Wintriss Smartpac pro User manual

Wintriss Press Automation Control

1143200

Rev. B October 2020

Tech Support Hotline 800-586-8324 8-5 EST

www.wintriss.com

Wintriss Controls Group, LLC

100 Discovery Way

Unit 110

Acton MA 01720 USA

Phone (800) 586-8324

Fax (978)263-2048

PRINTED IN USA

For complete SmartPAC PRO documentation, scan the

code below or visit www.wintriss.com/edocs/options

(case sensitive).

Thank you for purchasing a Wintriss product. We appreciate your business and want to do whatever we

can to ensure your satisfaction. Wintriss products are built to stay on the job day after day, and are

backed by an ironclad guarantee, international standards approvals, and unbeatable support. Whenever

you need assistance or service, we back all our products with excellent spare parts inventories, training

programs, and prompt repair service. We would like to share with you a list of service options –

probably the largest number of service options offered in the industry.

•Technical Assistance

We offer a toll-free line for technical assistance. Call our Wintriss Technical Support Hotline at

1-800-586-TECH (8324) should you have any questions about your equipment. Our technical staff is

ready to assist you Monday through Friday, 8 a.m. to 5 p.m. Eastern Time. In many cases our

experienced technical staff can resolve your inquiry right over the phone.

•Return Authorization

Please call our 800 number for a return authorization (RMA) number to return a product for repair.

Returned goods must arrive freight prepaid. In order to process your return quickly, we ask that you

provide us with the following pertinent information when you call: purchase order number, shipping

address, contact name and telephone number, and product type. The assigned RMA number should

appear on all packages returned to Wintriss Controls Group to ensure prompt service.

At the time of requesting an RMA, you will be quoted a flat-rate repair price for the product you are

returning. We ask that you either email or fax us a PO for that amount or enclose the PO with the

returned item. This will enable us to ship the item back to you as soon as the repair has been

completed. If the item cannot be repaired or there are additional charges, you will be contacted for

approval.

Please be sure to carefully pack all returned items and ship to our Acton, MA location.

•Expedited Repair Program

Rush service providing 48 hour turnaround is available for most products upon request. An Expedite

Fee will be applied to our standard repair rate.

•Board Exchange Program

If your needs are urgent, you can take advantage of our Board Exchange (EX) program. Call our 800

number between 8 a.m. and 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 Installation Manual 1143200 
Table of Contents 5 
Table of Contents 
Chapter 2 –Installing SmartPAC PRO.............................................................................15 
Before You Start............................................................................................................................16 
Installation Guidelines...................................................................................................................17 
Terminating Cable Shields......................................................................................................18 
Checking the Press.........................................................................................................................18 
Mounting the SmartPAC PRO Control Enclosure.........................................................................19 
Installing SmartPAC PRO as a Panel Mount.................................................................................20 
Installing the Resolver ...................................................................................................................21 
Mounting the Resolver............................................................................................................23 
Wiring the Resolver.................................................................................................................24 
Connecting Power Wiring –AC Powered Units ...........................................................................25 
Connecting Power Wiring –24 VDC Powered Units....................................................................27 
Connecting Stop Circuits and Input Check Circuit........................................................................27 
Making Wiring Connections..........................................................................................................27 
Setting the Input Check Voltage Switch........................................................................................28 
Adding or Upgrading DiProPAC or ProCamPAC Option.............................................................29 
Connecting DiPro Sensor Interface to SmartPAC PRO ................................................................31 
Connecting ProCamPAC Programmable Cam Channels........................................................34 
Wiring Setup Mode Circuit............................................................................................................39 
Wiring a Remote Reset Switch (Optional) ....................................................................................40 
Wiring a Sensor-Disabled Output (Optional) ................................................................................40 
Wiring the ProCamPAC Output with Your Mechanical Top Stop Cam Switch (Optional)..........41 
Zeroing the Resolver......................................................................................................................42 
Turning on Power to SmartPAC PRO ...........................................................................................42 
Verifying Installation of DiProPAC and/or ProCamPAC (Optional)............................................43 
Moving the Ram to Top Dead Center (TDC)................................................................................44 
Setting the Resolver Zero Position ................................................................................................44 
Installing the Position Sensor (Optional).......................................................................................45 
Final Checkout...............................................................................................................................49 
Set Up a “Test” Tool ...............................................................................................................49 
Check and Set Direction of Rotation of Resolver ...................................................................49 
Check for Position Sensor (If Installed) Error Messages........................................................49 
Check the Top-stop Circuit .....................................................................................................50 
Check the Emergency-stop Circuit..........................................................................................50 
Check Cam Channels (ProCamPAC Only).............................................................................50 
Test Complete..........................................................................................................................50 
What Next? ....................................................................................................................................50 
Wiring Tables for Other SmartPAC PRO Connections.................................................................51 

1143200 SmartPAC PRO Installation Manual 
6 Table of Contents 
Chapter 8 –SmartPAC PRO Fault Messages..................................................................53 
Responding to the Brake Warning LED................................................................................. 53 
Responding to Fault Messages...................................................................................................... 53 
Counter Preset Reached Messages................................................................................................ 54 
“Good parts counter preset reached” ...................................................................................... 54 
“Strokes counter preset reached” ............................................................................................ 54 
“Batch # counter preset reached”............................................................................................ 55 
Messages for Equipment or Brake Monitor Problems .................................................................. 55 
“Loss of rotation detected” ..................................................................................................... 55 
“Angle resolver failure”.......................................................................................................... 56 
“Input check circuit failure”.................................................................................................... 56 
“Position sensor incorrect” ..................................................................................................... 56 
E-Stop errors........................................................................................................................... 57 
“Inboard ram test failure” ....................................................................................................... 57 
“Resolver signals incorrect” or “Resolver drive signal incorrect”.......................................... 57 
“Stop time exceeded”.............................................................................................................. 58 
Messages for Programming Problems........................................................................................... 59 
“No tool number has been loaded” ......................................................................................... 59 
“Tool number table checksum error”...................................................................................... 59 
Messages for Sensor Faults........................................................................................................... 60 
“Green sensor missed”............................................................................................................ 60 
“Green sensor actuated late”................................................................................................... 60 
“Green sensor failure”............................................................................................................. 60 
“Green constant fault”............................................................................................................. 60 
“Green quick check sensor actuated outside ready” ............................................................... 61 
“Green special fault”............................................................................................................... 61 
Fault message for yellow sensors “This N/O sensor is grounded” ......................................... 61 
Fault message for red sensors “This N/C sensor is open” ...................................................... 61 
Miscellaneous Fault Messages...................................................................................................... 62 
“Maximum press speed exceeded” ......................................................................................... 62 
“Minimum press speed exceeded”.......................................................................................... 62 
“The resolver position is different from when the unit was turned off” ................................. 62 
“One of the sensor auto enable counters is greater than 99”................................................... 62 
“Loss of Communication at Address X”................................................................................. 62 
Troubleshooting Using the Error/Event Log................................................................................. 63 
 
 

SmartPAC PRO Installation Manual 1143200 
Table of Contents 7 
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 2-1. SmartPAC PRO Mounting Dimensions ............................................................................19 
Figure 2-2. SmartPAC PRO Panel Mount Cutout Dimension .............................................................20 
Figure 2-3. SmartPAC PRO Panel Mount Dimensions........................................................................21 
Figure 2-4. Resolver Dimensions.........................................................................................................22 
Figure 2-5. Location of Terminal Blocks TB1 through TB8 ...............................................................22 
Figure 2-6. Wiring AC to Terminal Block, Inside Enclosure, Top Right............................................26 
Figure 2-7. Input Check Voltage Switch (S101) in the Factory Default (60-250V) Position..............28 
Figure 2-8. SmartPAC PRO Main (RTS) Board showing option module boards and TB3 and TB4..30 
Figure 2-9. DiProPAC Boards (8-, 16-, and 32-Sensor): Location of Components.............................31 
Figure 2-10. ProCamPAC Boards (8- and 16-Channel): Location of Components.............................35 
Figure 2-11. ProCamPAC Output Assembly .......................................................................................36 
Figure 2-12. Installing Suppressors Across an AC Load .....................................................................39 
Figure 2-13. Installing a Diode Across a DC Load..............................................................................39 
Figure 2-14. Optional Top-Stop Wiring...............................................................................................41 
Figure 2-15. Main Program Menu........................................................................................................43 
Figure 2-16. Installed Options Screen (yours may list different options) ............................................44 
Figure 2-17. “Resolver Zero” Screen ...................................................................................................45 
Figure 2-18. Position Sensor Dwell on Different Diameter Shafts......................................................46 
Figure 2-19. Position Sensor Screen ....................................................................................................47 
Figure 2-20. Position Sensor Installation .............................................................................................48 
Figure 8-1. Error Code Message ..........................................................................................................53 
Figure 8-2. Counter Preset Message.....................................................................................................54 
Figure 8-3. Location of JP101..............................................................................................................58 

1143200 SmartPAC PRO Installation Manual 
8 Table of Contents 
Tables 
Table 2-1. Resolver Wiring.................................................................................................................. 25 
Table 2-2. Stop and Input Check Circuit Wiring Connections: TB4................................................... 28 
Table 2-3. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Wiring, Sensors 1-8 .......................... 32 
Table 2-4. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Wiring, Sensors 9-16 ........................ 32 
Table 2-5. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Wiring, Sensors 17-24 ...................... 33 
Table 2-6. DiPro Sensor Interface (DSI) 2 to SmartPAC PRO Wiring, Sensors 25-32 ...................... 33 
Table 2-7. ProCamPAC to Cam Output Assembly SMARTPAC PRO01 Wiring, Cams 1-8............. 37 
Table 2-8. ProCamPAC to Cam Output Assembly SMARTPAC PRO01 Wiring, Cams 9-16........... 37 
Table 2-9. Connections to Relays........................................................................................................ 38 
Table 2-10. Aux I/O (TB5) Wiring...................................................................................................... 40 
Table 2-11. SFI Port (1) and Module
 
Port (2) (TB6) Wiring.............................................................. 51 
Table 2-12. Special Port (3) and Comm Test Port (4) (TB7) Wiring .................................................. 51 
Table 2-13. Spare 1 Port (5) and WPC
 
Port (6) (TB8) Wiring........................................................... 51 
Table 8-1. Communication Errors: SmartPAC PRO Option Identified by Address Number.............. 63 
 
 
 
 
 