Wintriss SmartPAC PRO Servo User manual

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www.wintriss.com
®
Servo
Wintriss Press Automation Control
1147100
Rev. A April 2020
®
Wintriss Controls Group, LLC
100 Discovery Way
Unit 110
Acton MA 01720 USA
Phone [phone]
Fax [phone]
PRINTED IN USA
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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. Eastern Time. 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.

1147100 SmartPAC PRO Servo User Manual
Table of Contents 5
Table of Contents
Chapter 1 –Introduction...................................................................................................19
SmartPAC PRO Servo Standard Features .....................................................................................20
SmartPAC PRO Servo Options .....................................................................................................21
SmartPAC PRO Servo Operation..................................................................................................21
SmartPAC PRO Servo Settings.....................................................................................................21
Sensors Available for DiProPAC...................................................................................................22
Programmable Cam Channels........................................................................................................23
SmartPAC PRO Servo’s Three Modes of Operation.....................................................................23
SmartPAC PRO Servo Specifications ...........................................................................................24
Chapter 2 –Installation.....................................................................................................27
Before You Start............................................................................................................................28
Installation Guidelines...................................................................................................................28
Terminating Cable Shields.............................................................................................................31
Checking the Press.........................................................................................................................31
Mounting the SmartPAC PRO Servo Control Enclosure ..............................................................32
Installing SmartPAC PRO Servo as a Panel Mount ......................................................................33
Installing SmartPAC PRO Servo with Remote HMI.....................................................................34
Installing the MTS Linear Transducer...........................................................................................35
MountingtheTransducer....................................................................................................................................35
WiringtheTransducer.........................................................................................................................................37
WiringtheTransducertoDCPower.................................................................................................................39
Connecting Power Wiring –AC Powered Units ...........................................................................40
Connecting Power Wiring –24 VDC Powered Units....................................................................41
Connecting Stop Circuits and Input Check Circuit........................................................................41
MakingWiringConnections...............................................................................................................................42
SettingtheInput CheckVoltage Switch............................................................................................................42
Connecting to the Network............................................................................................................43
Adding or Upgrading DiProPAC or ProCamPAC.........................................................................43
Connecting DiPro Sensor Interface to SmartPAC PRO Servo......................................................45
Connecting Programmable Cam Channels....................................................................................49
Wiring Setup Mode Circuit............................................................................................................55
Wiring a Remote Reset Switch (Optional) ....................................................................................55
Wiring a Sensor-Disabled Output (Optional) ................................................................................55
Turning on Power to SmartPAC PRO Servo.................................................................................56
Verifying Installation of DiProPAC and ProCamPAC..................................................................57
Final Checkout...............................................................................................................................58
Set Up a “Test” Tool............................................................................................................................................58
Check StrokeLimits............................................................................................................................................59
ChecktheTop-stop Circuit.................................................................................................................................59
ChecktheEmergency-stopCircuit....................................................................................................................59
Check CamChannels..........................................................................................................................................59
TestComplete.......................................................................................................................................................59
What Next? ....................................................................................................................................60
Wiring Tables for SmartPAC PRO Servo Options........................................................................60

1147100 SmartPAC PRO Servo User Manual
6 Table of Contents
Chapter 3 –Displays and Operating Modes....................................................................63
SmartPAC PRO Operating Modes................................................................................................ 64
InitializationMode...............................................................................................................................................66
ProgramMode......................................................................................................................................................66
RunMode.............................................................................................................................................................66
On-Screen Data Entry ................................................................................................................... 66
On-ScreenNumericKeypad..............................................................................................................................66
On-ScreenKeyboard...........................................................................................................................................67
The “ALT” Menu .......................................................................................................................... 68
ScreenCaptures....................................................................................................................................................68
Chapter 4 –SmartPAC PRO Servo Initialization Mode...................................................71
POSITION SENSOR .................................................................................................................... 73
PositionSensorMode..........................................................................................................................................73
ResolverMotionMode(NormalMotion–LinkMotion)..............................................................................73
AngleWheelRotation(Clockwise–Counterclockwise)...............................................................................73
CounterSetupMode............................................................................................................................................74
CounterIncrementMode....................................................................................................................................74
INSTALLED OPTIONS............................................................................................................... 75
OPTIONS MANAGER................................................................................................................. 75
PREFERENCES............................................................................................................................ 76
SELECTLANGUAGE(OPTIONAL)............................................................................................................77
PRESS NAME .............................................................................................................................. 78
SELECT CAM NAMES (Optional).............................................................................................. 78
SET GLOBAL CAMS (Optional)................................................................................................. 80
CUSTOM SENSOR NAMES (Optional) ..................................................................................... 82
SENSOR ENABLE MODE (Optional)......................................................................................... 83
SelectingSensor EnableMode...........................................................................................................................83
EnablingSetupMode..........................................................................................................................................84
LINEAR SENSOR........................................................................................................................ 84
TOOL INFORMATION ............................................................................................................... 87
SECURITY ACCESS ................................................................................................................... 92
SettingSecurityAccess.......................................................................................................................................95
ChangingPasswords............................................................................................................................................96
BACKUP/RESTORE.........................................................................................................................................97
BackingUpToolstoaUSBDisk......................................................................................................................98
RestoringToolsfromaUSBDisk.....................................................................................................................98
SETUP DATA COMMS (Optional)............................................................................................. 98
SETUP NETWORK...................................................................................................................... 99
E-MAILFUNCTION.........................................................................................................................................99
SMARTVIEWFUNCTION...........................................................................................................................100
SETUPE-MAIL................................................................................................................................................100
CHANGENETWORKSETTINGS..............................................................................................................100
PRESSTYPE.....................................................................................................................................................100
DIAGNOSTICS .......................................................................................................................... 101
COMMUNICATIONS....................................................................................................................................102
SETCLOCK......................................................................................................................................................102
SAVETOUSBDISK......................................................................................................................................103
UPDATEFIRMWARE...................................................................................................................................104

SmartPAC PRO Servo User Manual 1147100
Table of Contents 7
Chapter 5 –Program Mode.............................................................................................105
Entering and Exiting Program Mode...........................................................................................106
TOOL MANAGER......................................................................................................................106
Creating aNewTool..........................................................................................................................................107
CopyinganExistingTool..................................................................................................................................108
CopyingToolTemplatetoaNewTool...........................................................................................................109
LoadingaTool....................................................................................................................................................110
ChangingSettingsforaLoadedTool..............................................................................................................111
Deleting aTool...................................................................................................................................................112
Tool Program Menu.....................................................................................................................112
TOOLNAME....................................................................................................................................................113
COUNTERS ................................................................................................................................114
SettingPresetValues..........................................................................................................................................115
ChangingCountValues....................................................................................................................................116
Clearing the Total Hits Counter...................................................................................................117
SettingBatch CounterOutputandIncrementModes....................................................................................117
SettingCounterIncrementAngle.....................................................................................................................118
SettingPartsper StrokeorStrokesperPart.....................................................................................................119
SettingBatch Pre-Load Counts........................................................................................................................120
DIE PROTECTION (Optional) ...................................................................................................120
UnderstandingSensorTerminology................................................................................................................121
Programming SensorSettings...........................................................................................................................125
Programming DiProPAC32Sensors..............................................................................................................136
CAM SWITCH............................................................................................................................142
SelectingaCamChannel..................................................................................................................................144
MakinganON/OFFSetting..............................................................................................................................145
SettingMultiple ON/OFFCycles.....................................................................................................................145
MakingaTimedOutputSetting.......................................................................................................................148
SettingDSVONChannelTiming...................................................................................................................149
Deleting Channel Settings.................................................................................................................................150
ViewingtheCamSummary.............................................................................................................................151
ViewingGlobalCams.......................................................................................................................................151
TOOL INFORMATION..............................................................................................................152
RAM POSITION.........................................................................................................................154
SENSOR ENABLE/DISABLE & STATUS (Optional)..............................................................156
ViewingSensorStatus.......................................................................................................................................157
EnablingorDisablingAllSensors...................................................................................................................157
TurningaSensorOfforOn..............................................................................................................................157
Chapter 6 –Run Mode ....................................................................................................159
Entering and Exiting Run Mode..................................................................................................160
Loading a Tool.............................................................................................................................161
Settings Locked, or Password Required ......................................................................................161
Displaying Multiple Faults ..........................................................................................................162
Opening the Ram Angle Window................................................................................................162
DISABLE (ENABLE) SENSORS...............................................................................................163
COUNTERS ................................................................................................................................165
DIE PROTECTION (Optional) ...................................................................................................167
AdjustingtheReadySignalforGreenSensors...............................................................................................168
AdjustingtheStrokePresetforGreenSpecial Sensors..................................................................................170
ViewingtheSensorSummary..........................................................................................................................170

1147100 SmartPAC PRO Servo User Manual
8 Table of Contents
ViewingSensorStatus.......................................................................................................................................171
AdjustingDiProPAC32Sensors.....................................................................................................................172
CAM SWITCH............................................................................................................................ 175
ViewingCamTiming........................................................................................................................................176
ViewingtheGlobalCamSummary................................................................................................................177
ViewingtheCamSummary.............................................................................................................................177
TOOL INFORMATION ............................................................................................................. 177
RAM POSITION......................................................................................................................... 179
ERROR/EVENT LOG ................................................................................................................ 180
LOAD NEW TOOL.................................................................................................................... 181
MESSAGING.............................................................................................................................. 182
SendingE-mailtoWintrissTechnicalSupport..............................................................................................184
Chapter 7 –Fault Messages...........................................................................................185
Responding to Fault Messages.................................................................................................... 186
Counter Preset Reached Messages.............................................................................................. 187
Messages for Equipment Problems............................................................................................. 187
Messages for Programming Problems......................................................................................... 188
Messages for Sensor Faults......................................................................................................... 189
Miscellaneous Fault Messages.................................................................................................... 191
Troubleshooting Using the Error/Event Log............................................................................... 192
Appendix A –Installing the Balluff Linear Transducer..............................................193
Mounting the Transducer ............................................................................................................ 193
WiringtheTransducer.......................................................................................................................................194
Glossary ..........................................................................................................................197
Index................................................................................................................................199
Setup Sheets
SmartPAC PRO Servo Setup Sheet
ProCamPAC Cam Switch –SmartPAC PRO Servo Setup Sheet Channels 1 –8
ProCamPAC Cam Switch –SmartPAC PRO Servo Setup Sheet Channels 9 –15
DiProPAC Die Protection –SmartPAC PRO Servo Setup Form Sensors 1-16
DiProPAC Die Protection –SmartPAC PRO Servo Setup Form Sensors 17-32

SmartPAC PRO Servo User Manual 1147100
Table of Contents 9
Wiring Diagrams at End of Manual
Figure 1. SmartPAC Pro Servo 8 Cams with DSI 2 MTS Internal PS
Figure 2. SmartPAC Pro Servo Press ProCamPAC 15 MTS Transducer Wiring Diagram
Figure 3. SmartPAC Pro Servo Press Wiring
Figure 4. DiProPAC Sensors 1-16 to DSI 2 Wiring Diagram
Figure 5. DiProPAC Sensors 17-32nto DSI 2 Wiring Diagram
Figure 6. SmartPAC Pro Servo Press ProCamPAC 8 Balluff Transducer Wiring Diagram
Figure 7. SmartPAC Pro Servo Press ProCamPAC 15 Balluff Transducer Wiring Diagram
Figure 8. SmartPAC Pro Loopback Test Wiring
List of Figures
Figure 1-1. SmartPAC PRO Servo Front Panel ...................................................................................19
Figure 2-1. Installation Overview.........................................................................................................30
Figure 2-2. SmartPAC PRO Servo Mounting Dimensions..................................................................32
Figure 2-3. SmartPAC PRO Servo Panel Mount Cutout Dimensions..................................................33
Figure 2-4. SmartPAC PRO Servo Panel Mount Dimensions .............................................................34
Figure 2-5. Real Time SmartPAC (RTS) Board Mounting Dimensions..............................................35
Figure 2-6. MTS Linear Transducer Dimensions.................................................................................36
Figure 2-7. SmartPAC PRO Servo Board –ProCamPAC Board, Left, Outlined in Red.....................37
Figure 2-8. ProCamPAC Linear Boards, Location of Components.....................................................38
Figure 2-9. MTS Linear Transducer Pinout .........................................................................................39
Figure 2-10. Wiring AC to Terminal Block, Inside Enclosure, Top Right ..........................................40
Figure 2-11. Location of Terminal Blocks TB1 to TB8.......................................................................41
Figure 2-12. Input Check Voltage Switch (S101) in the Factory Default (60-250V) Position............43
Figure 2-13. SmartPAC PRO Servo Board –DiProPAC Board, Right, Outlined in Red....................44
Figure 2-14. ProCamPAC Output Assembly .......................................................................................50
Figure 2-15. Cam Outputs Board .........................................................................................................51
Figure 2-16. TB302 and TB 303 for Wiring Relays to Equipment......................................................53
Figure 2-17. Install Suppressors Across AC Loads..............................................................................54
Figure 2-18. Installing a Diode Across a DC Load..............................................................................54
Figure 2-19. Main Program Menu........................................................................................................56
Figure 2-20. Main Program Menu........................................................................................................57
Figure 2-21. Main Initialization Menu.................................................................................................58
Figure 2-22. Installed Options Screen..................................................................................................58
Figure 3-1. SmartPAC PRO Servo.......................................................................................................63
Figure 3-2. SmartPAC PRO Servo Operating Modes, Showing Main Menus.....................................64
Figure 3-3. Numeric Keypad................................................................................................................67
Figure 3-4. SmartPAC PRO Servo On-screen Keyboard.....................................................................67
Figure 3-5. Save to USB Disk..............................................................................................................69
Figure 3-6. USB Disk Error Message...................................................................................................69
Figure 4-1. Main Initialization Menu...................................................................................................71
Figure 4-2. Main Initialization Menu, Next Items................................................................................72

1147100 SmartPAC PRO Servo User Manual
10 Table of Contents
Figure 4-3. Position Sensor Screen...................................................................................................... 73
Figure 4-4. Installed Options Screen.................................................................................................... 75
Figure 4-5. Options Manager Screen................................................................................................... 75
Figure 4-6. Main Initialization Menu................................................................................................... 76
Figure 4-7. Preferences Screen ............................................................................................................ 76
Figure 4-8. Select Language Screen .................................................................................................... 77
Figure 4-9.Press Name Entry Window................................................................................................ 78
Figure 4-10. Cam Channel Name Menu.............................................................................................. 79
Figure 4-11. Select Name for Cam Channel Screen............................................................................ 79
Figure 4-12. Global Cams Menu.......................................................................................................... 81
Figure 4-13. Global Cam Timing Type Screen.................................................................................... 81
Figure 4-14. Custom Sensor Names Screen......................................................................................... 82
Figure 4-15. Die Protection Enable Mode Selection Menu................................................................. 83
Figure 4-16. Linear Sensor Setup Screen............................................................................................. 85
Figure 4-17. Tool Information Setup Screen ....................................................................................... 88
Figure 4-18. Tool Information Name Screen....................................................................................... 89
Figure 4-19. Tool Information Units Selection Screen........................................................................ 90
Figure 4-20. Tool Information Setup Screen with Sample Entries...................................................... 92
Figure 4-21. Security Access Menu..................................................................................................... 92
Figure 4-22. Enter Password Window................................................................................................. 93
Figure 4-23. Set Passwords Menu........................................................................................................ 97
Figure 4-24. “Enter a New Password” Window .................................................................................. 97
Figure 4-25. Network Setup Utility Screen ......................................................................................... 99
Figure 4-26. Diagnostics Menu.......................................................................................................... 101
Figure 4-27. Communications Data Viewer Screen .......................................................................... 102
Figure 4-28. Set the Clock Screen ..................................................................................................... 103
Figure 5-1. Mail Program Menu........................................................................................................ 105
Figure 5-2. Tool Manager Screen...................................................................................................... 107
Figure 5-3. Enter New Tool Number Window.................................................................................. 107
Figure 5-4. Copy Tool Template Window......................................................................................... 108
Figure 5-5. Tool Template Copied..................................................................................................... 109
Figure 5-6. Load Tool Warning Window .......................................................................................... 110
Figure 5-7. Enter Password Window................................................................................................. 110
Figure 5-8. Enter Password Window................................................................................................. 111
Figure 5-9. Delete Tool Confirmation Message ................................................................................ 112
Figure 5-10. Tool Program Menu...................................................................................................... 113
Figure 5-11. Tool Name Entry Window............................................................................................ 114
Figure 5-12. Counters Screen ............................................................................................................ 114
Figure 5-13. Enter Password Window............................................................................................... 116
Figure 5-14. Change Count Confirmation Window........................................................................... 117
Figure 5-15. Counter Mode Selections Screen .................................................................................. 118
Figure 5-16. Advanced Counter Mode Selections Screen................................................................. 119
Figure 5-17. Die Protection Sensor Menu ......................................................................................... 121
Figure 5-18. Ready Signal Programming for a “Green” Sensor ........................................................ 123
Figure 5-19. Ready Signal Programming for a “Green Quick Check” Sensor .................................. 123
Figure 5-20. Ready Signal Programming for a “Green Constant” Sensor......................................... 124
Figure 5-21. “Enter General Password” Screen................................................................................. 126
Figure 5-22. Die Protection Sensor Menu with Auto Enable by Tool Counter................................. 126
Figure 5-23. Sensor Names Screen.................................................................................................... 127
Figure 5-24. Custom Sensor Names Screen....................................................................................... 128
Figure 5-25. Auto Enable by Sensor Counter Screen........................................................................ 128