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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8 Table of Contents
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
Table of Contents 9
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

1143100 SmartPAC PRO User Manual
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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