device so that it does not detect false signals from other devices or equipment in the area The presence sensing device cannot protect against a catastrophic failure of the press which causes unintended cycling act...

Page 402: ...ating conditions or which incorporate fixed blanking or floating blanking features shall be designed so that the adjustments or features are capable of supervisory control by the user E8 6 3 10 Typically these adjustments or controls are key operated or located under lockable covers 8 6 3 11 The device shall be provided with a means that visibly indicates when it is functioning properly E8 6 3 11 ...

Page 403: ...ence sensing device to the press control shall conform to the requirements of 6 11 and 8 8 8 6 3 15 The sensitivity of the device to intrusion shall not be adversely affected by changing conditions around the press 8 6 3 16 The effective sensing field of the device shall be located at distance from the nearest point of operation hazard so that individuals cannot reach into the point of operation w...

Page 404: ...ing performance monitor 6 12 NOTE No increase in safety distance is required for fixed blanking applications if the blanked area is entirely occupied by the material or fixtures In some instances the use of blanking does not allow efficient production of certain piece parts Horizontal placement of the sensing field so that it detects that operator s waist area may present a solution In this applic...

Page 405: ... response time or object sensitivity is greater than the value used to calculate the safety distance E8 6 3 18 Examples of ambient light are associated with windows light fixtures skylights bay doors or die lights 8 6 3 19 All areas of entry to the point of operation not protected by the presence sensing device shall be otherwise safeguarded E8 6 3 19 Usually the electro optical presence sensing d...

Page 406: ...presence sensing device should have a minimum object sensitivity stated by the supplier For example an electro optical device may detect an opaque object with a diameter of 32 mm 1 25 anywhere in its sensing field but allow an obstruction with a diameter of 25 mm 1 to pass undetected at certain points in the field The RF radio frequency presence sensing device shall provide means to adjust the sen...

Page 407: ...s light fixtures skylights bay doors or work area lights the response time or object sensitivity should not be adversely affected 8 3 1 8 Components subassemblies or modules of electro optical RF and area scanning presence sensing devices shall conform to the requirements of 6 1 or shall be designed and constructed to meet the safety performance level risk reduction as determined by a risk assessm...

Page 408: ...tical application that this situation can occur with as little as 75 mm 3 depending on the positioning e g height and the minimum object sensitivity of the sensing field and the ability of the individual to lean against the machine frame or guarding It should not be possible to climb on or walk on the machine support structure to avoid detection by the presence sensing device when the sensing fiel...

Page 409: ...sensing field prevents individuals from reaching the hazard s during the hazardous portion of the machine cycle E8 3 2 3 The safety distance calculation is dependent upon the speed of approach of the individual total response time of the safeguarding device as stated by the supplier response time of the interface response time of the control system time it takes the machine to stop hazardous motio...

Page 410: ...control system and shall require that the device or machine control be manually reset before hazardous situation can occur The operator should ensure that no individual is in the safeguarded area before re setting the presence sensing device or machine control and initiating a hazardous situation The reset function and devices shall comply with 6 5 8 3 2 5 Indication that the sensing field is bein...

Page 411: ...ies or modules of the interface or machine control system shall conform to the requirements of 6 1 or shall be designed and constructed to meet the safety performance level risk reduction as determined by a risk assessment E8 3 2 6 See also clause 5 and ANSI B11 0 B11 TR3 8 3 2 7 Bypassing of the presence sensing device shall comply with 6 6 8 3 2 8 Muting of the presence sensing device shall comp...

Page 412: ...ice is horizontally mounted the detection area or zone should be visibly marked on the floor This verification can be accomplished by using a programming device or by physically identifying the perimeter of the detection area with an appropriate test rod following the supplier s recommendation This verification is to ensure that a pre programmed area scanning presence sensing device with a small o...

Page 413: ...t the Operator Station meets the requirements of all applicable safety regulations Ensure that the Operator Station is wired correctly Ensure that on any non Wintriss Operator Station the Run buttons are placed so that two hands are required to push them at the same time and that buttons cannot be pushed simultaneously with one hand or with one hand and one elbow Ensure that on any non Wintriss Op...

Page 414: ...han Two Operator Stations page 4 43 Table B 2 Specifications for Operator Station Switches Switch Specifications Run NEMA 12 or 13 UL rated 1 NC 1 N0 single contact block with transfer style contacts One contact bar moves from N C contacts to the N O contacts to ensure that the N C and N O contacts cannot be closed simultaneously Allen Bradley AB S 800T D1JA Square D 9001KR25GH13 or equivalent Mus...

Page 415: ... the same way all the time However with just in time manufacturing shorter job runs and more tool changes presses and auxiliary equipment must frequently change the way that they operate Each change results in varying degrees of wear and tear on the machinery As a result traditional PM programs are not the most effective way to handle these kinds of variations Here is an example A traditional PM p...

Page 416: ...til 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 Some examples to help you properly set up your PM monitor are pro...

Page 417: ...or For New Systems from the Factory If you purchased a SmartPAC 2 system with the PM Monitor pre installed at the factory you can proceed directly to the section Using the PM Monitor in Initialization mode For Existing Systems If you ordered the PM Monitor options separately in other words if you already had a SmartPAC 2 and you were just adding the PM option you must first physically upgrade your...

Page 418: ...efore you can use it see page C 6 SELECT HIGHLIGHT ENTER When this manual says SELECT it means highlight the item and press ENTER Before changing modes make sure your screen shows the first display in the mode you are in If that display is not shown nothing will happen when you turn the Program Run key In that case keep pressing the RESET key When the first display in the mode is reached SmartPAC ...

Page 419: ...is will take you immediately to the PM Entry screen 2 As we mentioned above you do not need to initialize your PM Monitor option as it has already been done at the factory However it is advisable for you to change your password from the default 1234 to a different number for security reasons 3 To do this press F6 which is labeled Init It is at this screen Initialize PM see Figure C 5 where you can...

Page 420: ... the password screen and call the factory at the telephone number on the cover of this manual Because you have an upgraded system the password may not be 1234 You should already have installed the firmware upgrade If not go back to the section Installing the PM Monitor before proceeding further The password prompt will appear EVERY time that you select PM Monitor from the Initialization mode Figur...

Page 421: ... initialize the PM Monitor To initialize select Clear PM Info Notice that you can also change your password at this screen To change your password refer to the next section Assigning a New PM Password Number Figure C 4 PM Entry Screen Figure C 5 Initialize PM Screen 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 I...

Page 422: ...Initialization menu see Chapter 4 1 Go to the PM Entry screen Figure C 4 Press F6 Init 2 You will see the Initialize PM screen Figure C 5 Select Change Password 3 As the screen indicates enter a new password up to 4 digits numeric only Use the numeric keypad or the up down cursor keys Then press Enter 4 Make sure that you record this number and keep it in a place where you can find it Without it y...

Page 423: ...t find a suitable name but you still want to name the item you can select Custom Name by highlighting it and pressing Enter 5 As the screen suggests see the next illustration certain keys enable you to custom name the item The name you select can be any combination of alphanumeric characters Figure C 7 PM Monitor Screen Figure C 8 List of Available PM Names Screen ITEM ALERT EVERY USE THE CURSOR K...

Page 424: ... have named the item you are prompted to set the PM monitor tracking units You can select a time based measure such as run hours days weeks months or you can select measures linked to the process such as strokes die changes or programmable cam channel cycles Select the most applicable tracking unit of measure Figure C 9 Alphanumeric Display Superimposed over PM Names Screen Figure C 10 Tracking Un...

Page 425: ...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 You made all the required settings in the Initialization mode Figure C 11 Superimposed Number Display Figure C 12 Programmed PM Item Example ENTER A MAINTENANCE FREQUENCY FOR AIR ROTARY SEALS USE THE KEYPAD TO ENTER NUMBERS USE THE UP DOWN CURSOR KEYS TO INCR...

Page 426: ...wn below is the first display you see in Run mode From this display you can access the PM Monitor selection Before changing modes make sure your screen shows the first display in the mode you are in If that display is not shown nothing will happen when you turn the Program Run key In that case keep pressing the RESET key When the first display in the mode is reached you will instantly switch to th...

Page 427: ...limits set in Initialization Figure C 14 Run Mode Screen Showing PM Monitor in Normal Status Mode You may notice that some of the current values do not update on every stroke while the press is running SmartPAC is keeping track of these items but does not refresh the display until the press actually stops USE CURSOR KEYS TO CHANGE SELECTION PRESS ENTER TO SELECT RESET WHEN DONE CLUTCH VALVE ALERT ...

Page 428: ...ey and enter the PM password The number display will be superimposed over the screen similar to Figure C 9 Use the number keys or cursor keys to modify the tracking frequency for that PM item 7 Once you are done viewing or modifying this screen press RESET to return to the main Run menu Figure C 15 Run Mode Screen Showing Slide Adjust Motor in Alert Mode When you clear the alert condition for a ce...

Page 429: ...ou select this option you pay for shipping and the cost of the USB disk You also have to wait for delivery of the order Follow the instructions in Installing Updated Firmware from USB Disk to SmartPAC 2 on the next page if you choose this method Firmware is available via an e mail with a link to the Wintriss download site You download a compressed file containing the firmware then copy the firmwar...

Page 430: ...refix SP2 for SmartPAC 2 followed by a numeric code i e SP2nnnnnnnn The numeric code is the serial number of your SmartPAC 2 unit If you elect to download SmartPAC 2 firmware from Wintriss you must have A PC with a USB port and one of the following Windows operating systems Windows 2000 Windows XP and Windows 7 A USB disk with at least 4 MB of available space If you downloaded your firmware from W...

Page 431: ...USB port double click on My Computer and open the USB disk usually identified by the label Removable Disk with a drive letter next to it If you downloaded your firmware from Wintriss the serial number is the name of the compressed file you downloaded Figure D 1 Firmware Load Menu with XFER FROM USB DISK Highlighted ELECTRIC SHOCK HAZARD Ensure that the power source is off before you replace electr...

Page 432: ...D 1 and press ENTER After a few seconds the message USB DISK TRANSFER COMPLETE displays briefly then the Firmware Load Menu appears again as shown in Figure D 2 DAMAGE TO BOARD FROM STATIC DISCHARGE Ground yourself before touching circuit boards or chips by touching a large metal object such as the press Static electricity can destroy electronic components Failure to comply with these instructions...

Page 433: ... minutes for the firmware to load If the USB disk does not contain the correct folder for this SmartPAC 2 serial number you will first see a message at the bottom of the screen that says SP2nnnnnnnn DIRECTORY NOT FOUND and then a red window with the message THERE WAS NO RESPONSE TO THE USB DISK FILE TRANSFER REQUEST If these messages display re check the serial numbers of the SmartPAC 2 and the Sm...

Page 434: ... to load SmartPAC 2 firmware reload the tool and enter the counts for your job in progress from Table D 1 page D2 as follows a Enter Run mode and select COUNTERS b Enter the count values from Table D 1 for each line in the display c When you are finished you can continue running the job that was in progress Figure D 4 SmartPAC 2 Display with Loading Firmware Message If power is lost to SmartPAC 2 ...

Page 435: ...he icon displays the WinZip logo and the file name SP2nnnnnnnn and double click on it to launch the WinZip Self Extractor utility 7 When the WinZip Self Extractor window displays select the folder to which you want the contents of the unzipped file saved the default is C WintrissUpdates and click on Unzip 8 Click on OK in the window displaying the message that the file has been unzipped successful...

Page 436: ...a message saying New hardware has been found Follow the on screen instructions to find and install the proper drivers for your USB disk For assistance contact your information technology staff 11 With both the SP2nnnnnnnn folder and the USB Removable Disk icon visible in My Computer windows copy the SP2nnnnnnnn folder to the USB disk 12 Stop the USB disk using the Unplug or Eject Hardware utility ...

Page 437: ...0 MAKE SURE TO SPECIFY YOUR SMARTPAC 2 SERIAL NUMBER When you order a replacement Compact Flash CF card make sure to include the serial number of your SmartPAC 2 Wintriss needs the serial number to create the correct firmware for your SmartPAC 2 The serial number is located on the top mounting flange of the SmartPAC 2 enclosure and on the Boot Loader chip U124 on the SmartPAC 2 board see Figure 2 ...

Page 438: ... TO REPROGRAM THE SMARTPAC 2 RTS UNIT see Figure D 6 5 Press ENTER to continue The message PLEASE WAIT WHILE THE FIRMWARE MEMORY IS BEING ERASED displays briefly followed by a display like the one shown in Figure D 7 page D 11 indicating that the firmware is being loaded It takes about five minutes for the firmware to load Figure D 5 Firmware Load Menu with RELOAD CURRENT FIRMWARE Highlighted Figu...

Page 439: ...alization Menu and select INSTALLED OPTIONS to verify that all the options in your SmartPAC 2 configuration have been installed Figure D 7 SmartPAC 2 Display with Loading Firmware Message If power is lost to SmartPAC 2 during installation of the firmware SmartPAC 2 will default to the Firmware Load Menu display when the unit is powered back up Repeat steps 4 and 5 to install the firmware again If ...

Page 440: ...1128600 SmartPAC 2 with WPC 2000 Integration User Manual D 12 Updating SmartPAC 2 Firmware ...

Page 441: ...PAC 2 on your network SmartView s email facility enables press operators to send diagnostic information screen captures or custom text messages to Wintriss Technical Support or to any device capable of receiving an email based text message including computers cell phones pagers and PDAs The SmartPAC 2 Error Event Log can be sent to Wintriss Tech Support or any other recipient aiding in troubleshoo...

Page 442: ... the 1 and CLEAR keys simultaneously for a few seconds until the Main Initialization Menu displays see Figure 4 1 page 4 1 2 Select SETUP NETWORK to access the Network Setup Utility screen see Figure 4 37 page 4 57 3 Make sure that the E mail and SmartView functions are both enabled If they aren t press ENTER to toggle the appropriate entry from DISABLED to ENABLED 4 Make sure that the Press Type ...

Page 443: ... need to track or be notified of undeliverable e mails If you are unsure of what to enter contact your IT department 8 Email From Name You will probably want to enter the name of the press in this field e g Press yourcompany com although you can enter any name Depending on how your company s SMTP server software is configured and what rules are in place you may have to experiment with different na...

Page 444: ...ccess the PS 2 J120 or USB J117 connector on the SmartPAC 2 board see Figure 2 25 page 2 51 for location and plug in your mouse 3 Power up the SmartPAC 2 Once the unit has finished booting up you should see a mouse pointer on your display and be able to move it around 4 Turn the PROG RUN key switch to PROG 5 Access the Main Initialization Menu and select SETUP NETWORK 6 On the Network Setup Utilit...

Page 445: ...t the SmartPAC 2 and save your new network settings 16 To test these changes try launching SmartView and viewing the press Also go to the Setup Page in SmartView see page E 10 and see if the IP address you entered is displayed If you do not have network connectivity you may need to repeat the preceding steps to make changes and or have your settings saved Changing Computer Name and Member Settings...

Page 446: ...r PC must meet the following requirements Microsoft Internet Explorer version 5 5 or higher Client must have administrative privileges If a firewall is used SmartPAC 2 must be a trusted site Checking Explorer Settings 1 Open Microsoft Internet Explorer 2 At the top of the Explorer window click on the Tools drop down menu and select Internet Options see Figure E 1 SmartPAC 2 is configured at the fa...

Page 447: ... following security browser settings are configured Download signed ActiveX controls Prompt Run ActiveX controls and plug ins Enable Script ActiveX controls marked safe for scripting Enable Active scripting Enable 6 When all settings are verified click on the OK button on the Security Settings screen then click on OK on the Internet Options screen Figure E 2 Internet Options Screen Figure E 3 Secu...

Page 448: ...rtView for the first time the SmartView introductory page see Figure E 4 will display Otherwise you will be taken directly to the SmartView Setup Page see Figure E 5 2 Click on the Go to the SmartView Setup Page on the SmartView introductory page if necessary to access the SmartView Setup Page see Figure E 5 3 Click in the Network Name window and type Demo1 as shown in Figure E 5 Figure E 4 SmartV...

Page 449: ...so type network and press names directly into the large window Additional Demo Press simulations are available To add these simulations repeat steps 3 through 5 but instead of using Demo1 type Demo2 etc in the Network Name field You can enter names with up to two digits e g Demo Press 35 in the Press Name window These Demos are for testing and demonstration purposes Figure E 6 Mabry Winsock Active...

Page 450: ...or static IP address 3 Enter in Press Name window a name for your press using up to 25 characters e g Press 8 Press 9 etc 4 Click on the Add button Your entries are displayed in the large window beneath the Network Name and Press Name windows 5 Enter a user name if you have not already done so 6 Click on the Submit Changes button SmartView will check for networked units and indicate if a connectio...

Page 451: ...ion of job Number of parts required Number of parts made Percent of job complete The color of the press graphic at the right of each press summary indicates the press s current state Green Press is running Red Press is stopped Grey Press is offline i e power is off or there is no network connection When a press is offline the message Off Line displays next to the press graphic The Refresh button a...

Page 452: ...s made Percent of job complete Current job running time Estimated hours to job completion Current press tonnage Tonnage as a percent of press capacity The Update button at the top of the page allows you to view the most current detail information You can view the Error Event Log or Installed Options screen by clicking on the Error Log or Installed Options link at the top of the page To return to t...

Page 453: ... if the transmission was successful Your message will display as a post it note on the SmartPAC 2 to which you have directed it see Figure E 10 page E 14 Once the message is read it can be cleared by going to the Error Event Log click on the Error Log link and pressing the F4 key The Error Event log maintains the status of all messages i e Sent or Cleared by date and time Figure E 9 Press Status I...

Page 454: ...ay in the two large windows on the screen A status box displays to inform you that the data has been received and is ready to change 2 To add an email name address entry click in the Name window and type the person s name then click in the Email Address window and type his or her E mail address Click on the Add button Your entries are displayed in the large window beneath the Name and E mail Addre...

Page 455: ...p entry For example to copy the same email list to multiple email enabled SmartPAC2s just left click and drag your mouse over the entire email recipient list on one SmartPAC2 and paste Control V it into the Email Setup Page on another SmartPAC2 SmartView Ping Utility The Ping utility is an administrator s tool that is used to check whether a SmartPAC 2 is connected to the network and communicating...

Page 456: ...download To Ping your SmartPAC2 from SmartView follow these steps 1 Make sure your SmartPAC 2 is turned on and the network cable is plugged into the Ethernet connector J122 2 On the SmartView Setup Page click on the Ping Utility link The Ping Utility window shown in Figure E 13 displays 3 Click on the Net Name or IP Addr ess window and enter the SmartPAC 2 serial number i e SPAC2 nnnnnnnn where nn...

Page 457: ... entered on the target device is not present on the network The message The current connection has timed out is typical of what you might find if the SmartPAC 2 is turned off or the physical network connection is faulty e g the RJ45 connector is not plugged in or seated correctly or the Cat 5 cable between the SmartPAC 2 and the Hub is cut or defective You can determine the source of the problem m...

Page 458: ...00 Integration User Manual E 18 SmartView If you continue to get results like those shown in Figure E 15 you may want to contact your IT department 5 To clear the message s from the Ping Utility Window click on the Clear List button ...

Page 459: ... page F 12 SmartPAC Initialization settings cannot be restored to SmartPAC 2 Initialization settings should be copied to a paper form see the SmartPAC Initialization Setup Sheet at the back of the manual then after tool settings have been restored entered manually one by one into SmartPAC 2 referring to the settings on the form ADDING PM MONITOR If you had an AutoSetPAC module on your original Sma...

Page 460: ...is provided with the SBR software Backing Up Tools to a Network Server To back up tools on your SmartPAC 1 to a network server perform the following steps 1 With the Main Program Menu displayed on the SmartPAC 1 front panel press the 1 and CLEAR keys at the same time and hold them down for a few seconds until the Main Initialization Menu displays 2 Select the BACKUP RESTORE menu item to display th...

Page 461: ...C 1 5 Remove the DiProPAC and ProCamPAC boards from the SmartPAC 1 board if they are installed and are to be reused 6 Remove the SmartPAC 1 from your press and place it in a safe location 7 Determine how you will mount your new SmartPAC 2 One convenient way to easily remember pinouts and wire colors is to snip wires about 1 2 in from their connectors leaving a colored wire stub in each pin locatio...

Page 462: ...on sensor if used DiProPAC ProCamPAC WPC port integration only Remote dual op station select optional remote switch WPC adjustment lockout switch optional Remote reset optional AutoSetPAC WaveFormPAC 2 or 4 channel optional SFI optional MultiPAC special port optional Follow the instructions below to transfer the wiring from your old SmartPAC to SmartPAC 2 If the SmartPAC 1 you are replacing is int...

Page 463: ... locations Re cut and strip wires where necessary 5 Make the appropriate wiring connections between DiProPAC and ProCamPAC boards if installed see step 3 and DSI 2 and the Cam Output assembly See Figures 9 10 and 11 at the back of the manual 6 If you plan to network your SmartPAC 2 run Cat 5 cable with an RJ 45 connector into the enclosure 7 Check your work making sure that all wiring is correct t...

Page 464: ... Pin Number Connector Pin Number Done L1 TB101 201 AC Input L1 High 201 L2 TB101 202 AC Input L2 Neutral 202 GND TB101 203 GND Setscrew terminal or ground stud Table F 2 SmartPAC 1 to SmartPAC 2 Wiring Changes Zero Cam Original SmartPAC SmartPAC 2 Signal Type Connector Pin Number Connector Pin Number Done ZERO CAM TB101 211 TB107 248 Table F 3 SmartPAC 1 to SmartPAC 2 Wiring Changes Input Check E ...

Page 465: ... 2 Wiring Changes Position Sensor If Used Original SmartPAC SmartPAC 2 Signal Type Connector Pin Number Connector Pin Number Done V TB107 245 TB107 245 POS TB107 246 TB107 246 GND TB107 247 TB107 247 Table F 6 SmartPAC 1 to SmartPAC 2 Wiring Changes DiProPAC 8 Channel Original SmartPAC SmartPAC 2 Signal Type Connector Pin Number Connector Pin Number Done SENSOR 1 TB501 282 TB554 282 SENSOR 2 TB501...

Page 466: ...92 TB554 292 SENSOR 10 TB552 293 TB554 293 SENSOR 11 TB552 294 TB554 294 SENSOR 12 TB552 295 TB554 295 SENSOR 13 TB552 296 TB554 296 SENSOR 14 TB552 297 TB554 297 SENSOR 15 TB552 298 TB554 298 SENSOR 16 TB552 299 TB554 299 SENS PWR TB552 300 TB554 300 GND TB552 301 TB554 301 Table F 8 SmartPAC 1 to SmartPAC 2 Wiring Changes ProCamPAC 8 Channel Original SmartPAC SmartPAC 2 Signal Type Connector Pin...

Page 467: ... VDC TB451 268 TB451 268 GND TB451 269 TB451 269 RELAY PWR TB451 270 TB451 270 CHANNEL 9 TB452 271 TB452 271 CHANNEL 10 TB452 272 TB452 272 CHANNEL 11 TB452 273 TB452 273 CHANNEL 12 TB452 274 TB452 274 CHANNEL 13 TB452 275 TB452 275 CHANNEL 14 TB452 276 TB452 276 CHANNEL 15 TB452 277 TB452 277 CHANNEL 16 TB452 278 TB452 278 5 VDC TB452 279 TB452 279 GND TB452 280 TB452 280 RELAY PWR TB452 281 TB45...

Page 468: ...l SmartPAC SmartPAC 2 Signal Type Connector Pin Number Connector Pin Number Done LOCKOUT TB202 255 TB107 251 GND TB202 256 TB107 250 Table F 13 SmartPAC 1 to SmartPAC 2 Wiring Changes Remote Reset Optional Original SmartPAC SmartPAC 2 Signal Type Connector Pin Number Connector Pin Number Done REMOTE RES TB203 257 TB107 249 GND TB203 258 TB107 250 Table F 14 SmartPAC 1 to SmartPAC 2 Wiring Changes ...

Page 469: ... 235 TB103 235 RXD1 TB102 236 TB103 236 TXD1 TB102 237 TB103 237 TXD1 TB102 238 TB103 238 TXD1 TB102 239 TB103 239 GND TB102 240 TB103 240 Table F 16 SmartPAC 1 to SmartPAC 2 Wiring Changes MultiPAC Special Port Optional Original SmartPAC SmartPAC 2 Signal Type Connector Pin Number Connector Pin Number Done RXD3 TB103 224 TB104 224 RXD3 TB103 225 TB104 225 TXD3 TB103 226 TB104 226 TXD3 TB103 227 T...

Page 470: ...und stud located on the face plate below the AC input terminal block Restoring Tools to SmartPAC 2 You can use SBR to restore backed up tools from a SmartPAC 1 to a SmartPAC 2 via a connected laptop or if the SmartPAC 2 is on a network you can restore tool settings from a network server However you cannot restore SmartPAC 1 Initialization settings to SmartPAC 2 To transfer this information to Smar...

Page 471: ... the following steps 1 On the Backup Restore Control Menu in Initialization mode on the SmartPAC 2 press the F5 Restore function key The message shown in Figure F 3 displays 2 Press ENTER to continue with the restore When the restore has been completed the following message displays on the Backup Restore Control Menu Restore complete Make sure to identify the control you are restoring to as a Smar...

Page 472: ...re correct If they aren t make corrections 4 Access the Main Program Menu and select GO TO THE TOOL MANAGER 5 When the Tool Manager screen displays make sure that all tools that were programmed in SmartPAC 1 are shown 6 Load a test tool following the instructions in Creating a New Tool page 5 3 7 Turn the Program Run key to RUN 8 Go through the menu choices to make sure your new SmartPAC 2 is func...

Page 473: ...t the serial number located on its label matches the serial number on the Boot Loader chip on the board being replaced 4 Put the PC board back in its anti static bag until you are ready to install it Under the board exchange program a replacement board can usually be shipped to you overnight if you contact Wintriss Tech Support the previous business day Full details about the program are available...

Page 474: ...ce is off before you replace electronic components in a control Disconnect power from the machinery it is connected to before replacing electronic components This includes disconnecting power to the machine control and motor Ensure that servicing is performed by qualified personnel Failure to comply with these instructions could result in death or serious injury DAMAGE TO BOARD FROM STATIC DISCHAR...

Page 475: ... lever on the bottom of the compact flash receptacle all the way to the left To reinstall the compact flash card insert the card into the flash receptacle with the INSERT arrow on the label pointing toward the receptacle and carefully push the card into the receptacle until you hear it click into place ProCam DiPro U105 U124 SimpleTech S101 Input Check Switch 60 250 12 60 Master Slave JP 101 JP 10...

Page 476: ...s on the ProCamPAC and DiProPAC boards if installed Make sure to insert the display connector J115 in Figure G 1 into the SmartPAC 2 board with the correct orientation 16 Double check to make that sure all connectors are plugged into the correct slots To remove the Battery Backed Up Ram chip 1 Place a small flat blade screwdriver between the Boot Loader Chip U124 in Figure G 1 and the bottom of th...

Page 477: ...pleted you are ready to resume normal operation 22 Place the malfunctioning board in the anti static bag in which you received the replacement board Place the anti static bag with the old board in the box in which you received the replacement board and ship it back to Wintriss using the shipping label with the Return Authorization RA number Contact Wintriss Tech Support if you have additional ques...

Page 478: ...1128600 SmartPAC 2 with WPC 2000 Integration User Manual G 6 Replacing SmartPAC 2 PC Board ...

Page 479: ...ceives from SmartPAC 2 Machine states are differentiated as follows Running Time Press is running and making parts Idle Time Press is stopped no SmartPAC error has occurred and the reason the press is stopped has not been documented in SmartPAC 2 Unplanned Downtime Press is stopped due to a SmartPAC 2 error or if the press is stopped for another reason that reason has been assigned to the Unplanne...

Page 480: ...ly displays The Dialog Menu a selection on the SmartPAC 2 Main Run Menu displays a list of downtime reasons from which the operator must select to report downtime to SFC Refer to Programming Downtime Reasons page H 12 for instructions on how to set up the Dialog Menu The Forced Dialog message can be programmed to display a specified number of minutes after the press stops see Figure H 1 This Idle ...

Page 481: ...ack on Line is selected SFC begins documenting the machine state as Running time see Figure H 1 When the operator selects Back on Line without restarting the press the subsequent period until the press is restarted is logged to Idle Time see Figure H 2 Figure H 1 Forced Idle Dialog Mode Time Line Downtime Reason Backfilled Press is running Press is stopped by operator or auxiliary equipment Operat...

Page 482: ...ing which a new coil is located and brought to the press unless the operator selects a more appropriate downtime reason such as Waiting for Coil and using the backfill option see Backfilling vs Forward Filling page H 2 applies it to the incompletely documented period When the Figure H 2 Forced Idle Dialog Mode Time Line Downtime Reason Forward Filled Press is running Press is stopped by operator o...

Page 483: ...rmally documented as Offline Time and the period following the next power up assigned to Idle Time Periods subsequent to machine power ups are documented as Idle Time even when the period immediately preceding the shutdown has been assigned to an Unplanned Downtime reason The only machine states that carry over from the period immediately preceding a shutdown to the period immediately succeeding a...

Page 484: ...nning only a fraction of the time even when the operator is maintaining an acceptable production rate this data stream does not accurately reflect press productivity skewing OEE ratings unfairly downward When you make this cycle time setting SmartPAC 2 no longer looks for a change of state to determine whether the press is running but rather expects to see the press stroke at least once during the...

Page 485: ...s All downtime reasons can be customized to meet the specific needs of your shop floor setup up to 32 custom names can be created in SFC Administrator and you can include all reasons in the Downtime by Reason report which allows you to track occurrences of a specific downtime reason across multiple machines With the 16 16 setting you can create only 16 custom reasons the other 16 are canned and on...

Page 486: ...ommunications Menu see Figure H 5 displays Figure H 4 SmartPAC 2 Main Initialization Menu Figure H 5 Set Communications Menu Wintriss recommends that you take advantage of the additional features provided by the 32 Custom dialog screen mode setting The 16 16 setting should be selected only when you have both SmartPAC 1s and SmartPAC 2s and even then only if complete consistency is required NOTICE ...

Page 487: ...uctions on how to make settings Table H 1 Set Communications Menu Settings Field Settings RSR SBR CPU NUMBER When SmartPAC 2 is connected to SFC this field must be set to 1 Other CPU Number values may be used when SmartPAC 2 is connected to certain legacy software products that require each SmartPAC 2 to be assigned a unique identifier FORCED IDLE DIALOG Indicates whether SmartPAC 2 displays the F...

Page 488: ...d up again Normally the interval during a press shutdown is assigned to Offline Time and the period after the press is powered up to Idle Time There are two settings ENABLED Persist Dialog mode enabled DISABLED Persist Dialog mode disabled AUTO BACKFILL Indicates whether time occurring after the press has been stopped up to the point when the operator selects a downtime reason is automatically doc...

Page 489: ...mber of strokes required to return the press to production following a lunch or other break Set the Changeover Reset Strokes counter to the maximum number of strokes required to complete a die setup SINGLE STROKE MODE This setting which is used for hand fed applications when the press is being run in Single stroke mode indicates whether SFC counts press cycles or parts made within the period speci...

Page 490: ...splaying up to 30 items When planning the order in which you want Dialog Menu items to display you should attempt to predetermine the downtime causes that are likely to occur most frequently and place these at the beginning of the downtime reason sequence SET SPECIAL NAMES Displays the Dialog Special Choice Name Menu on which you can create up to 16 custom downtime reasons for display on the Dialo...

Page 491: ...to maintain the necessary intervals in your canned name numbering scheme to accommodate these items To prevent a canned name from appearing on the Dialog Menu set its sequence number to 0 It is recommended that you include the following canned items in the Dialog Menu TOOL CHANGE This downtime reason is logged to the Changeover Time machine state enabling SFC to track time for tool changes separat...

Page 492: ...7 page H 15 displays This menu allows you to select the special names that will appear on the Dialog Menu Special names are downtime reasons created by the user Each name can be up to 12 characters in length and you can include up to 16 of them in the Dialog Menu You specify the order in which special names appear on the Dialog Menu by entering a sequence number to the right of each text entry The...

Page 493: ...to appear on the Dialog Menu then press ENTER to save your entry and return to the Dialog Special Choice Name Menu 5 Move the cursor to the SPEC 2 field using the Down cursor key and repeat steps 2 through 4 Do the same for the remaining menu items 6 When you have finished programming special downtime reasons press RESET to save your entries and return to the Set Communications Menu Figure H 7 Dia...

Page 494: ... that the press has stopped under the appropriate circumstances This message is shown in Figure H 8 To respond to this prompt perform the following steps 1 Press RESET to clear the message The Dialog Menu displays If dialog screen mode is set to 16 16 see Setting up SmartPAC 2 to Report Downtime page H 7 the Dialog Menu looks like the example shown in Figure H 9 page H 17 If 32 CUSTOM is the dialo...

Page 495: ...CH PROBLEM is selected as an example using the Up or Down cursor key and press ENTER or Press the function key for Operator Number Back on Line or Changeover 32 CUSTOM dialog screen mode only see Figure H 10 Figure H 9 Dialog Menu 16 16 Dialog Screen Mode Figure H 10 Dialog Menu 32 CUSTOM Dialog Screen Mode F1 F2 F3 F4 F5 F6 F7 F8 F1 F2 F3 F4 F5 F6 F7 F8 ...

Page 496: ...he window shown in Figure H 11 displays Press the F2 Change Prev Reason function key to backfill the selected downtime reason in other words to assign it to the period from the time that the press was stopped up to entry of the next downtime reason or the BACK ON LINE selection If a SmartPAC 2 fault has already been assigned to this period of press inactivity that fault will be documented as havin...

Page 497: ...H 12 select the DIALOG MENU item 2 On the Dialog Menu highlight the downtime reason you want using the Up or Down cursor key and press ENTER or Press the function key for Operator Number Back on Line or Changeover 32 CUSTOM dialog screen mode only 3 If Auto Backfill has been enabled on the Set Communications Menu see Table H 1 page H 10 the downtime reason you selected is automatically backfilled ...

Page 498: ... computer Ending a Job If you are using the 32 CUSTOM dialog screen mode setting the Dialog Menu allows you to close out the previous job when no subsequent job is immediately available thereby preventing any non job related downtime to be charged against it You close out the previous job by pressing the F7 End Job function key see Figure H 10 page H 17 Normally in ShopFloorConnect one job ends an...

Page 499: ...ate a Hot Key using the Up or Down cursor key Use the fewest number of keystrokes possible in scrolling to the item 5 Press the 2 and 0 keys simultaneously for a few seconds until the Hot Keys Instruction Window displays see Figure 6 4 page 6 4 then press the function key you want to make the Hot Key for the selected menu item To program Hot Keys for function keys F4 through F7 on the Dialog Menu ...

Page 500: ...and Good Parts counter adjustments to be made in Run mode you must set the CHANGE COUNT and CHG GOOD PRTS CNT items on the Security Access Menu in Initialization mode to PROGRAM AND RUN MODES as shown in Figure H 13 To display the Security Access Menu select SECURITY ACCESS from the Main Initialization Menu see Figure H 4 page H 8 If you want to allow scrap entries to be made in Run mode but preve...

Page 501: ... 15 shows a scrap entry of 30 as an example When you press ENTER the Scrap Value Entry window disappears The value you keyed in is added to the current scrap value and the result is displayed beneath the Scrap Value caption to the left of the F3 function key as shown in Figure H 16 page H 24 where a scrap value of 30 is used as an example The Good Parts counter is reduced by the amount of your scr...

Page 502: ...H 23 is automatically added to the total For example if the count in the Scrap Value field is 30 and you want to include an additional 10 parts in the count you would enter 10 in the Scrap Value Entry window see Figure H 17 When you are returned to the Counters screen the Scrap Value counter would display 40 parts the 30 parts in the current total plus the 10 parts you entered the Good Parts count...

Page 503: ...od Parts by larger amounts see Adjusting the Good Parts Counter in Program Mode next page This capability is useful if new firmware is installed in the middle of a job causing the Good Parts counter to reset to zero Adjusting the Good Parts Counter in Run Mode To increase the Good Parts count in Run mode do the following 1 Select the GOOD PARTS COUNT field on the Counters screen Figure H 18 Counte...

Page 504: ...unt in Program mode do the following 1 On the Counters screen in Run mode press RESET to return to the Main Run Menu 2 Turn the Program Run key to PROG to display the Main Program Menu 3 Select GO TO THE TOOL MANAGER to display the Tool Manager screen 4 Press F4 Edit Tool with the loaded tool selected to display the Tool Program Menu 5 Select COUNTERS to display the Counters screen 6 Perform steps...

Page 505: ... for an individual press is the number of hours in a production day e g 12 hours 24 hours etc LETS selects the machine state to which to log press time on the basis of downtime reporting and other information it receives from SmartPAC 2 Machine states are differentiated as follows Running Time Press is running and making parts Idle Time Press is stopped no SmartPAC error has occurred and the reaso...

Page 506: ... Mode below Downtime reasons may also be assigned manually to provide additional detail for periods documented automatically with specific error conditions see Forced Error Dialog Mode page I 4 Forced Idle Dialog Mode If the SmartPAC 2 is set to Forced Idle Dialog mode see Making Downtime Reporting Settings page I 7 a downtime reason must be entered whenever the press is stopped by the operator or...

Page 507: ...ot display following selection of the downtime reason and downtime is automatically backfilled Putting the Press Back on Line A period of Idle Time or downtime either Planned or Unplanned comes to an end when the operator selects Back on Line from the Dialog Menu If the press is restarted at the same time LETS begins documenting the machine state as Running time see Figure I 1 When the operator se...

Page 508: ...e press unless the operator selects a more appropriate downtime reason such as Waiting for Coil and using the backfill option see Backfilling vs Forward Filling page I 2 applies it to the incompletely documented period When the downtime reason is backfilled see Figure I 3 page I 5 for a schematic time line SmartPAC Figure I 2 Forced Idle Dialog Mode Time Line Downtime Reason Forward Filled Press i...

Page 509: ...e period following the next power up assigned to Idle Time Periods subsequent to machine power ups are documented as Idle Time even when the period immediately preceding the shutdown has been assigned to an Unplanned Downtime reason The only machine states that carry over from the period immediately preceding a shutdown to the period immediately succeeding a power up are Changeover Time and Planne...

Page 510: ...topped SmartPAC 2 looks for at least one press cycle during a pre programmed interval and if it detects no stroke considers that the press is stopped reporting subsequent time as Idle Time Reset Strokes Counters Normally a period of Idle Time Planned or Unplanned Downtime or Changeover Time is ended when the operator selects Back on Line from the Dialog Menu and restarts the press see Putting the ...

Page 511: ...n perform the following steps 1 At the SmartPAC 2 turn the Program Run key to PROG then press the 1 and CLEAR keys simultaneously for a second or two until the Main Initialization Menu see Figure I 4 displays 2 Highlight the SETUP DATA COMMS menu item using the Up or Down cursor key and press ENTER The Set Communications Menu see Figure I 5 displays Figure I 4 SmartPAC 2 Main Initialization Menu F...

Page 512: ...ations Menu Settings Field Settings RSR SBR CPU NUMBER When SmartPAC 2 is connected to LETS this field must be set to 1 Other CPU Number values may be used when SmartPAC 2 is connected to certain legacy software products that require each SmartPAC 2 to be assigned a unique identifier FORCED IDLE DIALOG Indicates whether SmartPAC 2 displays the Forced Dialog message and Dialog Menu after the press ...

Page 513: ...ST DIALOG Indicates whether an Unplanned Downtime reason from the Dialog Menu that is assigned before a press shutdown continues to be applied to the period during which the press is down and to the time after the press is powered up again Normally the interval during a press shutdown is assigned to Offline Time and the period after the press is powered up to Idle Time There are two settings ENABL...

Page 514: ...ress is being run in Single stroke mode indicates whether LETS counts press cycles or parts made within the period specified in the IDLE TIMER field see next entry to determine whether the press is running When this field is set to ENABLED LETS only documents the press as Idle when no cycles occur i e no parts are made during an Idle Timer period There are two settings ENABLED Single stroke Mode e...

Page 515: ...and special entries displaying up to 30 items When planning the order in which you want Dialog Menu items to display you should attempt to predetermine the downtime causes that are likely to occur most frequently and place these at the beginning of the downtime reason sequence Selecting Canned Names on the Dialog Fixed Name Choice Menu When you select the SET CANNED NAMES item on the Set Communica...

Page 516: ...alue BACK ON LINE This selection enables the operator to end a downtime event When BACK ON LINE is selected the machine state will change from Unplanned Downtime Planned Downtime or Changeover Time to Running Time if the press is running or from one of these downtime states to Idle Time if the press is stopped OPER NUMBER This canned name allows the operator to enter an operator number enabling LE...

Page 517: ...ach text entry The sequence number specifies the position in which that item will appear on the Dialog Menu Since canned downtime reasons may also appear on the Dialog Menu be sure to maintain the necessary intervals in your special name numbering scheme to accommodate these items To prevent a special name from appearing on the Dialog Menu set its sequence number to 0 To program special downtime r...

Page 518: ... Menu A downtime reason can be selected on the Dialog Menu either in response to the Forced Dialog message or when the operator wants to change a previous downtime entry or add detail to reported downtime Documenting Downtime in Response to the Forced Dialog Message With Forced Idle Dialog mode or Forced Error Dialog mode enabled see Making Downtime Reporting Settings page I 7 the operator is prom...

Page 519: ... 1 page I 9 the downtime reason you selected is automatically backfilled i e assigned to the period from the time that the press was stopped up to entry of the next downtime reason or the BACK ON LINE selection If a SmartPAC 2 fault has already been assigned to this period of press inactivity that fault will be documented as having consumed 1 second and the remainder of the period filled with the ...

Page 520: ...AC 2 fault has already been assigned to this period of press inactivity that fault will be documented as having consumed 1 second and the remainder of the period filled with the downtime reason you selected If the period has been documented as Idle Time your downtime reason will replace that entry or Press F3 Keep Prev Reason to leave documentation of the period up to the present unchanged and for...

Page 521: ...m the following steps 1 On the Main Run Menu see Figure I 11 select the DIALOG MENU item 2 On the Dialog Menu highlight the downtime reason you want using the Up or Down cursor key and press ENTER 3 If Auto Backfill has been enabled on the Set Communications Menu see Table I 1 page I 9 the downtime reason you selected is automatically backfilled i e assigned to the period from the time that the pr...

Page 522: ...ill display a message stating that the downtime reason has been sent to the host computer Creating Hot Keys for Dialog Menu Functions You can create Hot Keys on the Main Run Menu see page 3 12 for an overview for selections on the Dialog Menu enabling you to perform Dialog Menu tasks from the Run Menu To do so perform the following steps 1 On the Main Run Menu select the DIALOG MENU item 2 On the ...

Page 523: ...ents in Program mode To enable scrap entries and Good Parts counter adjustments to be made in Run mode you must set the CHANGE COUNT and CHG GOOD PRTS CNT items on the Security Access Menu in Initialization mode to PROGRAM AND RUN MODES as shown in Figure I 12 To display the Security Access Menu select SECURITY ACCESS from the Main Initialization Menu see Figure I 4 page I 7 If you want to allow s...

Page 524: ...re I 13 2 Press F3 Scrap Value The Scrap Value Entry window displays see Figure I 14 3 If this is your first scrap entry for the job perform this step otherwise go to step 4 Key in the amount of scrap you wish to document following the directions in the window and press ENTER Figure I 14 shows a scrap entry of 30 as an example Figure I 13 Counters Screen with Scrap Value Function F3 Shown Figure I...

Page 525: ...SCRAP ENTRIES MUST INCLUDE CURRENT SCRAP TOTAL The Scrap Value counter maintains a cumulative total of the scrap items documented for each job In order to increment this counter the value you enter in the Scrap Value Entry window see Figure I 14 page I 20 must include the current scrap total in other words you must add the number of scrap items you wish to document to the current value shown in th...

Page 526: ...crap total of 40 is used as an example The Good Parts counter is reduced by the difference between the amount of your Scrap Value entry and the current Scrap Value e g 1 720 40 30 1 710 in Figure I 17 5 Repeat step 4 for the remaining scrap entries associated with the current job until the job is completed Figure I 16 Counters Screen with Scrap Value Entry Window Displayed 40 Items Shown Figure I ...

Page 527: ...ct the GOOD PARTS COUNT field on the Counters screen 2 When the Good Parts Entry window like the window shown in Figure I 14 displays key in the number of good parts you want to add 1 000 parts maximum and press ENTER A Confirmation window like the one shown in Figure I 18 displays 3 Press the Up cursor key to confirm that you want to change the Good Parts counter value You are returned to the Cou...

Page 528: ...he Main Run Menu 2 Turn the Program Run key to PROG to display the Main Program Menu 3 Select GO TO THE TOOL MANAGER to display the Tool Manager screen 4 Press F4 Edit Tool with the loaded tool selected to display the Tool Program Menu 5 Select COUNTERS to display the Counters screen 6 Perform steps 1 through 3 of the procedure for adjusting the Good Parts counter in Run mode above In Program mode...

Page 529: ...e changed at SmartPAC 2 see Changing User Input Stop Type page J 8 Non control reliable user inputs i e inputs12 31 can be set to Top stop Top stop Lockout a new setting E stop Estop Lockout or Unused Control reliable input pairs 32 33 34 35 36 37 and 38 39 can be set to E stop or E stop Lockout A setup sheet on which you can document stop type assignments for Option 1 user inputs is provided on p...

Page 530: ...NPN E stop User input 17 NPN E stop User input 18 NPN E stop User input 19 NPN E stop User input 20 NPN E stop User input 21 NPN E stop User input 22 PNP E stop User input 23 PNP E stop User input 24 PNP E stop User input 25 PNP E stop User input 26 PNP E stop User input 27 PNP E stop User input 28 PNP E stop User input 29 PNP E stop User input 30 PNP E stop User input 31 PNP E stop User input 32 ...

Page 531: ...the press Static electricity can destroy electronic components Failure to comply with these instructions could result in property damage Be sure to save the shipping box and protective anti static bag in case you need to return the Option 1 board ELECTRIC SHOCK HAZARD Ensure that the power source is off before you replace electronic components in a control Disconnect power from the machinery it is...

Page 532: ...wn using the Phillips screws provided 7 If you are ready to connect auxiliary equipment to the Option 1 board proceed to the next section Otherwise close the door of the WPC 2000 enclosure or console Figure J 1 Option 1 Board Installed on WPC 2000 Main Processor Board Green Orange 438 439 440 441 442 443 444 445 446 447 431 432 433 434 435 436 437 448 449 450 451 452 453 454 455 456 457 458 459 46...

Page 533: ...e any of the jumpers installed at the factory make sure to bypass those inputs by connecting them to 24 Vdc or ground as shown in Table J 2 or Table J 3 TB601 provides one 24 Vdc terminal and one ground terminal for jumper connections TB602 provides two 24 Vdc terminals and two ground terminals Figure J 2 WPC 2000 Option 1 Board 5V A processor LED DS630 5V B processor LED DS629 438 439 440 441 442...

Page 534: ... 24 24 Vdc 451 User input 25 24 Vdc 452 User input 36 cross checked with user input 37 24 Vdc 453 User input 38 cross checked with user input 39 24 Vdc 454 Ground Table J 3 WPC 2000 Option 1 Board Wiring Connections TB602 Pin User Input Terminal for Jumper Bypass Connection Upper Row 438 User input 33 cross checked with user input 32 24 Vdc 439 User input 35 cross checked with user input 34 24 Vdc...

Page 535: ...x ch w 35 433 User input 12 434 User input 13 435 User input 14 GROUP 8 453 User input 38 x ch w 39 448 User input 22 449 User input 23 450 User input 24 451 User input 25 452 User input 36 x ch w 37 GROUP 11 445 User input 21 438 User input 33 x ch w 32 439 User input 35 x ch w 34 440 User input 16 441 User input 17 442 User input 18 443 User input 19 444 User input 20 GROUP 10 462 User input 39 ...

Page 536: ... stop type for a user input follow these instructions 1 On the SmartPAC 2 Main Initialization Menu see Figure 4 1 page 4 1 move the highlight bar to PRESS CONTROL using the cursor keys and press ENTER The WPC Initialization Menu see Figure 4 18 page 4 23 displays with the USER INTERLOCKS item highlighted by default 2 On the WPC Initialization Menu press ENTER with USER INTERLOCKS highlighted The C...

Page 537: ...status is a useful diagnostic tool for troubleshooting your Option 1 user inputs and the auxiliary equipment they are connected to To view input status follow these steps 1 On the WPC Initialization Menu see Figure 4 18 page 4 23 move the selection bar to INPUT STATUS using the cursor keys and press ENTER The Display WPC Input Status screen shown in Figure J 5 displays Figure J 4 Change User Inter...

Page 538: ...liary equipment that input is connected to An additional fault code is documented following the table To correct the problem that caused the fault code to display check the equipment and wiring connected to that user input When you have corrected the problem reset SmartPAC 2 and WPC 2000 If the problem recurs contact Wintriss Tech Support Table J 4 WPC 2000 Option 1 Fault Codes Fault Code User Inp...

Page 539: ...140 144 User 32 paired with User 33 E stop 431 24 Vdc E stop 438 24 Vdc 141 145 User 34 paired with User 35 E stop 432 24 Vdc E stop 439 24 Vdc 142 146 User 36 paired with User 37 E stop Lockout 452 24 Vdc E stop Lockout 461 24 Vdc 143 147 User 38 paired with User 39 E stop Lockout 453 24 Vdc E stop Lockout 462 24 Vdc Removal of the Option 1 board should only be performed after careful considerati...

Page 540: ...iary Equipment User 12 120 433 Ground User 13 121 434 Ground User 14 122 435 Ground User 15 123 436 Ground User 16 124 440 Ground User 17 125 441 Ground User 18 126 442 Ground User 19 127 443 Ground User 20 128 444 Ground User 21 129 445 Ground User 22 130 448 24 Vdc User 23 131 449 24 Vdc User 24 132 450 24 Vdc User 25 133 451 24 Vdc User 26 134 455 24 Vdc User 27 135 456 24 Vdc User 28 136 457 2...

Page 541: ... delay is controlled by an advance constant a specified number of degrees of advance for each 100 SPM increase in press speed auto carry up A signal that causes the press to automatically complete the stroke stopping at TDC when the operator releases his hands from the palm buttons after the Auto Carry up Angle has been reached Also called Operator Station mute auto carry up angle The crank angle ...

Page 542: ...haft angles checksum A numeric value calculated when a tool is stored in memory and when it is loaded The two values must match or SmartPAC 2 displays a fault message communications Data sent by SmartPAC 2 to one of its installed options e g WPC SFI etc or received from an installed option concurrent time The length of time within which each pair of palm switches on all Operator Stations connected...

Page 543: ...on to the operator Dual diverse redundancy provides optimum clutch brake control and operator safety Dual Safety Valve The control reliable device on the press that controls the flow of air to the press s clutch dwell The range of angles during which a sensor or cam is actuated or on Also called actuation angle emergency stop A signal sent to the press in response to a malfunction that stops the p...

Page 544: ... pushed in Inch mode Micro inch is designed for high speed and or short stroke presses NEMA 12 A rating that certifies that an electrical device is protected against dust water and oil ninety degree 90 stop time test A test required to set the proper safety distance for personnel guarding devices including light curtains two hand controls and type B movable barriers This test checks the stopping t...

Page 545: ...stallation of the overrun limit switch palm time The length of time within which the two palm switches on each Operator Station connected to WPC 2000 must be activated in order to start the press This interval is 1 2 0 5 second as required by ANSI If the palm time on any Operator Station is exceeded the press will not start ANSI standards refer to the palm time as synchronous time pinch point The ...

Page 546: ...op stop if the fault occurs after the critical angle See critical angle emergency stop and top stop start time The amount of time it takes the resolver to start turning after the Dual Safety Valve DSV is energized stopping angle The number of degrees of crankshaft rotation required for the press to stop after a stop command is issued The stopping angle is calculated by subtracting the crankshaft p...

Page 547: ... a press automation function at WPC 2000 This feature works best on presses that have speed ranges of several hundred to over a thousand strokes per minute total hits counter A counter that maintains a count of the total number of hits made by a tool used in determining when a tool needs regrinding See counter zero cam A closure to ground signal that turns on at approximately 270 and turns off at ...

Page 548: ...1128600 SmartPAC 2 with WPC 2000 Integration User Manual GL 8 Glossary ...

Page 549: ...iary outputs change conditions 2 35 setting aux output 1 response to interrupted stroke 4 40 wiring 2 35 B backup tool and initialization data performing 4 52 bar mode fault 7 11 mounting and wiring the control 2 44 operating the press in 6 53 testing the control 2 112 batch counters See also counters setting increment mode 5 13 setting output mode 5 13 Board 2 51 board SmartPAC 2 installing repla...

Page 550: ...rts per stroke or strokes per part 5 14 setting the auto enable by sensor counter 5 23 setting the auto enable by tool counter 5 21 setting the strokes counter for a green special sensor 5 29 crank angle clock setting cam channel timing on 5 40 5 41 5 43 5 45 setting green sensor ready signal on 5 29 setting rotational direction 4 6 crankshaft angle window opening 6 6 critical angle setting for a ...

Page 551: ... overrun limit switch faults 7 21 press control faults 7 5 resolver faults 7 6 7 24 responding to 7 2 sensor faults 7 28 Shadow light curtain input faults 7 18 tool programming faults 7 27 top stop and overrun setting faults 7 21 top stop circuit driver failure 7 17 viewing in the error event log 6 34 firmware downloading updated SmartPAC 2 firmware from Wintriss D 7 installing updated SmartPAC 2 ...

Page 552: ...g light curtain break mode 4 36 faults 7 16 7 18 increasing the safety distance for floating or blanking windows 6 29 installation requirements 2 16 2 22 installing non Shadow light curtains 2 23 jumper settings Shadow VII Shadow 8 and Shadow 9 2 23 object sensitivity 6 25 response times 6 25 testing safeguarding devices 2 90 testing Shadow light curtains 2 98 link motion press compensating for sp...

Page 553: ... 17 components 1 8 enabling dual operator stations 4 41 installing multiple operator stations 2 21 labelling dual operator stations 2 22 mounting and wiring 2 16 setting concurrent time for multiple op stations 4 43 setting palm time for one or two op stations 4 43 setting prior act time for automatic modes 4 38 testing emergency stop button in continuous mode 2 92 testing top stop button 2 93 usi...

Page 554: ...rading 2 56 board layouts 2 58 installing new board 2 59 replacing board 2 57 testing cam channels 2 113 verifying installation 2 74 ProCamPAC output assembly board layout 2 66 connecting relays to equipment 2 68 installing diodes 2 69 mounting 2 64 mounting dimensions 2 65 running wiring in conduit 2 64 selecting relays for cam channels 2 64 wiring 2 64 Program mode entering and exiting 5 1 main ...

Page 555: ...bling counters 4 8 SFC ShopFloorConnect Asset Utilization Software reporting downtime to H 1 reporting good parts count to H 22 reporting scrap count to H 22 setting communications with SmartPAC 2 H 7 shutdown time setting 4 32 single stroke mode operating the press in automatic single stroke 6 49 operating the press in single stroke foot 6 48 operating the press in single stroke one hand 6 45 ope...

Page 556: ...g angle 2 79 4 28 setting angle range 4 36 top stop button operator station location 1 8 testing top stop circuit 2 93 top stop bypass operating the press in 6 42 top stop in inch operating the press in 6 42 top stop mode for F and H errors setting 4 39 tracking frequency preventive maintenance modifying C 14 setting C 11 tracking units preventive maintenance setting C 10 two hand mode operating t...

Page 557: ...C 2 with WPC 2000 Integration User Manual 1128600 Index IN 9 WPC 2000 main processor board TB101 TB104 2 114 WPC 2000 board layout 2 28 Y yellow sensors faults 7 29 overview 5 18 selecting as sensor type 5 24 ...

Page 558: ...1128600 SmartPAC 2 with WPC 2000 Integration User Manual IN 10 Index ...

Page 559: ... Batch 3 Ch 8 Preset Value Output mode circle one Top Stop Toggle Pulse for _______mS Top Stop Toggle Pulse for _______mS Top Stop Toggle Pulse for _______mS Increment mode circle one Strokes Good Parts Strokes Good Parts Strokes Good Parts Increment angle degrees Item Value Units Tool Memo box text 30 characters total __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _...

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Page 561: ...ime to shut off after press stops in seconds ON OFF Multiple arcs for ON OFF only 6 extras total Arc Normally 1 arc per channel can be up to 4 ON angle OFF angle 1 mS sec Arc 1 Arc 2 Arc 3 Arc 4 2 mS sec Arc 1 Arc 2 Arc 3 Arc 4 3 mS sec Arc 1 Arc 2 Arc 3 Arc 4 4 mS sec Arc 1 Arc 2 Arc 3 Arc 4 5 mS sec Arc 1 Arc 2 Arc 3 Arc 4 6 mS sec Arc 1 Arc 2 Arc 3 Arc 4 7 mS sec Arc 1 Arc 2 Arc 3 Arc 4 8 mS se...

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Page 563: ...ff after press stops in seconds ON OFF Multiple arcs for ON OFF only 6 extras total Arc Normally 1 arc per channel can be up to 4 ON angle OFF angle 9 mS sec Arc 1 Arc 2 Arc 3 Arc 4 10 mS sec Arc 1 Arc 2 Arc 3 Arc 4 11 mS sec Arc 1 Arc 2 Arc 3 Arc 4 12 mS sec Arc 1 Arc 2 Arc 3 Arc 4 13 mS sec Arc 1 Arc 2 Arc 3 Arc 4 14 _____ms sec Arc 1 Arc 2 Arc 3 Arc 4 15 mS sec Arc 1 Arc 2 Arc 3 Arc 4 16 mS sec...

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Page 565: ... Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP ON OFF 6 G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP ON OFF 7 G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP ON OFF 8 G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP ON OFF 9 G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP ON OFF 10 G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP ON OFF 11 G R Y GC GQ...

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Page 567: ... to Sensor ____ 22 G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP Linked to Sensor ____ 23 G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP Linked to Sensor ____ 24 G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP Linked to Sensor ____ 25 G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP Linked to Sensor ____ 26 G R Y GC GQ GS ______strokes E STOP TOP STOP SMART STOP L...

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Page 569: ...s Control Lube Speed Control Press Name Set Brake Monitor Stop Time Limit msec Start Time Limit msec Select Cam Names Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6 Channel 7 Channel 8 Channel 9 Channel 10 Channel 11 Channel 12 Channel 13 Channel 14 Channel 15 Channel 16 Auto Advance Advance Constant 1 Advance Constant 2 Top Stop Constant Slow RPM Custom Sensor Names Custom 1 Custom 2...

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Page 571: ...ames cont Custom 11 Custom 12 Custom 13 Custom 14 Custom 15 Custom 16 Sensor Enable Mode Sensor Enable Mode Manual Enable Auto by Tool Auto by Sensor Tool Information Tool 1 Name Units Places Tool 2 Name Units Places Tool 3 Name Units Places Tool 4 Name Units Places Tool 5 Name Units Places Tool 6 Name Units Places ...

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Page 573: ...ed Reset Mode Program and Run Modes Program Mode Only Password Required Adjust Sensors Program and Run Modes Program Mode Only Password Required Disable Sensors Program and Run Modes Program Mode Only Password Required Turn Off Sensors Password Required Allowed Not Allowed Adjust Cams Program and Run Modes Program Mode Only Password Required Adjust Feed Program and Run Modes Program Mode Only Pass...

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Page 575: ... CNTR BAL STOP LIMIT START LIMIT SHUT DOWN TIME FLYWHEEL TIMER ACTS ANGLE ONLY WITH AUTO COMPENSATED TOP STOP OPTION PRESSURE UNITS 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 set...

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