Wintriss SmartPAC PRO User manual

Changes for Revision C of the SmartPAC PRO User Manual
(1143100)
This revision of the SmartPAC PRO user manual covers SmartPAC 2 software version 10.00 and
higher. The changes include:
•Added figure showing serial number on SD card (Chapter 2)
•Added detail on wiring for pendant installation (Chapter 2)
•Added or enhanced DiProPAC die protection features (Chapter 6)
•Added S-Codes to Chapter 8 –SmartPAC PRO Fault Messages
•Added Appendices:
Appendix A SmartPAC Preventive Maintenance (PM) Monitor (Optional)
Appendix B Updating SmartPAC PRO Firmware
Appendix C Reporting Downtime and Scrap to SFC

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 email a PO to [e-mail] 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 3:30 p.m. Eastern time 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.

SmartPAC PRO User Manual 1143100
Table of Contents 7
Table of Contents
Chapter 1 –Introduction to SmartPAC PRO....................................................................25
SmartPAC PRO Standard Features................................................................................................27
SmartPAC PRO Options................................................................................................................27
Resolver-based Operation..............................................................................................................28
SmartPAC PRO Settings................................................................................................................28
DiProPAC Die Protection Module (Optional)...............................................................................29
ProCamPAC Programmable Cam Switch (Optional)....................................................................29
SmartPAC PRO’s Modes of Operation .........................................................................................29
Initialization Mode..................................................................................................................31
Program Mode.........................................................................................................................31
Run Mode................................................................................................................................31
SmartPAC PRO User Interface......................................................................................................32
On-Screen Numeric Keypad ...................................................................................................32
On-Screen Keyboard...............................................................................................................33
Control and Navigation Buttons ....................................................................................................34
Screen Captures.......................................................................................................................35
Creating and Using Dashboards..............................................................................................36
SmartPAC PRO Specifications......................................................................................................41
Chapter 2 –Installing SmartPAC PRO.............................................................................43
Before You Start............................................................................................................................45
Installation Guidelines...................................................................................................................45
Terminating Cable Shields......................................................................................................46
Checking the Press.........................................................................................................................47
Mounting the SmartPAC PRO Control Enclosure.........................................................................47
Installing SmartPAC PRO as a Panel Mount.................................................................................48
Installing SmartPAC PRO in a Pendant.........................................................................................50
Installing the Resolver ...................................................................................................................52
Mounting the Resolver............................................................................................................54
Wiring the Resolver.................................................................................................................54
Connecting Power Wiring –AC Powered Units ...........................................................................55
Connecting Power Wiring –24 VDC Powered Units....................................................................57
Connecting Stop Circuits and Input Check Circuit........................................................................57
Making Wiring Connections..........................................................................................................58
Setting the Input Check Voltage Switch........................................................................................58
Adding or Upgrading DiProPAC or ProCamPAC Option.............................................................60
Connecting DiPro Sensor Interface to SmartPAC PRO ................................................................62
Connecting ProCamPAC Programmable Cam Channels........................................................66
Wiring Setup Mode Circuit............................................................................................................73

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Wiring a Remote Reset Switch (Optional).................................................................................... 73
Wiring a Sensor-Disabled Output (Optional)................................................................................ 73
Wiring the ProCamPAC Output with Your Mechanical Top Stop Cam Switch (Optional)......... 74
Zeroing the Resolver..................................................................................................................... 75
Turning on Power to SmartPAC PRO........................................................................................... 75
Verifying Installation of DiProPAC and/or ProCamPAC (Optional) ........................................... 76
Moving the Ram to Top Dead Center (TDC)................................................................................ 77
Setting the Resolver Zero Position................................................................................................ 77
Installing the Position Sensor (Optional) ...................................................................................... 78
Final Checkout .............................................................................................................................. 82
Set Up a “Test” Tool............................................................................................................... 82
Check and Set Direction of Rotation of Resolver................................................................... 82
Check for Position Sensor (If Installed) Error Messages........................................................ 82
Check the Top-stop Circuit..................................................................................................... 82
Check the Emergency-stop Circuit......................................................................................... 83
Check Cam Channels (ProCamPAC Only) ............................................................................ 83
Test Complete......................................................................................................................... 83
What Next?.................................................................................................................................... 83
Wiring Tables for Other SmartPAC PRO Connections ................................................................ 84
Chapter 3 –SmartPAC PROInitializationMode...............................................................85
RESOLVER ZERO ....................................................................................................................... 86
POSITION SENSOR .................................................................................................................... 86
POSITION SENSOR MODE........................................................................................................ 87
RESOLVER MOTION MODE (Normal Motion –Link Motion)................................................. 87
ANGLEWHEEL ROTATION (Clockwise-Counterclockwise) ................................................... 87
COUNTER SETUP MODE........................................................................................................... 87
Counter Increment Mode............................................................................................................... 88
INSTALLED OPTIONS................................................................................................................ 89
OPTIONS MANAGER .......................................................................................................... 90
PRESS NAME .............................................................................................................................. 91
SET BRAKE MONITOR (Optional with WPC 2000 Integration)................................................. 91
Calculating the Stop Time Limit (Optional with WPC 2000 Integration)............................... 92
Setting Stop Time and Start Time Limits(Optional with WPC 2000 Integration)................... 93
TOOL INFORMATION................................................................................................................ 93
SECURITY ACCESS ................................................................................................................... 94
Setting Security Access.................................................................................................................. 97
ChangingPasswords...................................................................................................................... 97
BACKUP/RESTORE.................................................................................................................... 98
Backing Up Tools to a USB Disk............................................................................................ 99
Backing Up Tools to a Network Folder................................................................................... 99
Restoring Tools from a USB Disk......................................................................................... 100

SmartPAC PRO User Manual 1143100
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Restoring Tools from a Network Folder ................................................................................100
Backup and Restore, Advanced.............................................................................................101
SETUP DATACOMMS/SFC (Optional).....................................................................................102
Entering Special Names and Sequence Numbers..................................................................104
Entering Sequence Numbers for Canned Names ..................................................................105
SETUP NETWORK ....................................................................................................................106
SETUP EMAIL............................................................................................................................107
Setting up the Recipient List.................................................................................................108
Entering Predefined Messages ..............................................................................................109
INFO CENTER.....................................................................................................................110
SMARTVIEWFUNCTION..................................................................................................110
PRESS TYPE........................................................................................................................111
REMOTE ADMIN SETTINGS............................................................................................111
CHANGENETWORKSETTINGS......................................................................................113
DIAGNOSTICS...........................................................................................................................114
COMMUNICATIONS..........................................................................................................115
SETCLOCK..........................................................................................................................116
SAVE TO USB DISK............................................................................................................117
UPDATEFIRMWARE..........................................................................................................117
System Init...................................................................................................................................118
Reset Initialization Data. . ....................................................................................................118
Application Data Menu.........................................................................................................120
Delete All Dashboards, Favorites, or Screen Captures .........................................................121
Disable Loss Rotation ...........................................................................................................122
Using SmartPAC PRO with a Link-motion Press........................................................................122
Setting Link Motion......................................................................................................................122
Using a ServoFeed Interface with Link Motion............................................................................123
Settling Time Compensation for Link Motion.......................................................................123
Press Speed Compensation for Link Motion..........................................................................124
Chapter 4 –SmartPAC PRO Program Mode..................................................................125
Entering and Exiting Program Mode...........................................................................................125
TOOL MANAGER......................................................................................................................126
Tool Manager List View .......................................................................................................126
Creating a New Tool .............................................................................................................128
Copying an Existing Tool......................................................................................................129
Copying Tool Template to a New Tool.................................................................................129
Loading a Tool ......................................................................................................................130
Changing Settings for a Loaded Tool....................................................................................130
Deleting a Tool......................................................................................................................131
Viewing Tool Data Summary................................................................................................131
Tool Program Menu ..............................................................................................................133

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Setting Counter Increment Angle ......................................................................................... 138
DIE PROTECTION (Optional) ............................................................................................ 140
CAM SWITCH (Optional) ................................................................................................... 140
PRESS SPEED ..................................................................................................................... 140
TOOL INFORMATION....................................................................................................... 141
SENSOR ENABLE/DISABLE & STATUS (Optional) ............................................................. 141
Chapter 5 –SmartPAC PRO Run Mode.........................................................................143
Entering and Exiting Run Mode.................................................................................................. 144
Settings Locked or Password Required....................................................................................... 145
Displaying Multiple Faults.......................................................................................................... 145
DISABLE (ENABLE) SENSORS (Optional)............................................................................. 146
COUNTERS................................................................................................................................ 147
DIE PROTECTION (Optional)................................................................................................... 148
BRAKE MONITOR.................................................................................................................... 148
Determining the Stopping Time of Your Press..................................................................... 149
Performing the 90 Stop-time Test....................................................................................... 150
Calculating the Safety Distance............................................................................................ 150
PRESS SPEED............................................................................................................................ 151
TOOL INFORMATION ............................................................................................................. 153
ERROR/EVENT LOG ................................................................................................................ 153
LOAD NEW TOOL.................................................................................................................... 154
MESSAGING.............................................................................................................................. 156
Chapter 6 –Using DiProPAC Die Protection (Optional)...............................................159
DiProPAC in Initialization Mode................................................................................................ 161
Sensor Names ....................................................................................................................... 161
Entering Global Sensor Names.............................................................................................. 162
SENSOR ENABLE MODE.................................................................................................. 164
Selecting Sensor Enable Mode .............................................................................................. 165
Enabling Setup Mode................................................................................................................... 165
DiProPAC Die Protection in Program Mode .............................................................................. 166
Selecting Sensor Enable Mode by Tool in Program Mode................................................... 167
Understanding Sensor Terminology ..................................................................................... 168
Sensor Types ............................................................................................................................... 168
Static Sensors: Yellow and Red Sensors............................................................................... 169
Cyclic Sensors: Green Sensors ............................................................................................. 171
Programming Sensor Settings ..................................................................................................... 177
Setting Enable Mode............................................................................................................. 177
COPY A SENSOR...................................................................................................................... 178
Naming the Sensor................................................................................................................ 179
Setting the “Auto Enable by Tool” Counter Value............................................................... 182
Setting the Stroke Count for Auto Enable by Sensor............................................................ 183

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Setting Sensor Type...............................................................................................................184
Setting the Sensor Stop Type ................................................................................................185
Setting the Critical Angle for a Sensor Set to SMART STOP..............................................186
Setting the Ready Signal for a Green Sensor ........................................................................188
Setting the Counter Value for a Green Special Sensor..........................................................189
Viewing and Changing Sensor Settings................................................................................190
Viewing the Sensor Summary...............................................................................................191
Deleting a Sensor...................................................................................................................191
SENSOR ENABLE/DISABLE & STATUS ...............................................................................192
Viewing Sensor Status.................................................................................................................192
Enabling or Disabling All Sensors...............................................................................................193
Turning a Sensor Off or On.........................................................................................................193
Run Mode ....................................................................................................................................194
DISABLE (ENABLE) SENSORS........................................................................................194
Adjusting the Ready Signal for Green Sensors.....................................................................196
Adjusting the Stroke Preset for Green Special Sensors.........................................................198
Viewing the Sensor Summary...............................................................................................198
Viewing Sensor Status...........................................................................................................199
Chapter 7 –Using ProCamPAC Programmable Cams .................................................201
ProCamPAC Programmable Cam Switch....................................................................................202
Initialization.................................................................................................................................202
SELECT CAM NAMES (ProCamPAC)...............................................................................202
AUTO ADVANCE and Slow RPM (ProCamPAC)..............................................................204
Calculating the Auto Advance Constant.......................................................................................205
Setting Auto Advance Constants and Slow RPM .........................................................................205
SET GLOBAL CAMS (Optional)...............................................................................................206
ProCamPAC in Program Mode ...................................................................................................208
Programmable Cam Switch (ProCamPAC) ..........................................................................209
Selecting a Cam Channel ......................................................................................................209
Making an ON/OFF Setting..................................................................................................210
Setting Multiple ON/OFF Cycles..........................................................................................211
Making a Timed Output Setting............................................................................................213
Making an Auto Advance Setting .........................................................................................214
Setting DSV ON Channel Timing.........................................................................................215
Deleting Channel Settings.....................................................................................................216
Viewing the Cam Summary.........................................................................................................217
Viewing Global Cams..................................................................................................................217
Run Mode: CAM SWITCH (ProCamPAC).................................................................................218
Viewing Cam Timing............................................................................................................220
Viewing the Global Cam Summary ......................................................................................221
Viewing the Cam Summary ..................................................................................................221

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12 Table of Contents
Chapter 8 –SmartPAC PRO Fault Messages................................................................223
Responding to the Brake Warning LED............................................................................... 223
Responding to Fault Messages.................................................................................................... 223
Counter Preset Reached Messages.............................................................................................. 224
“S03 Good parts counter preset reached TS”........................................................................ 224
“S06 Strokes counter preset reached TS” ............................................................................. 224
“S0x Batch # counter preset reached TS”............................................................................. 225
Messages for Equipment or Brake Monitor Problems ................................................................ 225
“S11 Loss of rotation ES”..................................................................................................... 225
“Angle resolver failure”........................................................................................................ 226
“S12 Input check circuit failure” .......................................................................................... 226
“S10 Position sensor incorrect ES”....................................................................................... 226
E-Stop errors......................................................................................................................... 227
“Inboard ram test failure” ..................................................................................................... 227
“Resolver signals incorrect” or “Resolver drive signal incorrect”........................................ 227
“S13 Stop time exceeded” .................................................................................................... 228
Messages for Programming Problems......................................................................................... 229
“No tool number has been loaded” ....................................................................................... 229
“S09 Tool number table checksum error ES”....................................................................... 229
“S30 Program memory checksum 1 fault” ........................................................................... 230
“S31 Program memory checksum 2 fault” ........................................................................... 230
Messages for Sensor Faults......................................................................................................... 230
“Green sensor missed”.......................................................................................................... 230
“Green sensor actuated late”................................................................................................. 230
“Green sensor failure”........................................................................................................... 231
“Green constant fault”........................................................................................................... 231
“Green quick check sensor actuated outside ready” ............................................................. 231
“Green special fault”............................................................................................................. 231
Fault message for yellow sensors “This N/O sensor is grounded” ....................................... 232
Fault message for red sensors “This N/C sensor is open” .................................................... 232
Miscellaneous Fault Messages.................................................................................................... 232
“S00 Maximum press speed exceeded”................................................................................ 232
“S01 Minimum press speed exceeded”................................................................................. 232
“S33 The resolver position is different from when the unit was turned off ES” .................. 232
“One of the sensor auto enable counters is greater than 99”................................................. 233
“S32 Module communications fault”.................................................................................... 233
“S35 Loss of Communication at Address X ES”.................................................................. 233
Troubleshooting Using the Error/Event Log............................................................................... 234
Appendix A SmartPAC Preventive Maintenance (PM) Monitor (Optional)..............235
About SmartPAC PM Monitor.................................................................................................... 235
Comparison with Traditional Preventive Maintenance......................................................... 235

SmartPAC PRO User Manual 1143100
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How the PM Monitor Works.................................................................................................235
Examples of How to Use the PM Monitor............................................................................236
Installing the PM Monitor............................................................................................................237
For New Systems from the Factory.......................................................................................237
For Existing Systems.............................................................................................................237
Using the PM Monitor in InitializationMode..............................................................................238
How to Access SmartPAC Initialization and PMMonitor ....................................................238
Initializing the PM Monitor...................................................................................................240
Assigning a New PM Password Number ..............................................................................242
Selecting PM Item Names.....................................................................................................243
Using the PM Monitor in Run mode............................................................................................247
How to Get into SmartPAC Run Mode.................................................................................247
A Tool Number Must Be Loaded Before Switching to Run Mode.......................................247
Viewing and Modifying PM Alerts.......................................................................................247
Appendix B Updating SmartPAC PRO Firmware......................................................251
Installing Updated Firmware from USB Disk to SmartPAC PRO........................................252
Appendix C Reporting Downtime and Scrap to SFC................................................255
Machine States to Which SFC Logs Press Time .........................................................................255
SmartPAC PRO Downtime Reporting Features..........................................................................256
Forced Idle Dialog Mode ......................................................................................................256
Backfilling vs. ForwardFilling..............................................................................................256
Putting the Press “Back on Line” ..........................................................................................257
Forced Error Dialog Mode....................................................................................................259
Persist Dialog Mode..............................................................................................................260
Single-stroke Mode ...............................................................................................................260
Reset Strokes Counters..........................................................................................................260
Setting up SmartPAC PRO to Report Downtime ........................................................................261
Making Downtime Reporting Settings..................................................................................262
Programming Downtime Reasons.........................................................................................266
Documenting Downtime on the Dialog Menu.............................................................................270
Documenting Downtime in Response to the Forced Dialog Message..................................270
Documenting Downtime in Other Situations ........................................................................272
Ending a Job..........................................................................................................................274
Reporting Scrap and Good Parts to SFC......................................................................................274
Making Scrap Entries............................................................................................................275
Adjusting the Good Parts Counter.........................................................................................277

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14 Table of Contents
Glossary .................................................................................................................281
Index .................................................................................................................285
Setup Sheets
SmartPAC PRO Setup Sheet
ProCamPAC Cam Switch –SmartPAC PRO Setup Sheet Channels 1-8
ProCamPAC Cam Switch –SmartPAC PRO Setup Sheet Channels 9-16
DiProPAC Die Protection –SmartPAC PRO Setup Form Sensors 1-16
DiProPAC Die Protection –SmartPAC PRO Setup Form Sensors 17-32
Wiring Diagrams
Figure 1. DiProPAC Sensors 1-16 to DSI 2 Wiring Diagram
Figure 2. DiProPAC Sensors 17-32 to DSI 2 Wiring Diagram
Figure 3. ProCamPAC 16 to Cam Output Wiring Diagram
Figure 4. 120-240 VAC SmartPAC PRO Wiring Configuration
Figure 5. SmartPAC PRO Loopback Test Wiring
Figure 6. 24 VDC SmartPAC PRO Wiring Configuration
Figure 7. 120-240 VAC SmartPAC PRO with USB Extended Wiring Configuration
Figure 8. 24 VDC SmartPAC PRO with USB Extended Wiring Configuration
Figure 9. 120-240VAC SmartPAC PRO with Remote RTS Wiring Configuration
Figures
Figure 1-1. SmartPAC PRO Front Panel............................................................................................. 26
Figure 1-2. “Top” Screen for each of SmartPAC PRO’s 3 Operating Modes ..................................... 30
Figure 1-3. Numeric Keypad................................................................................................................ 32
Figure 1-4. SmartPAC PRO On-screen Keyboard............................................................................... 33
Figure 1-5. Save to USB Disk.............................................................................................................. 35
Figure 1-6. USB Transfer Complete.................................................................................................... 36
Figure 1-7. USB Disk Error Message.................................................................................................. 36
Figure 1-8. Favorites Button................................................................................................................ 36
Figure 1-9. Favorites Screen................................................................................................................ 37
Figure 1-10. Add Screen to Favorites.................................................................................................. 37
Figure 1-11. Delete Screens from Favorites ........................................................................................ 38
Figure 1-12. Dashboard Configuration Screen.................................................................................... 38
Figure 1-13. 1 x 2 Dashboard Example ............................................................................................... 39
Figure 1-14. 2 x 2 Dashboard Example ............................................................................................... 39
Figure 1-15. Dashboard Configuration Screen, Display Area 1 Filled................................................ 39
Figure 1-16. Dashboard Configuration Preview.................................................................................. 40
Figure 1-17. Dashboard Button............................................................................................................ 40
Figure 2-1. SmartPAC PRO Mounting Dimensions............................................................................ 47
Figure 2-2. SmartPAC PRO Panel Mount Cutout Dimension............................................................. 49
Figure 2-3. SmartPAC PRO Panel Mount Dimensions....................................................................... 50
Figure 2-4. Pendant Installation........................................................................................................... 51

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Figure 2-5. Resolver Dimensions.........................................................................................................52
Figure 2-6. Location of Terminal Blocks TB1 through TB8 ...............................................................53
Figure 2-7. Wiring AC to Terminal Block, Inside Enclosure, Top Right............................................56
Figure 2-8. Schematic of Input Check Circuit for 10-130 Vac or Vdc ................................................57
Figure 2-9. Input Check Voltage Switch (S101) in the Factory Default (60-250V) Position..............59
Figure 2-10. Location of Serial Number on SD Card (HMI Board) ....................................................59
Figure 2-11. SmartPAC PRO Main (RTS) Board Showing Location of Option Module Boards, and
TB3 and TB4...................................................................................................................61
Figure 2-12. DiProPAC Boards (8-, 16-, and 32-Sensor): Location of Components...........................62
Figure 2-13. ProCamPAC Boards (8- and 16-Channel): Location of Components.............................68
Figure 2-14. ProCamPAC Output Assembly .......................................................................................69
Figure 2-15. Installing Suppressors Across an AC Load .....................................................................72
Figure 2-16. Installing a Diode Across a DC Load..............................................................................72
Figure 2-17. Optional Top-Stop Wiring...............................................................................................74
Figure 2-18. Main Program Menu........................................................................................................76
Figure 2-19. Installed Options Screen (yours may list different options) ............................................77
Figure 2-20. “Resolver Zero” Screen ...................................................................................................78
Figure 2-21. Position Sensor Dwell on Different Diameter Shafts......................................................79
Figure 2-22. Position Sensor Screen ....................................................................................................80
Figure 2-23. Position Sensor Installation .............................................................................................81
Figure 3-1. Main Initialization Menu....................................................................................................85
Figure 3-2. Position Sensor Screen.......................................................................................................86
Figure 3-3. Installed Options Screen.....................................................................................................89
Figure 3-4. Select Language Screen .....................................................................................................89
Figure 3-5. Options Manager Screen....................................................................................................90
Figure 3-6. Press Name Entry Window................................................................................................91
Figure 3-7. Press Control Parameter Menu ..........................................................................................92
Figure 3-8. Security Access Menu .......................................................................................................94
Figure 3-9. “Enter Your Password” Screen...........................................................................................95
Figure 3-10. Set Passwords Menu.........................................................................................................98
Figure 3-11. Backup and Restore Utility Screen..................................................................................98
Figure 3-12. Backup/Restore Setup Network Folder Screen................................................................99
Figure 3-13. Backup and Restore Utility Advanced Screen...............................................................101
Figure 3-14. Set Communications Menu, Showing Default Values. .................................................102
Figure 3-15. Set Communications Menu, Dialog Screen Mode 16/16...............................................104
Figure 3-16. Dialog Special Name Choice Menu...............................................................................105
Figure 3-17. Dialog Fixed Name Choice Menu.................................................................................105
Figure 3-18. Network Setup Utility....................................................................................................106
Figure 3-19. Messaging Setup............................................................................................................107
Figure 3-20. E-mail Recipients...........................................................................................................108
Figure 3-21. Predefined Messages Screen..........................................................................................109
Figure 3-22. Info Center Setup Screen...............................................................................................110
Figure 3-23. Remote Admin Settings Screen.....................................................................................111
Figure 3-24. Fault List for Prohibiting Fault Reset............................................................................112
Figure 3-25. Change Network Settings: Local Area Connection.......................................................113
Figure 3-26. Diagnostics Menu ..........................................................................................................114
Figure 3-27. Initialize SmartPAC System Screen..............................................................................118
Figure 3-28. Modules Available to Initialize......................................................................................119
Figure 3-29. Modules, Press Control Selected...................................................................................119
Figure 3-30. Reset Initialization Warning..........................................................................................120
Figure 3-31. Application Data Menu, Tools.......................................................................................120

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Figure 3-32. Tool Deletion Confirmation.......................................................................................... 121
Figure 3-33. Application Data Menu, Configuration......................................................................... 121
Figure 4-1. Main Program Menu....................................................................................................... 125
Figure 4-2. Tool Manager Screen...................................................................................................... 126
Figure 4-3. Tool Manager List View................................................................................................. 127
Figure 4-4. Tool Manager List View, Tool Detail............................................................................. 127
Figure 4-5. Tool Manager Screen with Numeric Entry Window....................................................... 128
Figure 4-6. Copying an Existing Tool ............................................................................................... 129
Figure 4-7. Load Tool Warning Message.......................................................................................... 130
Figure 4-8. Delete Tool Confirmation Message ................................................................................ 131
Figure 4-9. Tool Data Summary Screen ............................................................................................ 131
Figure 4-10. Tool Data Summary Screen, Scrolled to Bottom.......................................................... 132
Figure 4-11. Tool Program Menu...................................................................................................... 133
Figure 4-12. On-screen keyboard....................................................................................................... 134
Figure 4-13. Counters Screen ............................................................................................................ 134
Figure 4-14. Count Preset Entry ........................................................................................................ 136
Figure 4-15. Set Counter Modes Screen............................................................................................ 137
Figure 4-16. Advanced Counter Mode Selections Screen................................................................. 139
Figure 4-17. Press Speed Parameters Screen..................................................................................... 141
Figure 5-1. Main Run Menu .............................................................................................................. 144
Figure 5-2. “Enter Your Password” Screen ....................................................................................... 145
Figure 5-3. Display All Errors Message Window.............................................................................. 146
Figure 5-4. Counters Screen .............................................................................................................. 147
Figure 5-5. Stop Time Status (Brake Monitor) Screen...................................................................... 149
Figure 5-6. View of Light Curtains and Press Showing Safety Distance.......................................... 151
Figure 5-7. Press Speed Parameters Screen....................................................................................... 151
Figure 5-8. Tool Information Screen ................................................................................................. 153
Figure 5-9. Error/Event Log .............................................................................................................. 154
Figure 5-10. Tool Manager Screen.................................................................................................... 155
Figure 5-11. Load Tool Warning Window ........................................................................................ 155
Figure 5-12. Messaging Screen.......................................................................................................... 156
Figure 5-13. Select Recipients........................................................................................................... 156
Figure 5-14. Select Message Window............................................................................................... 157
Figure 5-15. Select Attachments Window......................................................................................... 158
Figure 5-16. Sending the Message..................................................................................................... 158
Figure 6-1. Main Initialization Menu................................................................................................. 162
Figure 6-2. Global Sensor Names List, Empty.................................................................................. 162
Figure 6-3. Entry Keyboard for Global Sensor Name....................................................................... 163
Figure 6-4. Entry Keyboard Showing New Global Sensor Name..................................................... 163
Figure 6-5. Global Sensor Names Screen Showing Name Added..................................................... 164
Figure 6-6. Die Protection Mode Selection Menu.............................................................................. 164
Figure 6-7. Main Program Menu for a Tool ...................................................................................... 166
Figure 6-8. Die Protection Sensor Menu for Tool 1063, Sensors 1-16.............................................. 166
Figure 6-9. Die Protection Sensor Menu for Tool 1063, Sensors 16-32............................................ 167
Figure 6-10. Die Protection Tool Programming Screen for Tool 6160 Showing Sensor Enable
Mode............................................................................................................................. 168
Figure 6-11. Sensor Program Screen, Auto Reset = OFF.................................................................. 170
Figure 6-12. A Red Sensor Bypassed from 180⁰ to 210⁰. Actuations Within That Window Are
Ignored........................................................................................................................... 171
Figure 6-13. Ready Signal Programming for a “Green” Sensor........................................................ 172
Figure 6-14. Ready Signal Programming for a “Green Quick Check” Sensor .................................. 173

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Figure 6-15. Ready Signal Programming for a “Green Constant” Sensor .........................................173
Figure 6-16. Green Special Sensor with Startup Counter = 10..........................................................174
Figure 6-17. Sensor Program Screen for a Green Flex Sensor...........................................................175
Figure 6-18. Sensor Program Screen showing the Masking feature disabled (default setting)..........177
Figure 6-19. Standard Green Sensor Type with Masking Enabled....................................................177
Figure 6-20. The Sensor Type Screen Showing COPY A SENSOR.................................................178
Figure 6-21. This Tool’s Previously Programmed Sensors from Which You Can Copy the Timing
and Stop Type...............................................................................................................179
Figure 6-22. Sensor List for a Tool....................................................................................................180
Figure 6-23. Sensor Name List...........................................................................................................180
Figure 6-24. New Sensor Name Entry Keyboard...............................................................................181
Figure 6-25. Confirmation Window for Adding Name to Global List...............................................181
Figure 6-26. Die Protection Sensor Menu with Auto Enable by Tool Counter..................................182
Figure 6-27. Sensor Program Screen (for Previously Programmed Sensors) ....................................183
Figure 6-28. Auto Enable by Sensor Stroke Count Screen ................................................................183
Figure 6-29. Sensor Type Screen .......................................................................................................184
Figure 6-30. Sensor Stop Type Screen...............................................................................................185
Figure 6-31. Critical Angle Programming Screen..............................................................................187
Figure 6-32. Ready Signal Programming Screen...............................................................................188
Figure 6-33. Green Special Sensor Stroke Count Screen...................................................................189
Figure 6-34. Sensor Program Screen..................................................................................................190
Figure 6-35. Sensor Summary Screen................................................................................................191
Figure 6-36. Sensor On/Off Status.....................................................................................................192
Figure 6-37. “Sensor Turned Off” Message.......................................................................................193
Figure 6-38. Main Run Menu with SENSORS DISABLED..............................................................194
Figure 6-39. Disable Sensors Confirmation Message........................................................................195
Figure 6-40. Sample Die Protection Run Mode Menu.......................................................................196
Figure 6-41. Ready Signal Programming Screen...............................................................................196
Figure 6-42. Sensor Summary Screen................................................................................................198
Figure 6-43. Sensor Status Screen......................................................................................................199
Figure 7-1. Cam Channel Name Menu...............................................................................................203
Figure 7-2. Cam Channel Name Selection Screen..............................................................................203
Figure 7-3. Auto Advance Menu........................................................................................................204
Figure 7-4. Global Cams Menu ..........................................................................................................207
Figure 7-5. Global Cam Timing Type Screen.....................................................................................207
Figure 7-6. Program Menu.................................................................................................................208
Figure 7-7. Sample Cam Channel Menu............................................................................................209
Figure 7-8. Cam Channel Program Type Menu.................................................................................210
Figure 7-9. Cam Channel On/Off Program Screen ............................................................................211
Figure 7-10. Cam Channel On/Off Program Screen: One On/Off Arc..............................................211
Figure 7-11. Cam Channel On/Off Program Screen: Two On/Off Arcs............................................212
Figure 7-12. Cam Channel On/Off Program Screen: Three On/Off Arcs..........................................213
Figure 7-13. Cam Channel Timed Output Program Screen ...............................................................214
Figure 7-14. Cam Channel Auto Advance Program Screen...............................................................215
Figure 7-15. Cam Channel DSV On Program Screen........................................................................216
Figure 7-16. Cam Channel Deletion Confirmation Window .............................................................216
Figure 7-17. Cam Summary Screen ...................................................................................................217
Figure 7-18. Global Cam Summary Screen .......................................................................................218
Figure 7-19. Cam Switch Menu .........................................................................................................219
Figure 7-20. Cam Timing Screen.......................................................................................................220
Figure 7-21. Global Cam Summary Screen .......................................................................................221

1143100 SmartPAC PRO User Manual
18 Table of Contents
Figure 7-22. Cam Summary Screen................................................................................................... 221
Figure 8-1. Error Code Message........................................................................................................ 223
Figure 8-2. Counter Preset Message.................................................................................................. 224
Figure 8-3. Location of JP101 ........................................................................................................... 228
Tables
Table 1-1. Initialization, Program and Run Modes: Entry and Exit Procedures................................... 30
Table 1-2. Control Buttons on SmartPAC PRO .................................................................................. 34
Table 1-3. SmartPAC PRO Specifications .......................................................................................... 41
Table 2-1. Connecting HMI to RTS Boards for a Pendant-mounted Display ..................................... 51
Table 2-2. Resolver Wiring.................................................................................................................. 55
Table 2-3. Stop and Input Check Circuit Wiring Connections: TB4................................................... 58
Table 2-4. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Wiring, Sensors 1-8 .......................... 63
Table 2-5. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Wiring, Sensors 9-16 ........................ 64
Table 2-6. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Wiring, Sensors 17-24 ...................... 65
Table 2-7. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Wiring, Sensors 25-32 ...................... 66
Table 2-8. ProCamPAC to Cam Output Assembly SMARTPAC PRO01 Wiring, Cams 1-8............. 70
Table 2-9. ProCamPAC to Cam Output Assembly SMARTPAC PRO01 Wiring, Cams 9-16........... 70
Table 2-10. Connections to Relays...................................................................................................... 71
Table 2-11. Aux I/O (TB5) Wiring...................................................................................................... 73
Table 2-12. SFI Port (1) and Module Port (2) (TB6) Wiring.............................................................. 84
Table 2-13. Special Port (3) and Comm Test Port (4) (TB7) Wiring .................................................. 84
Table 2-14. Spare 1 Port (5) and WPC Port (6) (TB8) Wiring........................................................... 84
Table 3-1. Security Access Settings..................................................................................................... 95
Table 3-2. Advanced Backup/Restore Operations............................................................................. 101
Table 3-3. Communications Settings................................................................................................. 102
Table 5-1. Instructions for Entering and Exiting Run Mode ............................................................. 144
Table 6-1. Sensor Names................................................................................................................... 161
Table 8-1. Communication Errors: SmartPAC PRO Option Identified by Address Number............ 233

HOW TO USE THIS MANUAL
This manual shows you how to install, set up, program, operate, and troubleshoot SmartPAC PRO,
including the ProCamPAC and DiProPAC options.
Chapter 1 provides an overview of the operation and features of SmartPAC PRO, including the
display and user interface.
Chapter 2 shows you how to install SmartPAC PRO, including the optional ProCamPAC and
DiProPAC modules.
Chapter 3 shows you how to use SmartPAC PRO in Initialization mode, which is the mode you select
to make settings that apply to SmartPAC PRO operation for all tools.
Chapter 4 shows you how to use SmartPAC PRO in Program mode, which is the mode you select to
program settings that apply to SmartPAC PRO operation for individual tools.
Chapter 5 shows you how to use SmartPAC PRO in Run mode, which is the mode you select to run
the press and make minor adjustments to programmed settings.
Chapter 6 shows you how to use the DiProPAC die protection option in all three operation modes.
Chapter 7 shows you how to use the ProCamPAC programmable cam option in all three operation
modes.
Chapter 8 provides explanations of the messages that display on the SmartPAC PRO front panel
when a fault condition occurs or a counter preset is reached, and shows you how to correct SmartPAC
PRO faults.
Appendix A shows you how to use SmartPAC PRO preventive maintenance.
Appendix B shows you how to update SmartPAC PRO firmware.
Appendix C shows you how to report downtime and scrap to ShopFloorConnect (SFC).
The Glossary provides definitions of some of the terms used in the manual that may be unfamiliar to
you.
Setup sheets at the end of the manual provide forms on which you can maintain a record of
Initialization and Program settings for your SmartPAC PRO.
Wiring diagrams (Figures 1 through 9) following the Setup sheets provide wiring connections for
SmartPAC PRO, DiProPAC, ProCamPAC, and the SmartPAC PRO loopback test.