Wintriss SmartPAC 2 User manual

SmartPAC 2
Tech Support Hotline [phone] EST
www.wintriss.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 [phone]
Fax [phone]
PRINTED IN USA DA70482
®
®

Thank you for purchasing a Wintriss Product. We appreciate your business and want to do whatever
we can to ensure your satisfaction. Wintriss products are built to stay on the job day after day, and are
backed by an ironclad guarantee, international standards approvals, and unbeatable support.
Whenever you need assistance or service, we back all our products with excellent spare parts
inventories, training programs, and prompt repair service. We would like to share with you a list of
service options–probably the largest number of service options offered in the industry.
• Technical Assistance
We offer a toll-free line for technical assistance. Call our Wintriss Technical Support Hotline at
1-800-586-TECH (8324) should you have any questions about your equipment. Our technical
staff is ready to assist you Monday through Friday, 8 a.m. to 5 p.m. EST. In many cases our
experienced technical staff can resolve your inquiry right over the phone.
• Return Authorization
Please call our “800” number for a return authorization (RMA) number to return a product for
repair. Returned goods must arrive freight prepaid. In order to process your return quickly, we ask
that you provide us with the following pertinent information when you call: purchase order
number, shipping address, contact name and telephone number, and product type. The assigned
RMA number should appear on all packages returned to Wintriss Controls Group to ensure prompt
service.
At the time of requesting an RMA, you will be quoted a flat-rate repair price for the product you
are 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 Program
Rush service providing 48 hour turnaround is available for most products upon request. An
Expedite Fee will be applied to our standard repair rate.
• Board Exchange Program
If your needs are urgent, you can take advantage of our Board Exchange (EX) program. Call our
“800” number between 8 a.m. and 5 p.m. EST and we will send a replacement to you overnight. A
fee does apply to this service. Contact Wintriss Technical Support at 800-586-8324 for details.
• Service Center
Our Service Center for product service is located at our headquarters in Acton MA. If your
equipment requires repair, please contact us at 800-586-8324 to obtain a return authorization
number.
Nationwide field service is also available. Contact the Wintriss Technical Support group at
800-586-8324.
• Product Training
We also offer both product training and maintenance/troubleshooting courses at our Acton, MA
and Chicago-area facilities. On-site training is available from the factory or through your local
Wintriss representative.
• Restocking Charge
Returned goods are subject to a 20% restocking charge if returned for credit. The minimum charge
is $50, not to exceed $250 per item.
Whatever the product, we are committed to satisfying you with innovative engineering, quality
construction, reliable performance, and ongoing, helpful support. Call us whenever you need
assistance.

Changes for Revision P of the
SmartPAC 2 with WPC 2000 User Manual (1128600)
This revision of the SmartPAC 2 user manual covers SmartPAC 2 software version 13.81 and
higher and WPC 2000 software version 6.00 and higher. The changes include:
•In How to Use This Manual, added link 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, revised Extracts from ANSI B11.19-2003 8.3 to 2010 edition (ANSI
B11.19-2010 8.3).

Table of Contents i
Table of Contents
Chapter 1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
WPC 2000 and Control Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
SmartPAC 2 with WPC 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
SmartPAC 2 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
WPC 2000 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
SmartPAC 2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
WPC 2000 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Resolver-based Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
SmartPAC 2 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
WPC 2000 Operator Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
SmartPAC 2 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Sensors Available for DiProPAC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
ProCamPAC Programmable Cams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
SmartPAC 2’s Three Modes of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
SmartPAC 2 with WPC 2000 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Chapter 2. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installation Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Connecting Wires to 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 Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Installing a Light Curtain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Installing the Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Installing the Overrun Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Wiring WPC 2000 User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Connecting Other Wintriss Products to WPC 2000. . . . . . . . . . . . . . . . . . . . . . . . 2-34
Installing WPC 2000 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
Wiring the Lockout Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Wiring Auxiliary Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Wiring Operator Mode Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Wiring a Foot Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Installing a One-hand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

1128600 SmartPAC 2 with WPC 2000 Integration User Manual
ii Table of Contents
Wiring a Keylock Switch to Prevent Changes to WPC 2000 Settings . . . . . . . . . . 2-43
Installing Flywheel Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Mounting and Wiring the Bar Control Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Wiring Automatic Single-stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Wiring Automatic Continuous On-demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Installing SmartPAC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Mounting the SmartPAC 2 Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Installing SmartPAC 2 as a Panel Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Wiring between WPC 2000 and SmartPAC 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Connecting SmartPAC 2 to a Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Installing SmartPAC 2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Adding or Upgrading DiProPAC or ProCamPAC . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Connecting DiPro Sensor Interface to SmartPAC 2 . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Connecting Programmable Cam Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Setting Up High-speed Version of SmartPAC 2 with WPC 2000 . . . . . . . . . . . . . 2-70
Wiring a Remote Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Wiring a Sensor-Disabled Output (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Setting Up SmartPAC 2 with WPC 2000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Turning on Power to SmartPAC 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 Checkout Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
WPC 2000 Power Supply Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
Checking Safeguarding Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
Checking Dual Safety Valve (DSV) Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
Checking the Emergency-stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Checking the Top-stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
System Static Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
Anti-tiedown Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
Anti-repeat Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
Shadow Light Curtain Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
Single-stroke Mode Test with Light Curtain(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
Single Stroke Mode Test without Light Curtain(s). . . . . . . . . . . . . . . . . . . . . . . . 2-102
Continuous Mode Test with Light Curtain(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
Continuous Mode Test without Light Curtain(s) . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
Foot Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108
One-hand Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
Bar Mode Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112
Checking Operation of the User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
Checking Cam Channels (ProCamPAC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
What Next? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
Wiring Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113

SmartPAC 2 with WPC 2000 Integration User Manual 1128600
Table of Contents iii
Chapter 3. SmartPAC 2 Keyboard, Displays and Operating
Modes 3-1
Comparing SmartPAC 2 with Original SmartPAC . . . . . . . . . . . . . . . . . . . . . . .3-2
SmartPAC 2 Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Stroke Select Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Number Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
CLEAR Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Cursor Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
HELP Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
ENTER Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
RESET Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Program/Run Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Hot Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
SmartPAC 2 Display Layout in Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Selecting an Item on a Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
SmartPAC 2 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Initialization Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Screen Capture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Screen Capture in SmartPAC 2 Main 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 (Normal Motion – Link Motion). . . . . . . . . . . . . . . . . . . . 4-6
Angle Wheel Rotation (Clockwise – Counterclockwise) . . . . . . . . . . . . . . . . . . . . 4-6
Tool Number Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Counter Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Counter Increment Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
INSTALLED OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
PRESS NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
SELECT CAM NAMES (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
AUTO ADVANCE and Slow RPM (Optional). . . . . . . . . . . . . . . . . . . . . . . . .4-12
Calculating the Auto Advance Constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Setting Auto Advance Constants and Slow RPM . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
SET GLOBAL CAMS (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
CUSTOM SENSOR NAMES (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

1128600 SmartPAC 2 with WPC 2000 Integration User Manual
iv Table of Contents
SENSOR ENABLE MODE (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Selecting Sensor Enable Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Enabling Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
PRESS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
User Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Press Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Press Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Input Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
SECURITY ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Setting Security Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Changing Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Additional Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
BACKUP/RESTORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Backing Up Tools to a USB Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Restoring Tools from a USB Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
SETUP DATA COMMS (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
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. SmartPAC 2 Program Mode . . . . . . . . . . . . . . . . . . . . . 5-1
Entering and Exiting Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
TOOL MANAGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Creating a New Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Copying an Existing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Copying Tool Template to a New Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Loading a Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Changing Settings for a Loaded Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Deleting a Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Tool Program Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
TOOL NAME or TOOL ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
COUNTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

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Setting Preset Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Changing Count Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Clearing the Total Hits Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Setting Batch Counter Output and Increment Modes . . . . . . . . . . . . . . . . . . . . . . 5-13
Setting Counter Increment Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Setting Parts per Stroke or Strokes per Part. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Setting Batch Pre-Load Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
DIE PROTECTION (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Understanding Sensor Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Programming Sensor Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Programming DiProPAC 32 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
CAM SWITCH (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-38
Selecting a Cam Channel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Making an ON/OFF Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Setting Multiple ON/OFF Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
PRESS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-48
TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-50
SENSOR ENABLE/DISABLE & STATUS (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 (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Adjusting the Ready Signal for Green Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Adjusting the Stroke Preset for Green Special Sensors. . . . . . . . . . . . . . . . . . . . . 6-13
Viewing the Sensor Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Show Sensor Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Adjusting DiProPAC 32 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
CAM SWITCH (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
Viewing Cam Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Viewing the Global Cam Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Viewing the Cam Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
BRAKE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
Determining the Stopping Time of Your Press . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Performing the 90× Stop-time Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Calculating the Safety Distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

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PRESS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Adjusting Program Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Displaying Overrun Sensor On/Off Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
ERROR/EVENT LOG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
LOAD NEW TOOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
MESSAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Sending E-mail to Wintriss Technical Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
TOGGLE HOT KEYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Operating the Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Responding to an Interrupted Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Selecting Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Operating the Press in Inch Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Operating the Press in Single-stroke Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Operating the Press in Automatic Single-stroke Mode . . . . . . . . . . . . . . . . . . . . . 6-49
Operating the Press in Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Operating the Press in Automatic Continuous On-demand Mode . . . . . . . . . . . . . 6-52
Operating 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 Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Customized Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Light Curtain Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Emergency-stop Circuit Driver Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Top-stop Circuit Driver Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Shadow Light Curtain Input Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
DSV Interface and Lockout Relay Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Loss of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Internal Timing Input Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Top-stop and Overrun Setting Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Overrun Limit Switch Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Overrun Limit Switch Test Angle Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Overrun Limit Switch Setting Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Internal Memory Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

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Counter Preset Reached Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
Messages for Equipment or Brake Monitor Problems . . . . . . . . . . . . . . . . . . .7-24
Messages for Programming Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
Messages for Sensor Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
Miscellaneous Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30
Troubleshooting Using the Error/Event Log. . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
Resetting Ross DM2 DSV Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
Appendix A. Extracts from OSHA Regulations and ANSI
Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Extracts from OSHA Regulation 1910.217. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Extracts from ANSI Standards for Presence-sensing Devices and Two-hand
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Appendix B. Specifications for User-built Operator Stations . . . .B-1
Run Button Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Switch Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Appendix C. SmartPAC Preventive Maintenance (PM) Monitor
(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 Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Assigning a New PM Password Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
Select PM Item Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
Using the PM Monitor in Run mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
How to Get into SmartPAC Run mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
A Tool Number Must Be Loaded Before Switching to Run Mode . . . . . . . . . . . . C-12
Viewing and Modifying PM Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13
Appendix D. Updating SmartPAC 2 Firmware . . . . . . . . . . . . . . . .D-1
Updating Firmware Using a USB Disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Installing Updated Firmware from USB Disk to SmartPAC 2 . . . . . . . . . . . . . . . . D-2
Downloading Updated Firmware from the Wintriss Server . . . . . . . . . . . . . . . . . . D-7
Installing Firmware from a Replacement Compact Flash (CF) Card . . . . . . . . D-9

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Appendix E. SmartView Remote Viewing and E-mail Setup . . . . E-1
Network Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Network Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Plugging in the Network Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Programming Network Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Changing Network Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Installing SmartView . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Checking Explorer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
Installing SmartView on your Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8
SmartView Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10
Setup Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-10
Main Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-11
Press Status Information Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-12
Remote Messaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13
E-mail Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-14
SmartView Ping Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-15
Appendix F. Upgrading from Original SmartPAC to SmartPAC 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 Which SFC Logs Press Time . . . . . . . . . . . . . . . . . . . . . . . . H-1
SmartPAC 2 Downtime Reporting Features . . . . . . . . . . . . . . . . . . . . . . . . . . . H-2
Forced Idle Dialog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-2
Backfilling vs. Forward Filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-2
Putting the Press “Back on Line” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-3
Forced Error Dialog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-4
Persist Dialog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-5
Single-stroke Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6
Reset Strokes Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6
Setting up SmartPAC 2 to Report Downtime . . . . . . . . . . . . . . . . . . . . . . . . . . H-7
Making Downtime Reporting Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-7
Programming Downtime Reasons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-12

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Documenting Downtime on the Dialog Menu . . . . . . . . . . . . . . . . . . . . . . . . H-16
Documenting Downtime in Response to the Forced Dialog Message . . . . . . . . . H-16
Documenting Downtime in Other Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-19
Ending a Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-20
Creating Hot Keys for Dialog Menu Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . H-21
Reporting Scrap and Good Parts to SFC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-22
Making Scrap Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-22
Adjusting the Good Parts Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-25
Appendix I. Reporting Downtime and Scrap to LETS . . . . . . . . . . I-1
Machine States to Which LETS Logs Press Time . . . . . . . . . . . . . . . . . . . . . . . I-1
SmartPAC 2 Downtime Reporting Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-2
Forced Idle Dialog Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-2
Backfilling vs. Forward Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 Other Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-17
Creating Hot Keys for Dialog Menu Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . I-18
Reporting Scrap and Good Parts to LETS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-19
Making Scrap Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-20
Adjusting the Good Parts Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-23
Appendix J. Option 1 User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . J-1
Installing the Option 1 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-3
Wiring Option 1 User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5
Changing User Input Stop Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-8
Viewing the Status of User Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-10
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-11
Option 1 User Input Setup Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-13

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Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Wiring Diagrams
Figure 1. WPC 2000 and SmartPAC 2 System Wiring
Figure 2. WPC 2000 Operator Station Wiring
Figure 3. WPC 2000 External Wiring
Figure 4. WPC 2000/Shadow V Wiring
Figure 5. WPC 2000 Dual Operator Station Wiring
Figure 6. Stop/Start Motor Control Station Wiring with Lockout
Figure 7. WPC 2000 OEM Operator Station with Separate One Hand Control
Figure 8. WPC 2000 Operator Station Wiring with Separate One Hand Control
Figure 9. DiProPAC 32 Sensors 1 - 16 to DSI 2 Wiring Diagram
Figure 10. DiProPAC 32 Sensors 17 - 32 to DSI 2 Wiring Diagram
Figure 11. ProCamPAC 16 to Cam Output Wiring Diagram
Figure 12. SmartPAC 2 Loopback Wiring Connections
Figure 13. Cross Checked User Interlocks with Positive Action Interlocks
Figure 14. WPC 2000 Shadow VI Wiring
Figure 15. WPC 2000 Shadow VI Integration Wiring
Figure 16. WPC 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 Diagram
Figure 25. WPC 2000 Plus Option 1 User Input External Wiring
Figure 26. WPC 2000 and Shadow 9 Control Box Wiring Diagram
Figure 27. WPC 2000 and Shadow 9 Wiring Diagram
Figure 28. WPC 2000 and Dual Shadow 9 Wiring Diagram
List of Figures
Figure 1-1. SmartPAC 2 Front Panel .............................................................................................. 1-7
Figure 1-2. Operator Station Components (Side-mounted Run/Inch Palm Buttons) ...................... 1-8
Figure 2-1. Installation Overview ................................................................................................... 2-4
Figure 2-2. Correct Way to Attach Wires to Terminal Block Connectors ...................................... 2-6
Figure 2-3. Connecting Shield Drain Wire to Ground Stud ............................................................ 2-6
Figure 2-4. WPC 2000 Enclosure: Mounting Dimensions ............................................................. 2-8
Figure 2-5. AC Input Wiring Connections .................................................................................... 2-10
Figure 2-6. WPC 2000 Mounting Plate: Mounting Dimensions ................................................... 2-11
Figure 2-7. Air Pressure Sensor .................................................................................................... 2-13

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Figure 2-8. Pre-wired Operator Stations Showing Mute Lamp Connections ................................2-17
Figure 2-9. Wiring Steps to Modify Operator Station for WPC 2000 ..........................................2-18
Figure 2-10. Pre-wired Operator Station with Side Run Buttons: Mounting Dimensions ..............2-19
Figure 2-11. Pre-wired Operator Station with Top Run Buttons: Mounting Dimensions ..............2-19
Figure 2-12. Unwired Operator Station: Mounting Dimensions .....................................................2-20
Figure 2-13. Resolver: Mounting Dimensions ................................................................................2-26
Figure 2-14. WPC 2000 Main Processor Board: Location of Important Components ...................2-28
Figure 2-15. Overrun Sensor Magnet Placement: Dwell as a Function of Shaft Diameter ............2-30
Figure 2-16. Overrun Sensor Magnetic Switch: Installation Example ............................................2-30
Figure 2-17. WPC 2000 Operator Mode Outputs: Wiring Example ...............................................2-37
Figure 2-18. One-hand Control Switch: Mounting Dimensions .....................................................2-40
Figure 2-19. One-hand Control Switch Base: Mounting Dimensions .............................................2-41
Figure 2-20. Wiring Connections in One-hand Control Switch (Switch Cover, Bottom View) .....2-42
Figure 2-21. Installing the LMCS and Magnets ..............................................................................2-44
Figure 2-22. Bar Control Enclosure: Mounting Dimensions ..........................................................2-45
Figure 2-23. SmartPAC 2 Mounting Dimensions: Enclosure .........................................................2-47
Figure 2-24. SmartPAC 2 Mounting and Cutout Dimensions: Panel Mount ..................................2-49
Figure 2-25. SmartPAC 2 Board: Location of Components ...........................................................2-51
Figure 2-26. Wiring AC to Terminal 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. Connector TB302 and TB303 for Wiring Relays to Equipment ................................2-68
Figure 2-34. Installing Suppressors Across an AC Load ................................................................2-69
Figure 2-35. Installing a Diode Across a DC Load .........................................................................2-69
Figure 2-36. SmartPAC 2 Startup Screen ........................................................................................2-72
Figure 2-37. SmartPAC 2 Main Program Menu ..............................................................................2-72
Figure 2-38. Main Initialization Menu ............................................................................................2-73
Figure 2-39. Installed Options Screen .............................................................................................2-75
Figure 2-40. Overrun Sensor Magnet Installation Worksheet .........................................................2-81
Figure 2-41. WPC 2000 LED Indicator Map (Center- or Right-mounted Board) ..........................2-89
Figure 3-1. SmartPAC 2 with WPC 2000 Front Panel ....................................................................3-1
Figure 3-2. Differences Between SmartPAC 2 and Original SmartPAC ........................................3-2
Figure 3-3. SmartPAC 2 Keyboard .................................................................................................3-3
Figure 3-4. Stroke Select Key Switch .............................................................................................3-3
Figure 3-5. Number Keys ................................................................................................................3-4
Figure 3-6. Numeric Entry Window (Left); Alphabetic Entry Window (Right) .............................3-4
Figure 3-7. Alphanumeric Entry Window .......................................................................................3-5
Figure 3-8. Clear Key ......................................................................................................................3-5
Figure 3-9. Cursor Keys ..................................................................................................................3-6
Figure 3-10. Highlighted Item on Run Menu ....................................................................................3-6
Figure 3-11. Cam Channel Timing: On=0°, Off=0° .........................................................................3-8
Figure 3-12. Cam Channel Timing: On=239°, Off=0° .....................................................................3-9
Figure 3-13. Cam Channel Timing: On=239°, Off=270° .................................................................3-9
Figure 3-14. HELP Key ...................................................................................................................3-10
Figure 3-15. ENTER Key ................................................................................................................3-10
Figure 3-16. RESET Key .................................................................................................................3-11

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Figure 3-17. Program/Run Key Switch ........................................................................................... 3-11
Figure 3-18. Function Keys ............................................................................................................. 3-12
Figure 3-19. Hot Keys Programmed on Main Run Menu ............................................................... 3-13
Figure 3-20. SmartPAC 2 Display, Run Mode ............................................................................... 3-14
Figure 3-21. Main Run Menu with “CAM SWITCH” Highlighted ............................................... 3-14
Figure 3-22. SmartPAC 2 Operating Modes, Showing Main Menus ............................................. 3-15
Figure 3-23. Initialization Mode Main Menu ................................................................................. 3-17
Figure 3-24. Navigation Example: Initialization Mode ................................................................. 3-18
Figure 3-25. Program Mode Main Menu ........................................................................................ 3-19
Figure 3-26. Navigation Example: Program Mode ........................................................................ 3-20
Figure 3-27. Run Mode Main Menu ............................................................................................... 3-21
Figure 3-28. Navigation Example: Run Mode ............................................................................... 3-22
Figure 4-1. Main Initialization Menu .............................................................................................. 4-1
Figure 4-2. “Resolver Zero” Screen ................................................................................................ 4-4
Figure 4-3. Position Sensor Screen ................................................................................................. 4-5
Figure 4-4. Installed Options Screen ............................................................................................... 4-9
Figure 4-5. Select Language Screen ................................................................................................ 4-9
Figure 4-6. Alphabetic Entry Window .......................................................................................... 4-10
Figure 4-7. Cam Channel Name Menu (16-Channel ProCamPAC) ............................................. 4-11
Figure 4-8. Cam Channel Name Selection Screen ........................................................................ 4-11
Figure 4-9. Auto Advance Menu ..................................................................................................4-12
Figure 4-10. Global Cams Menu ..................................................................................................... 4-16
Figure 4-11. Global Cam Timing Type Screen ............................................................................... 4-16
Figure 4-12. Custom Sensor 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 Stop Name Screen ...........................................................................................4-26
Figure 4-21. Press Control Parameter Menu ................................................................................... 4-27
Figure 4-22. Initialize Parameters Warning Message ..................................................................... 4-34
Figure 4-23. Press Control Option Switch Menu ............................................................................ 4-35
Figure 4-24. S102 Option Switch OFF and ON Settings ................................................................ 4-42
Figure 4-25. Display WPC Input Status Screen .............................................................................. 4-44
Figure 4-26. WPC Buttons and Switches Input Status Screen ........................................................ 4-45
Figure 4-27. WPC Estop and Top Stop Input Status Screen ........................................................... 4-45
Figure 4-28. WPC Interlock Group 1 Input Status Screen .............................................................. 4-46
Figure 4-29. WPC Transducer Input Status Screen ........................................................................ 4-46
Figure 4-30. Security Access Menu ................................................................................................ 4-47
Figure 4-31. “Enter Your Password” Screen .................................................................................. 4-49
Figure 4-32. Set Passwords Menu ................................................................................................... 4-51
Figure 4-33. “Enter a New Password” Screen ................................................................................ 4-51
Figure 4-34. Backup/Restore Control Menu ................................................................................... 4-53
Figure 4-35. Backup/Restore Control Menu with Restore Confirmation Window Displayed ....... 4-55
Figure 4-36. Set Communications Menu ........................................................................................ 4-56
Figure 4-37. Network Setup Utility Screen ..................................................................................... 4-57
Figure 4-38. Setup E-mail Screen ................................................................................................... 4-58

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Figure 4-39. Alphanumeric Entry Window with Default Mail Server Displayed ...........................4-59
Figure 4-40. Diagnostics Menu .......................................................................................................4-61
Figure 4-41. Communications Data Viewer Screen ........................................................................4-62
Figure 4-42. Transmit and Receive Data Screen: Combined View (Left), Split View (Right) ......4-62
Figure 4-43. Set the Clock Screen ...................................................................................................4-64
Figure 5-1. Main Program Menu .....................................................................................................5-1
Figure 5-2. Tool Manager Screen ....................................................................................................5-3
Figure 5-3. Numeric Entry Window (Left); Alphanumeric Entry Window (Right) .......................5-3
Figure 5-4. Copy Tool Template Window ......................................................................................5-4
Figure 5-5. “Enter Your Password” Screen .....................................................................................5-6
Figure 5-6. Load Tool Warning Window ........................................................................................5-6
Figure 5-7. “Enter Your Password” Screen .....................................................................................5-7
Figure 5-8. Delete Tool Confirmation Message ..............................................................................5-7
Figure 5-9. Tool Program Menu ......................................................................................................5-8
Figure 5-10. Alphabetic Entry Window ............................................................................................5-9
Figure 5-11. Counters Screen ..........................................................................................................5-10
Figure 5-12. “Enter Your Password” Screen ...................................................................................5-11
Figure 5-13. Change Count Confirmation Window ........................................................................5-12
Figure 5-14. Counter Mode Selections Screen ................................................................................5-13
Figure 5-15. Advanced Counter Mode Selections Screen ...............................................................5-15
Figure 5-16. Die Protection Sensor Menu .......................................................................................5-16
Figure 5-17. Ready Signal Programming for a “Green” Sensor .....................................................5-18
Figure 5-18. Ready Signal Programming for a “Green Quick Check” Sensor ...............................5-19
Figure 5-19. Ready Signal 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 Angle Programming Screen ...........................................................................5-27
Figure 5-28. Ready Signal Programming Screen ............................................................................5-28
Figure 5-29. Green Special Sensor Stroke Count Screen ................................................................5-29
Figure 5-30. Sensor Settings Screen ................................................................................................5-30
Figure 5-31. Sensor Summary Screen .............................................................................................5-31
Figure 5-32. Tool Program Menu with DIPROPAC 1-16 and DIPROPAC 17-32 Items ...............5-32
Figure 5-33. Die Protection Sensor 17-32 Menu .............................................................................5-33
Figure 5-34. Sensor Names Screen with Stripper Function Highlighted ........................................5-33
Figure 5-35. Sensor Type Screen with “GREEN” Highlighted ......................................................5-34
Figure 5-36. Sensor Stop Type Screen ............................................................................................5-34
Figure 5-37. Sensor Summary Screen Showing Ready Signals for Green Sensors ........................5-35
Figure 5-38. Sensor Settings Screen ................................................................................................5-35
Figure 5-39. Sensor Names Screen with Slug Detection Function Highlighted .............................5-36
Figure 5-40. Sensor Type Screen with “GREEN SPECIAL” Highlighted .....................................5-36
Figure 5-41. Sensor Summary Screen Showing Stroke Counts for Green Special Sensors ...........5-37
Figure 5-42. Sensor Settings Screen ................................................................................................5-37
Figure 5-43. Cam Channel Menu ....................................................................................................5-38
Figure 5-44. “Enter Your Password” Screen ...................................................................................5-39
Figure 5-45. Cam Channel Program Type Menu ............................................................................5-39

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Figure 5-46. Cam Channel On/Off Program Screen ....................................................................... 5-40
Figure 5-47. Cam Channel On/Off Program Screen: One On/Off Arc ........................................... 5-41
Figure 5-48. Cam Channel On/Off Program Screen: Two On/Off Arcs ........................................ 5-42
Figure 5-49. Cam Channel On/Off Program Screen: Three On/Off Arcs ...................................... 5-43
Figure 5-50. Cam Channel Timed Output Program Screen ............................................................ 5-44
Figure 5-51. Cam Channel Auto Advance Program Screen ........................................................... 5-45
Figure 5-52. Cam Channel DSV On Program Screen ..................................................................... 5-46
Figure 5-53. Cam Channel Deletion Confirmation Window .......................................................... 5-47
Figure 5-54. Cam Summary Screen ................................................................................................5-47
Figure 5-55. Global Cam Summary Screen .................................................................................... 5-48
Figure 5-56. Press Control Parameters Screen ................................................................................ 5-49
Figure 5-57. “Enter Your Password” Screen .................................................................................. 5-49
Figure 5-58. Tool Information Screen ............................................................................................ 5-51
Figure 5-59. “Enter Your Password” Screen .................................................................................. 5-51
Figure 5-60. Sensor On/Off Status .................................................................................................. 5-52
Figure 5-61. “Sensor Turned Off” Message ................................................................................... 5-54
Figure 6-1. Main Run Menu ............................................................................................................ 6-1
Figure 6-2. No Tool Loaded Warning Window .............................................................................. 6-2
Figure 6-3. Main Run Menu, Showing Hot Keys Programmed ..................................................... 6-3
Figure 6-4. Hot Keys Instruction Window ...................................................................................... 6-4
Figure 6-5. “Enter Your Password” Screen .................................................................................... 6-5
Figure 6-6. Display All Errors Message Window ........................................................................... 6-5
Figure 6-7. Crankshaft Angle Window Displayed 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 Screen .................................................................................................. 6-14
Figure 6-16. Main Run Menu with DIPROPAC 1-16 and DIPROPAC 17-32 Items Shown ........ 6-15
Figure 6-17. Die Protection Sensor Menu for Sensors 17-32 ......................................................... 6-16
Figure 6-18. Ready Signal Programming Screen, Run Mode ......................................................... 6-16
Figure 6-19. Green Special Sensor Stroke Count Screen, Run Mode ............................................ 6-17
Figure 6-20. Cam Switch Menu ...................................................................................................... 6-18
Figure 6-21. Cam Timing Screen .................................................................................................... 6-19
Figure 6-22. Stop Time Status Screen ............................................................................................. 6-21
Figure 6-23. View of Light Curtains and Press Showing Safety Distance ..................................... 6-23
Figure 6-24. Press Control Parameters Screen ................................................................................ 6-30
Figure 6-25. Press Control Parameters Screen with Shown Overrun Angles Window .................. 6-31
Figure 6-26. Tool Number Information Screen .............................................................................. 6-32
Figure 6-27. Error/Event Log .......................................................................................................... 6-34
Figure 6-28. Tool Manager Screen ................................................................................................. 6-35
Figure 6-29. Load Tool Warning Window ..................................................................................... 6-35
Figure 6-30. Messaging Screen: List of Recipients ........................................................................ 6-36
Figure 6-31. Messaging Screen: List of Messages .......................................................................... 6-37
Figure 6-32. Sample E-mail to Wintriss Tech. Support .................................................................. 6-37
Figure 6-33. Toggle Hot Keys 1 and 2 Menu Items ....................................................................... 6-38
Figure 6-34. Mode Select Menu ...................................................................................................... 6-39