SmartPAC 2 Servo - Wintriss Controls

SmartPAC 2 Servo - Wintriss Controls
®
SmartPAC 2 Servo
®
Wintriss Press Automation Control
1131400
Rev. H January 2015
Tech Support Hotline
User
Manual
®
800-586-8324
8-5 EST
®
Wintriss Controls Group, LLC
100 Discovery Way
Unit 110
Acton MA 01720 USA
Phone (800) 586-8324
Fax (978) 263-2048
PRINTED IN USA
DA71363
www.wintriss.com
Changes for Revision H of the
SmartPAC 2 Servo User Manual (1131400)
This revision of the SmartPAC 2 Servo user manual covers SmartPAC 2 Servo software
version 13.24 and higher. The changes include:
• Revised procedure for wiring linear transducer to DC power (see page 2-14)
Thank you for purchasing a Wintriss Product.
We appreciate your business and want to do whatever
we can to ensure your satisfaction. Wintriss products are built to stay on the job day after day, and are
backed by an ironclad guarantee, international standards approvals, and unbeatable support.
Whenever you need assistance or service, we back all our products with excellent spare parts
inventories, training programs, and prompt repair service. We would like to share with you a list of
service options–probably the largest number of service options offered in the industry.
• Technical Assistance
We offer a toll-free line for technical assistance. Call our Wintriss Technical Support Hotline at
1-800-586-TECH (8324) should you have any questions about your equipment. Our technical
staff is ready to assist you Monday through Friday, 8 a.m. to 5 p.m. EST. In many cases our
experienced technical staff can resolve your inquiry right over the phone.
• Return Authorization
Please call our “800” number for a return authorization (RMA) number to return a product for
repair. Returned goods must arrive freight prepaid. In order to process your return quickly, we ask
that you provide us with the following pertinent information when you call: purchase order
number, shipping address, contact name and telephone number, and product type. The assigned
RMA number should appear on all packages returned to Wintriss Controls Group to ensure prompt
service.
At the time of requesting an RMA, you will be quoted a flat-rate repair price for the product you
are returning. We ask that you either fax us a PO for that amount or enclose the PO with the
returned item. This will enable us to ship the item back to you as soon as the repair has been
completed. If the item cannot be repaired or there are additional charges, you will be contacted for
approval.
Please be sure to carefully pack all returned items and ship to our Acton, MA location.
• Expedited Repair Program
Rush service providing 48 hour turnaround is available for most products upon request. An
Expedite Fee will be applied to our standard repair rate.
• Board Exchange Program
If your needs are urgent, you can take advantage of our Board Exchange (EX) program. Call our
“800” number between 8 a.m. and 5 p.m. EST and we will send a replacement to you overnight. A
fee does apply to this service. Contact Wintriss Technical Support at 800-586-8324 for details.
• Service Center
Our Service Center for product service is located at our headquarters in Acton MA. If your
equipment requires repair, please contact us at 800-586-8324 to obtain a return authorization
number.
Nationwide field service is also available. Contact the Wintriss Technical Support group at
800-586-8324.
• Product Training
We also offer both product training and maintenance/troubleshooting courses at our Acton, MA
and Chicago-area facilities. On-site training is available from the factory or through your local
Wintriss representative.
• Restocking Charge
Returned goods are subject to a 20% restocking charge if returned for credit. The minimum charge
is $50, not to exceed $250 per item.
Whatever the product, we are committed to satisfying you with innovative engineering, quality
construction, reliable performance, and ongoing, helpful support. Call us whenever you need
assistance.
Table of Contents
Chapter 1.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
SmartPAC 2 Servo Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
SmartPAC 2 Servo Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
SmartPAC 2 Servo Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
SmartPAC 2 Servo Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
SmartPAC 2 Servo Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Sensors Available for DiProPAC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Programmable Cam Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
SmartPAC 2’s Three Modes of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
SmartPAC 2 Servo Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Chapter 2.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Installation Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Connecting Wires to Terminal Block Connectors. . . . . . . . . . . . . . . . . . . . . . . .2-5
Terminating Cable Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Checking the Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Mounting the SmartPAC 2 Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Installing SmartPAC 2 as a Panel Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Installing the MTS Linear Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
Mounting the Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Wiring the Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Wiring the Transducer to DC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
Connecting AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
Connecting Stop Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
Connecting to Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
Replacing ProCamPAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
Adding or Upgrading DiProPAC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
Replacing an Existing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Installing a New Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Connecting DiPro Sensor Interface to SmartPAC 2 . . . . . . . . . . . . . . . . . . . . .2-23
Connecting Programmable Cam Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
Wiring Setup Mode Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
Wiring a Remote Reset Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
Wiring a Sensor-Disabled Output (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
Wiring a Press-in-Motion Signal (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
Turning on Power to SmartPAC 2 Servo. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33
Verifying Installation of DiProPAC and ProCamPAC . . . . . . . . . . . . . . . . . . .2-34
Table of Contents
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SmartPAC 2 Servo User Manual
Final Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Set Up a “Test” Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Check Stroke Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Check the Top-stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Check the Emergency-stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Check Cam Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Test Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
What Next? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Wiring Tables for SmartPAC 2 Servo Options . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Chapter 3.
Keyboard, Displays and Operating Modes . . . . . . . 3-1
SmartPAC 2 Keyboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Number Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
CLEAR Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cursor Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
HELP Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
ENTER Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
RESET Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Program/Run Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Hot Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
SmartPAC 2 Servo Display Layout in Run Mode . . . . . . . . . . . . . . . . . . . . . . 3-12
Selecting an Item on a Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
SmartPAC 2 Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Initialization Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Screen Capture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Screen Capture in SmartPAC 2 Main Versions Earlier than V 5.3.1 . . . . . . . . . . . 3-22
Screen Capture in SmartPAC 2 Main Versions V 5.3.1 and Later . . . . . . . . . . . . . 3-24
Chapter 4.
Initialization Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Entering and Exiting Initialization Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Position Sensor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Resolver Motion Mode (Normal Motion – Link Motion) . . . . . . . . . . . . . . . . . . . . 4-3
Angle Wheel Rotation (Clockwise – Counterclockwise) . . . . . . . . . . . . . . . . . . . . . 4-3
Tool Number Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Counter Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Counter Increment Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
INSTALLED OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESS NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SELECT CAM NAMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SET GLOBAL CAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
4-5
4-7
4-7
4-9
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SmartPAC 2 Servo User Manual
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CUSTOM SENSOR NAMES (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
SENSOR ENABLE MODE (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Selecting Sensor Enable Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Enabling Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
LINEAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
SECURITY ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
Setting Security Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Changing Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
BACKUP/RESTORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
Backing Up Tools to a USB Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Restoring Tools from a USB Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
SETUP DATA COMMS (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
SETUP NETWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
E-MAIL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SMARTVIEW FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETUP E-MAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGE NETWORK SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESS TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-31
4-32
4-32
4-34
4-35
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35
COMMUNICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SET CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAVE TO USB DISK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UPDATE FIRMWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-36
4-38
4-39
4-39
Using a Computer Keyboard to Enter Names . . . . . . . . . . . . . . . . . . . . . . . . . .4-39
Chapter 5.
Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Entering and Exiting Program Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
TOOL MANAGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Creating a New Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Copying an Existing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Copying Tool Template to a New Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading a Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Settings for a Loaded Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deleting a Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3
5-4
5-5
5-5
5-6
5-7
Tool Program Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
TOOL NAME or TOOL ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
COUNTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Setting Preset Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Count Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearing the Total Hits Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Batch Counter Output and Increment Modes . . . . . . . . . . . . . . . . . . . . . .
Setting Counter Increment Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Parts per Stroke or Strokes per Part. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Batch Pre-Load Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5-11
5-11
5-12
5-13
5-14
5-14
5-15
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DIE PROTECTION (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Understanding Sensor Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Programming Sensor Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Programming DiProPAC 32 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
CAM SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Selecting a Cam Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Making an ON/OFF Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Setting Multiple ON/OFF Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Making a Timed Output Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Setting DSV ON Channel Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Deleting Channel Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Viewing the Cam Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Viewing Global Cams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
RAM POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
SENSOR ENABLE/DISABLE & STATUS (Optional) . . . . . . . . . . . . . . . . . 5-52
Viewing Sensor Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Enabling or Disabling All Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Turning a Sensor Off or On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Chapter 6.
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Entering and Exiting Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Loading a Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Programming Hot Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Settings Locked, or Password Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Displaying Multiple Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Opening the Ram Angle Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
DISABLE (ENABLE) SENSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
COUNTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
DIE PROTECTION (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Adjusting the Ready Signal for Green Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Adjusting the Stroke Preset for Green Special Sensors . . . . . . . . . . . . . . . . . . . . . 6-13
Viewing the Sensor Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Viewing Sensor Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Adjusting DiProPAC 32 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
CAM SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Viewing Cam Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Viewing the Global Cam Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Viewing the Cam Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RAM POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ERROR/EVENT LOG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD NEW TOOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv
6-20
6-22
6-23
6-24
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MESSAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
Sending E-mail to Wintriss Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
TOGGLE HOT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28
Chapter 7.
Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Responding to Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Counter Preset Reached Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Messages for Equipment Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Messages for Programming Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Messages for Sensor Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Miscellaneous Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
Troubleshooting Using the Error/Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Appendix A. Installing the Balluff Linear Transducer . . . . . . . . . .A-1
Mounting the Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Wiring the Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Appendix B. SmartPAC Preventive Maintenance (PM) Monitor
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
About SmartPAC PM Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Comparison with Traditional Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . B-1
How the PM Monitor Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Examples of How to Use the PM Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Installing the PM Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
For New Systems from the Factory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
For Existing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Using the PM Monitor in Initialization Mode. . . . . . . . . . . . . . . . . . . . . . . . . . B-4
How to Get into SmartPAC Initialization and PM Monitor . . . . . . . . . . . . . . . . . . B-4
Initializing the PM Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Assigning a New PM Password Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
Selecting PM Item Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
Using the PM Monitor in Run mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
How to Get into SmartPAC Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
A Tool Number Must Be Loaded Before Switching to Run Mode . . . . . . . . . . . . B-12
Viewing and Modifying PM Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13
Appendix C. Updating SmartPAC 2 Firmware . . . . . . . . . . . . . . . .C-1
Updating Firmware Using a USB Disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Installing Updated Firmware from USB Disk to SmartPAC 2 . . . . . . . . . . . . . . . . C-2
Downloading Updated Firmware from the Wintriss Server . . . . . . . . . . . . . . . . . . C-7
Installing Firmware from a Replacement Compact Flash (CF) Card . . . . . . . . C-9
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Appendix D. SmartView Remote Viewing and E-mail Setup . . . . D-1
Network Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Network Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Plugging in the Network Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Programming Network Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Changing Network Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Installing SmartView . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6
Checking Explorer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6
Installing SmartView on Your Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8
SmartView Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
Setup Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
Main Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11
Press Status Information Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-12
Remote Messaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-13
E-mail Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14
SmartView Ping Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-15
Appendix E. Replacing SmartPAC 2 PC Board. . . . . . . . . . . . . . . E-1
Unpacking the Replacement Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Installing the Replacement Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Appendix F. Reporting Downtime and Scrap to SFC. . . . . . . . . . F-1
Machine States to Which SFC Logs Press Time . . . . . . . . . . . . . . . . . . . . . . . . F-1
SmartPAC 2 Downtime Reporting Features . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
Forced Idle Dialog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
Backfilling vs. Forward Filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
Putting the Press “Back on Line” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Forced Error Dialog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Persist Dialog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-5
Single-stroke Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-6
Reset Strokes Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-6
Setting up SmartPAC 2 to Report Downtime . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Making Downtime Reporting Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-7
Programming Downtime Reasons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-12
Documenting Downtime on the Dialog Menu. . . . . . . . . . . . . . . . . . . . . . . . . F-16
Documenting Downtime in Response to the Forced Dialog Message . . . . . . . . . .F-16
Documenting Downtime in Other Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19
Ending a Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-20
Creating Hot Keys for Dialog Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . .F-21
Reporting Scrap and Good Parts to SFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-22
Making Scrap Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-22
Adjusting the Good Parts Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25
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Appendix G. Reporting Downtime and Scrap to LETS . . . . . . . . G-1
Machine States to Which LETS Logs Press Time . . . . . . . . . . . . . . . . . . . . . . G-1
SmartPAC 2 Downtime Reporting Features . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
Forced Idle Dialog Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
Backfilling vs. Forward Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
Putting the Press “Back on Line” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
Forced Error Dialog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
Persist Dialog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
Single-stroke Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
Reset Strokes Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
Setting up SmartPAC 2 to Report Downtime . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
Making Downtime Reporting Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
Programming Downtime Reasons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11
Documenting Downtime on the Dialog Menu . . . . . . . . . . . . . . . . . . . . . . . . G-14
Documenting Downtime in Response to the Forced Dialog Message . . . . . . . . . G-14
Documenting Downtime in Other Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-17
Creating Hot Keys for Dialog Menu Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . G-18
Reporting Scrap and Good Parts to LETS. . . . . . . . . . . . . . . . . . . . . . . . . . . . G-19
Making Scrap Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-20
Adjusting the Good Parts Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-23
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GL-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Wintriss Manuals
SmartPAC 2 Setup Sheets
Figures at End of Manual
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
SmartPAC 2 Servo Press ProCamPAC 8 MTS Transducer Wiring Diagram
SmartPAC 2 Servo Press ProCamPAC 15 MTS Transducer Wiring Diagram
SmartPAC 2 Servo Press Wiring Diagram
DiProPAC Sensors 1-16 to DSI 2 Wiring Diagram
DiProPAC Sensors 17-32 to DSI 2 Wiring Diagram
SmartPAC 2 Servo Press ProCamPAC 8 Balluff Transducer Wiring Diagram
SmartPAC 2 Servo Press ProCamPAC 15 Balluff Transducer Wiring Diagram
SmartPAC 2 Loopback Wiring Connections
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vii
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List of Figures
Figure 1-1.
Figure 2-1.
Figure 2-2.
Figure 2-3.
Figure 2-4.
Figure 2-5.
Figure 2-6.
Figure 2-7.
Figure 2-8.
Figure 2-9.
Figure 2-10.
Figure 2-11.
Figure 2-12.
Figure 2-13.
Figure 2-14.
Figure 2-15.
Figure 2-16.
Figure 2-17.
Figure 2-18.
Figure 2-19.
Figure 2-20.
Figure 2-21.
Figure 3-1.
Figure 3-2.
Figure 3-3.
Figure 3-4.
Figure 3-5.
Figure 3-6.
Figure 3-7.
Figure 3-8.
Figure 3-9.
Figure 3-10.
Figure 3-11.
Figure 3-12.
Figure 3-13.
Figure 3-14.
Figure 3-15.
Figure 3-16.
Figure 3-17.
Figure 3-18.
Figure 3-19.
Figure 3-20.
Figure 3-21.
Figure 3-22.
Figure 3-23.
Figure 3-24.
Figure 3-25.
viii
SmartPAC 2 Servo Front Panel .................................................................................... 1-3
Installation Overview ................................................................................................... 2-4
Attaching Wires to Connector ...................................................................................... 2-5
Connecting Shield Drain Wire to Ground Stud ............................................................ 2-6
SmartPAC 2 Servo Mounting Dimensions: Enclosure ................................................ 2-7
SmartPAC 2 Servo Mounting and Cutout Dimensions: Panel Mount ......................... 2-9
MTS Linear Transducer Dimensions ......................................................................... 2-11
SmartPAC 2 Servo Board with ProCamPAC and DiProPAC Boards Installed ........ 2-12
ProCamPAC Linear Boards, Location of Components: ............................................ 2-13
MTS Linear Transducer Pinout .................................................................................. 2-14
Wiring AC to Terminal Block, Inside Enclosure, Top Right ..................................... 2-16
SmartPAC 2 Servo Board: Location of Components ................................................. 2-17
DiProPAC Boards (8-, 16-, and 32-Sensor): Location of Components ..................... 2-21
ProCamPAC Output Assembly .................................................................................. 2-27
Cam Outputs Board .................................................................................................... 2-28
Connector TB302 and TB303 for Wiring Relays to Equipment ................................ 2-30
Installing Suppressors Across an AC Load ................................................................ 2-31
Installing a Diode Across a DC Load ......................................................................... 2-31
SmartPAC 2 Startup Screen ....................................................................................... 2-33
Main Program Menu .................................................................................................. 2-34
Main Initialization Menu ............................................................................................ 2-35
Installed Options Screen ............................................................................................. 2-35
SmartPAC 2 Servo Front Panel .................................................................................... 3-1
SmartPAC 2 Keyboard ................................................................................................. 3-2
Number Keys ................................................................................................................ 3-2
Numeric Entry Window (Left); Alphabetic Entry Window (Right) ............................ 3-3
Alphanumeric Entry Window ...................................................................................... 3-3
Clear Key ...................................................................................................................... 3-4
Cursor Keys .................................................................................................................. 3-4
Highlighted Item on Run Menu .................................................................................... 3-5
Cam Channel Timing: On=0°, Off=0° ......................................................................... 3-7
Cam Channel Timing: On=239°, Off=0° ..................................................................... 3-7
Cam Channel Timing: On=239°, Off=270° ................................................................. 3-8
HELP Key .................................................................................................................... 3-8
ENTER Key ................................................................................................................. 3-9
RESET Key ................................................................................................................ 3-10
Program/Run Key Switch ........................................................................................... 3-10
Function Keys ............................................................................................................. 3-11
Hot Keys Programmed on Main Run Menu ............................................................... 3-12
SmartPAC 2 Servo Display, Run Mode ..................................................................... 3-13
Main Run Menu with “CAM SWITCH” Highlighted ............................................... 3-13
SmartPAC 2 Operating Modes, Showing Main Menus ............................................. 3-14
Initialization Mode Main Menu ................................................................................. 3-16
Navigation Example: Initialization Mode ................................................................. 3-17
Program Mode Main Menu ........................................................................................ 3-18
Navigation Example: Program Mode ........................................................................ 3-19
Run Mode Main Menu ............................................................................................... 3-20
Table of Contents
SmartPAC 2 Servo User Manual
Figure 3-26.
Figure 4-1.
Figure 4-2.
Figure 4-3.
Figure 4-4.
Figure 4-5.
Figure 4-6.
Figure 4-7.
Figure 4-8.
Figure 4-9.
Figure 4-10.
Figure 4-11.
Figure 4-12.
Figure 4-13.
Figure 4-14.
Figure 4-15.
Figure 4-16.
Figure 4-17.
Figure 4-18.
Figure 4-19.
Figure 4-20.
Figure 4-21.
Figure 4-22.
Figure 4-23.
Figure 4-24.
Figure 4-25.
Figure 4-26.
Figure 4-27.
Figure 4-28.
Figure 4-29.
Figure 4-30.
Figure 5-1.
Figure 5-2.
Figure 5-3.
Figure 5-4.
Figure 5-5.
Figure 5-6.
Figure 5-7.
Figure 5-8.
Figure 5-9.
Figure 5-10.
Figure 5-11.
Figure 5-12.
Figure 5-13.
Figure 5-14.
Figure 5-15.
Figure 5-16.
Figure 5-17.
Figure 5-18.
Figure 5-19.
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Navigation Example: Run Mode ...............................................................................3-21
Main Initialization Menu ..............................................................................................4-1
Position Sensor Screen ..................................................................................................4-3
Installed Options Screen ...............................................................................................4-6
Select Language Screen ................................................................................................4-6
Alphabetic Entry Window ............................................................................................4-7
Cam Channel Name Menu ............................................................................................4-8
Cam Channel Name Selection Screen ..........................................................................4-8
Global Cams Menu .....................................................................................................4-10
Global Cam Timing Type Screen ...............................................................................4-11
Custom Sensor Names Screen ....................................................................................4-12
Die Protection Mode Selection Menu .........................................................................4-13
Linear Sensor Setup Screen ........................................................................................4-15
Tool Information Setup Screen ...................................................................................4-18
Tool Information Name Screen ..................................................................................4-18
Tool Information Units Selection Screen ...................................................................4-19
Tool Information Setup Screen with Sample Entries .................................................4-21
Security Access Menu ................................................................................................4-22
“Enter Your Password” Screen ...................................................................................4-24
Set Passwords Menu ...................................................................................................4-26
“Enter a New Password” Window ..............................................................................4-26
Backup/Restore Control Menu ...................................................................................4-28
Backup/Restore Control Menu with Restore Confirmation Window Displayed .......4-30
Set Communications Menu .........................................................................................4-30
Network Setup Utility Screen .....................................................................................4-31
Setup E-mail Screen ....................................................................................................4-33
Alphanumeric Entry Window with Default Mail Server Displayed ...........................4-33
Diagnostics Menu .......................................................................................................4-35
Communications Data Viewer Screen ........................................................................4-36
Transmit and Receive Data Screen: Combined View (Left), Split View (Right) ......4-36
Set the Clock Screen ...................................................................................................4-38
Main Program Menu .....................................................................................................5-1
Tool Manager Screen ....................................................................................................5-3
Numeric Entry Window (Left); Alphanumeric Entry Window (Right) .......................5-3
Copy Tool Template Window ......................................................................................5-4
“Enter Your Password” Screen .....................................................................................5-6
Load Tool Warning Window ........................................................................................5-6
“Enter Your Password” Screen .....................................................................................5-7
Delete Tool Confirmation Message ..............................................................................5-7
Tool Program Menu ......................................................................................................5-8
Alphabetic Entry Window ............................................................................................5-9
Counters Screen ..........................................................................................................5-10
“Enter Your Password” Screen ...................................................................................5-11
Change Count Confirmation Window ........................................................................5-12
Counter Mode Selections Screen ................................................................................5-13
Advanced Counter Mode Selections Screen ...............................................................5-15
Die Protection Sensor Menu .......................................................................................5-16
Ready Signal Programming for a “Green” Sensor .....................................................5-19
Ready Signal Programming for a “Green Quick Check” Sensor ...............................5-19
Ready Signal Programming for a “Green Constant” Sensor ......................................5-20
Table of Contents
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Figure 5-20.
Figure 5-21.
Figure 5-22.
Figure 5-23.
Figure 5-24.
Figure 5-25.
Figure 5-26.
Figure 5-27.
Figure 5-28.
Figure 5-29.
Figure 5-30.
Figure 5-31.
Figure 5-32.
Figure 5-33.
Figure 5-34.
Figure 5-35.
Figure 5-36.
Figure 5-37.
Figure 5-38.
Figure 5-39.
Figure 5-40.
Figure 5-41.
Figure 5-42.
Figure 5-43.
Figure 5-44.
Figure 5-45.
Figure 5-46.
Figure 5-47.
Figure 5-48.
Figure 5-49.
Figure 5-50.
Figure 5-51.
Figure 5-52.
Figure 5-53.
Figure 5-54.
Figure 5-55.
Figure 5-56.
Figure 5-57.
Figure 5-58.
Figure 5-59.
Figure 5-60.
Figure 6-1.
Figure 6-2.
Figure 6-3.
Figure 6-4.
Figure 6-5.
Figure 6-6.
Figure 6-7.
Figure 6-8.
Figure 6-9.
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SmartPAC 2 Servo User Manual
“Enter Your Password” Screen .................................................................................. 5-22
Die Protection Sensor Menu with Auto Enable by Tool Counter .............................. 5-22
Sensor Names Screen ................................................................................................. 5-23
Custom Sensor Names Screen .................................................................................... 5-24
Auto Enable by Sensor Counter Screen ..................................................................... 5-24
Sensor Type Screen .................................................................................................... 5-25
Sensor Stop Type Screen ............................................................................................ 5-26
Critical Angle Programming Screen .......................................................................... 5-27
Ready Signal Programming Screen ............................................................................ 5-29
Green Special Sensor Stroke Count Screen ............................................................... 5-30
Sensor Settings Screen ............................................................................................... 5-31
Sensor Summary Screen ............................................................................................. 5-32
Tool Program Menu with DIPROPAC 1-16 and DIPROPAC 17-32 Items .............. 5-33
Die Protection Sensor 17-32 Menu ............................................................................ 5-33
Sensor Names Screen with Stripper Function Highlighted ........................................ 5-34
Sensor Type Screen with “GREEN” Highlighted ...................................................... 5-34
Sensor Stop Type Screen ............................................................................................ 5-35
Sensor Summary Screen Showing Ready Signals for Green Sensors ........................ 5-35
Sensor Settings Screen ............................................................................................... 5-36
Sensor Names Screen with Slug Detection Function Highlighted ............................. 5-36
Sensor Type Screen with “GREEN SPECIAL” Highlighted ..................................... 5-37
Sensor Summary Screen Showing Stroke Counts for Green Special Sensors ........... 5-37
Sensor Settings Screen ............................................................................................... 5-38
Cam Channel Menu .................................................................................................... 5-40
“Enter Your Password” Screen .................................................................................. 5-40
Cam Channel Program Type Menu ............................................................................ 5-41
Cam Channel On/Off Program Screen ....................................................................... 5-41
Cam Channel On/Off Program Screen: One On/Off Arc ........................................... 5-43
Cam Channel On/Off Program Screen: Two On/Off Arcs ........................................ 5-43
Cam Channel On/Off Program Screen: Three On/Off Arcs ...................................... 5-44
Cam Channel Timed Output Program Screen ............................................................ 5-45
Cam Channel DSV On Program Screen ..................................................................... 5-46
Cam Channel Deletion Confirmation Window .......................................................... 5-47
Cam Summary Screen ................................................................................................ 5-47
Global Cam Summary Screen .................................................................................... 5-48
Tool Information Screen ............................................................................................ 5-49
“Enter Your Password” Screen .................................................................................. 5-49
Ram Position Screen .................................................................................................. 5-50
“Enter Your Password” Screen .................................................................................. 5-51
Sensor On/Off Status .................................................................................................. 5-52
“Sensor Turned Off” Message ................................................................................... 5-54
Main Run Menu ............................................................................................................ 6-1
No Tool Loaded Warning Window .............................................................................. 6-3
Main Run Menu, Showing Hot Keys Programmed ..................................................... 6-4
Hot Keys Instruction Window ...................................................................................... 6-4
“Enter Your Password” Screen .................................................................................... 6-5
Display All Errors Message Window ........................................................................... 6-6
Ram Angle Window Displayed on Main Run Menu ................................................... 6-6
Main Run Menu with SENSORS ENABLED and SENSOR DISABLED Displays .. 6-7
Disable Sensors Confirmation Message ....................................................................... 6-7
Table of Contents
SmartPAC 2 Servo User Manual
Figure 6-10.
Figure 6-11.
Figure 6-12.
Figure 6-13.
Figure 6-14.
Figure 6-15.
Figure 6-16.
Figure 6-17.
Figure 6-18.
Figure 6-19.
Figure 6-20.
Figure 6-21.
Figure 6-22.
Figure 6-23.
Figure 6-24.
Figure 6-25.
Figure 6-26.
Figure 6-27.
Figure 6-28.
Figure 6-29.
Figure 7-1.
Figure 7-2.
Figure A-1.
Figure A-2.
Figure B-1.
Figure B-2.
Figure B-3.
Figure B-4.
Figure B-5.
Figure B-6.
Figure B-7.
Figure B-8.
Figure B-9.
Figure B-10.
Figure B-11.
Figure B-12.
Figure B-13.
Figure B-14.
Figure B-15.
Figure C-1.
Figure C-2.
Figure C-3.
Figure C-4.
Figure C-5.
Figure C-6.
Figure C-7.
Figure D-1.
Figure D-2.
Figure D-3.
Figure D-4.
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Counters Screen ............................................................................................................6-9
Counters Screen with “Reload Batch Counters” Function ...........................................6-9
Die Protection Menu (Run Mode) ..............................................................................6-10
Ready Signal Programming Screen ............................................................................6-11
Sensor Status Screen ...................................................................................................6-15
Main Run Menu with DIPROPAC 1-16 and DIPROPAC 17-32 Items Shown .........6-15
Die Protection Sensor Menu for Sensors 17-32 ..........................................................6-16
Ready Signal Programming Screen, Run Mode .........................................................6-17
Green Special Sensor Stroke Count Screen, Run Mode .............................................6-17
Cam Switch Menu ......................................................................................................6-18
Cam Timing Screen ....................................................................................................6-20
Tool Number Information Screen ...............................................................................6-21
Ram Position Screen ...................................................................................................6-22
Error/Event Log ..........................................................................................................6-24
Tool Manager Screen ..................................................................................................6-25
Load Tool Warning Window ......................................................................................6-25
Messaging Screen: List of Recipients .........................................................................6-26
Messaging Screen: List of Messages ..........................................................................6-27
Sample E-mail to Wintriss Tech. Support ..................................................................6-27
Toggle Hot Keys 1 and 2 Menu Items ........................................................................6-28
Error Code Window ......................................................................................................7-1
Counter Preset Message Window .................................................................................7-1
Balluff Linear Transducer Dimensions ........................................................................ A-2
Balluff Linear Transducer Pinout ................................................................................ A-3
“PM Monitor” Highlighted on SmartPAC 2 Initialization Menu ................................ B-4
PM Password Screen ................................................................................................... B-5
PM Password Screen Showing Password Retrieval Number ...................................... B-6
PM Entry Screen .......................................................................................................... B-7
Initialize PM Screen ..................................................................................................... B-7
Initialize Warning Screen ............................................................................................ B-8
PM Monitor Screen ...................................................................................................... B-9
List of Available PM Names Screen ............................................................................ B-9
Alphanumeric Display Superimposed over PM Names Screen ................................ B-10
Tracking Units Selection Screen ................................................................................ B-10
Superimposed Number Display ................................................................................. B-11
Programmed PM Item: Example ............................................................................... B-11
“PM Monitor” Highlighted on SmartPAC 2 Run Menu ............................................ B-12
Run Mode Screen Showing PM Monitor in “Normal” Status Mode ........................ B-13
Run Mode Screen Showing “Slide Adjust Motor” in “Alert” Mode ......................... B-14
Firmware Load Menu with “XFER FROM USB DISK” Highlighted ........................ C-3
Firmware Load Menu with “LOAD NEW FIRMWARE” Highlighted ...................... C-5
Firmware Load Menu with Yellow Status Window .................................................... C-5
SmartPAC 2 Display with “Loading Firmware” Message .......................................... C-6
Firmware Load Menu with “RELOAD CURRENT FIRMWARE” Highlighted ..... C-10
Firmware Load Menu with Yellow Status Window .................................................. C-10
SmartPAC 2 Display with “Loading Firmware” Message ........................................ C-11
Internet Explorer Window with “Internet Options” Selected ...................................... D-6
Internet Options Screen ............................................................................................... D-7
Security Tab with “Custom Level” Button .................................................................. D-7
SmartView Introductory Page ..................................................................................... D-8
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Figure D-5.
Figure D-6.
Figure D-7.
Figure D-8.
Figure D-9.
Figure D-10.
Figure D-11.
Figure D-12.
Figure D-13.
Figure D-14.
Figure D-15.
Figure E-1.
Figure E-2.
Figure F-1.
Figure F-2.
Figure F-3.
Figure F-4.
Figure F-5.
Figure F-6.
Figure F-7.
Figure F-8.
Figure F-9.
Figure F-10.
Figure F-11.
Figure F-12.
Figure F-13.
Figure F-14.
Figure F-15.
Figure F-16.
Figure F-17.
Figure F-18.
Figure F-19.
Figure G-1.
Figure G-2.
Figure G-3.
Figure G-4.
Figure G-5.
Figure G-6.
Figure G-7.
Figure G-8.
Figure G-9.
Figure G-10.
Figure G-11.
Figure G-12.
Figure G-13.
Figure G-14.
Figure G-15.
Figure G-16.
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SmartPAC 2 Servo User Manual
SmartView Setup Page ................................................................................................ D-8
Mabry Winsock ActiveX Control Window ................................................................. D-9
SmartView Main Page ............................................................................................... D-10
SmartView Main Page with Status of Multiple Presses Shown ................................ D-12
Press Status Information Page ................................................................................... D-13
SmartPAC 2 Remote Message .................................................................................. D-14
Email Setup Page ....................................................................................................... D-15
Mabry Internet Ping Window .................................................................................... D-16
Ping Utility Window ................................................................................................. D-16
Ping Utility Window with Example of a Successful Ping ......................................... D-17
Ping Utility Window with Examples of Two Unsuccessful Pings ............................ D-17
SmartPAC 2 PC Board .................................................................................................E-3
Firmware Load Menu with “RELOAD CURRENT FIRMWARE” Highlighted ........E-5
Forced Idle Dialog Mode Time Line (Downtime Reason Backfilled) ......................... F-3
Forced Idle Dialog Mode Time Line (Downtime Reason Forward Filled) ................. F-4
Forced Error Dialog Mode Time Line ......................................................................... F-5
SmartPAC 2 Main Initialization Menu ........................................................................ F-8
Set Communications Menu .......................................................................................... F-8
Dialog Fixed Name Choice Menu .............................................................................. F-13
Dialog Special Choice Name Menu ........................................................................... F-15
SmartPAC 2 Run Mode Main Menu with Forced Dialog Message Displayed .......... F-16
Dialog Menu (“16/16” Dialog Screen Mode) ............................................................ F-17
Dialog Menu (“32 CUSTOM” Dialog Screen Mode) ................................................ F-17
Dialog Menu with F2/F3 Option Window Displayed ................................................ F-18
SmartPAC 2 Run Mode Main Menu with DIALOG MENU Item Selected .............. F-19
Security Access Menu with CHANGE COUNT and CHG GOOD PRTS CNT
Items Set to “PROGRAM AND RUN MODES” ...................................................... F-22
Counters Screen with “Scrap Value” Function (F3) Shown ...................................... F-23
Counters Screen with Scrap Value Entry Window Displayed (30 Items Shown) ..... F-23
Counters Screen with Scrap Value Updated to 30 Items ........................................... F-24
Counters Screen with Scrap Value Entry Window Displayed (10 Items Shown) ..... F-24
Counters Screen with Scrap Value Updated to 40 Items ........................................... F-25
Good Parts Counter Adjustment Confirmation Window ........................................... F-26
Forced Idle Dialog Mode Time Line (Downtime Reason Backfilled) ........................ G-3
Forced Idle Dialog Mode Time Line (Downtime Reason Forward Filled) ................ G-4
Forced Error Dialog Mode Time Line ........................................................................ G-5
SmartPAC 2 Main Initialization Menu ....................................................................... G-7
Set Communications Menu ......................................................................................... G-7
Dialog Fixed Name Choice Menu ............................................................................. G-11
Dialog Special Choice Name Menu .......................................................................... G-13
SmartPAC 2 Run Mode Main Menu with Forced Dialog Message Displayed ......... G-15
Dialog Menu .............................................................................................................. G-15
Dialog Menu with F2/F3 Option Window Displayed ............................................... G-16
SmartPAC 2 Run Mode Main Menu with DIALOG MENU Item Selected ............. G-17
Security Access Menu with CHANGE COUNT and CHG GOOD PRTS CNT
Items Set to “PROGRAM AND RUN MODES” ..................................................... G-19
Counters Screen with “Scrap Value” Function (F3) Shown ..................................... G-20
Counters Screen with Scrap Value Entry Window Displayed (30 Items Shown) .... G-20
Counters Screen with Scrap Value Updated to 30 Items .......................................... G-21
Counters Screen with Scrap Value Entry Window Displayed (40 Items Shown) .... G-22
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Figure G-17. Counters Screen with Scrap Value Updated to 40 Items ........................................... G-22
Figure G-18. Good Parts Counter Adjustment Confirmation Window ........................................... G-23
List of Tables
Table 1-1.
Table 2-1.
Table 2-2.
Table 2-3.
Table 2-4.
Table 2-5.
Table 2-6.
Table 2-7.
Table 2-8.
Table 2-9.
Table 2-10.
Table 2-11.
Table 2-12.
Table 2-13.
Table 2-14.
Table 2-15.
Table 2-16.
Table 3-1.
Table 3-2.
Table 4-1.
Table 4-2.
Table 4-3.
Table 4-4.
Table 4-5.
Table 4-6.
Table 4-7.
Table 5-1.
Table 5-2.
Table 6-1.
Table 7-1.
Table A-1.
Table A-2.
Table B-1.
Table B-2.
Table C-1.
Table C-2.
Table D-1.
Table F-1.
Table G-1.
SmartPAC 2 Servo Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
MTS Linear Transducer Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
Linear Transducer Wiring: DC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
Stop Circuit Wiring Connections: TB102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 1-8 . . . . . . . . . . . . .2-23
DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 9-16 . . . . . . . . . . . .2-24
DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 17-24 . . . . . . . . . . .2-24
DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 25-32 . . . . . . . . . . .2-25
ProCamPAC Linear to Cam Output Assembly TB301 Wiring, Cams 1-8 . . . . . . . . .2-29
ProCamPAC Linear to Cam Output Assembly TB301 Wiring, Cams 9-15 . . . . . . . .2-29
Connections to Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
Stop and Input Check Circuit (TB102) Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38
SFI Port (1) and Module Port (2) (TB103) Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38
Special Port (3) and PACNet Port (4) (TB104) Wiring . . . . . . . . . . . . . . . . . . . . . . . .2-38
Spare 1 Port (5) and WPC Port (6) (TB105) Wiring . . . . . . . . . . . . . . . . . . . . . . . . . .2-38
Spare 3 Port (7) and Spare 4 Port (8) (TB106) Wiring . . . . . . . . . . . . . . . . . . . . . . . .2-39
Aux I/O (TB107) Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39
Number Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Initialization, Program and Run Modes: Entry and Exit Procedures . . . . . . . . . . . . . .3-15
Instructions for Entering and Exiting Initialization Mode . . . . . . . . . . . . . . . . . . . . . . .4-2
Numeric and Alphanumeric Tool Number Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Linear Sensor Setup Screen Field Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Tool Information Setup Screen: Abbreviations for Units . . . . . . . . . . . . . . . . . . . . . .4-20
Tool Information Setup Screen: Decimal Places and Formats . . . . . . . . . . . . . . . . . .4-20
Security Access Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
Setup E-mail Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34
Instructions for Entering and Exiting Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Additional On/Off Settings, 8-channel ProCamPAC: Examples . . . . . . . . . . . . . . . . .5-42
Instructions for Entering and Exiting Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Communication Errors: SmartPAC 2 Option Identified by Address Number . . . . . . . .7-8
Balluff Linear Transducer: Number of Mounting Feet . . . . . . . . . . . . . . . . . . . . . . . . A-1
Balluff Linear Transducer Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Preventive Maintenance Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
PM Tracking Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Record of Current Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Record of Linear Sensor Initialization Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
SmartPAC 2 Board: PS 2 and Y-Cable Configuration . . . . . . . . . . . . . . . . . . . . . . . . D-4
Set Communications Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-9
Set Communications Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
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SmartPAC 2 Servo User Manual
How To Use This Manual
This manual shows you how to install, set up, program, operate, and troubleshoot SmartPAC
2 Servo, including the standard ProCamPAC and optional DiProPAC modules.
Chapter 1 provides an overview of the operation and features of SmartPAC 2 Servo.
Chapter 2 shows you how to install SmartPAC 2 Servo.
Chapter 3 shows you how to use the SmartPAC 2 displays and keyboard.
Chapter 4 shows you how to use SmartPAC 2 Servo in Initialization mode, which is the mode
you select to make settings that apply to SmartPAC 2 Servo operation for all tools.
Chapter 5 shows you how to use SmartPAC 2 Servo in Program mode, which is the mode you
select to program settings that apply to SmartPAC 2 Servo operation for individual tools.
Chapters 6 shows you how to use SmartPAC 2 Servo in Run mode, which is the mode you
select to run the press and make minor adjustments to programmed settings.
Chapter 7 provides explanations of the messages that display on the SmartPAC 2 front panel
when a fault condition occurs or a counter preset is reached, and shows you how to correct
SmartPAC 2 Servo faults.
Appendix A shows you how to install a Balluff linear sensor.
Appendix B shows you how to use the optional PM (Preventative Maintenance) Monitor
available with SmartPAC 2.
Appendix C shows you how to upgrade SmartPAC 2 firmware.
Appendix D shows you how to install and use the SmartView remote viewing utility.
Appendix E shows you how to install a replacement SmartPAC 2 board.
Appendix F shows you how to report downtime and scrap to Wintriss’s ShopFloorConnect
Asset Utilization Software (SFC).
Appendix G shows you how to report downtime and scrap to Wintriss’s Line Efficiency
Tracking Software (LETS).
The Glossary provides definitions of some of the terms used in the manual that may be
unfamiliar to you.
Setup sheets at the back of the manual provide forms on which you can maintain a record of
Initialization and Program settings for your SmartPAC 2 Servo.
Wiring diagrams (Figures 1 through 8) following the Setup sheets provide wiring connections
for SmartPAC 2 Servo, DiProPAC, ProCamPAC, and the SmartPAC 2 loopback test.
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SmartPAC 2 Servo User Manual
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Important Highlighted Information
Important danger, warning, caution and notice information is highlighted throughout the
manual as follows:
!
DANGER
A DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result
in death or serious injury.
!
WARNING
A WARNING symbol indicates a potentially hazardous situation, which, if not avoided, could result
in death or serious injury.
CAUTION
A CAUTION symbol indicates a potentially hazardous situation, which, if not avoided, may result in
property damage.
NOTICE
A NOTICE symbol indicates important information that you should remember, including tips to aid
you in performance of your job.
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SmartPAC 2 Servo User Manual
WARRANTY
Wintriss Controls warrants that Wintriss electronic controls are free from defects in
material and workmanship under normal use and service for a period of one year (two
years for Shadow light curtains) from date of shipment. All software products (LETS/
SFC and SBR), electro-mechanical assemblies, and sensors are warranted to be free
from defects in material and workmanship under normal use and service for a period
of 90 days from date of shipment. Wintriss’s obligations under this warranty are
limited to repairing or replacing, at its discretion and at its factory or facility, any
products which shall, within the applicable period after shipment, be returned to
Wintriss Controls freight prepaid and which are, after examination, disclosed to the
satisfaction of Wintriss to be defective. This warranty shall not apply to any equipment
which has been subjected to improper installation, misuse, misapplication, negligence,
accident, or unauthorized modification. The provisions of this warranty do not extend
the original warranty of any product which has either been repaired or replaced by
Wintriss Controls. No other warranty is expressed or implied. Wintriss accepts no
liability for damages, including any anticipated or lost profits, incidental damages,
consequential damages, costs, time charges, or other losses incurred in connection
with the purchase, installation, repair or operation of our products, or any part thereof.
Please note:
It is solely the user’s responsibility to properly install and maintain Wintriss controls
and equipment. Wintriss Controls manufactures its products to meet stringent
specifications and cannot assume responsibility for consequences arising from their
misuse.
Wintriss Controls Group, LLC
100 Discovery Way
Unit 110
Acton, MA 01720
Telephone:
(800) 586-TECH (8324)
(978) 268-2700
Fax:
(978) 263-2048
Internet:
http://www.wintriss.com
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USER MANUAL
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©2015 Wintriss Controls Group, LLC
Table of Contents
Chapter 1. Introduction
SmartPAC 2 Servo is a smart modular interface for multiple press automation functions. With
the same user interface as SmartPAC 2, which is widely used on standard mechanical presses,
SmartPAC 2 Servo tracks the position of the ram using a linear transducer instead of a
resolver. “Ram Position” settings for top and bottom linear position (see page 5-50)
determine the stroke length for each tool, which is converted to 0° to 180° for the downstroke
and 181° to 359° for the upstroke. Ram Position must be programmed properly for SmartPAC
2 Servo to work correctly.
CAUTION
Some Servo presses are capable of hitting the same part more than once at Bottom Dead Center
(BDC) before returning to the top of the stroke. You will have to note the angle ranges at which
repeated strokes occur. Any cams programmed within these ranges will actuate once for each hit.
Die protection ready signals programmed within these ranges will expect sensor actuation once for
each hit. If this is not feasible, please contact Wintriss Tech. Support to learn about new advanced
features.
Failure to comply with these instructions could result in property damage.
Every SmartPAC 2 Servo provides a magnetostrictive position transducer, eight-channel
programmable cam switch, and extensive counter capabilities. SmartPAC 2 Servo can make
instantaneous decisions for up to 8 cams (15 cams with the ProCamPAC 15 Linear board
option) and for up to 32 sensors if DiProPAC is installed. Because SmartPAC 2 Servo is
microprocessor-based, it can monitor or control all these different functions during a press
stroke. Additionally, it saves these settings for up to 200 tools.
SmartPAC 2 Servo features a large, bright color display, a numeric keypad, and easy-to-use
keys to program and run your press. SmartPAC 2 Servo can be connected to a computer
network, enabling press operation to be monitored remotely and e-mail messages to be sent
from the SmartPAC 2 Servo control.
SmartPAC 2 Servo can be configured with the following options:
• Up to 32-sensor die protection system
• Up to 15-channel programmable cam switch
• Two- or four-input load monitoring
• Automated shut-height and counterbalance control
• Servofeed interface
• Preventive maintenance monitor
In addition, SmartPAC 2 Servo can be linked to Wintriss’s ShopFloorConnect Asset
Utilization Software (SFC) or Line Efficiency Tracking Software (LETS) for data collection,
analysis and reporting.
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SmartPAC 2 Servo User Manual
NOTICE
If this is a retrofit, do not disconnect existing linear and pressure sensors from your control.
Installation instructions identify the old inputs from which sensors are disconnected and the new
inputs to which they are connected.
SmartPAC 2 Servo Standard Features
SmartPAC 2 Servo brings a multitude of press automation functions to one central location.
The following capabilities are standard features:
• All settings are made at the operator console, using SmartPAC 2’s keyboard and large,
bright, color display
• All tool programming is automatically saved in SmartPAC 2’s non-volatile memory. To
use the same settings when you run the job again, simply re-load your stored tool number.
SmartPAC 2 can save settings for up to 200 tools.
• SmartPAC 2 Servo’s programmable cam switch provides cam timings for feeder signals
and other press equipment, including global cams for press operation functions and
multiple on-off cycles.
• Fault messages appear on the SmartPAC 2 display whenever the press malfunctions or
counter presets are reached. An error/event log maintains a record of the last 100 errors
and events.
• SmartPAC 2 Servo is Ethernet-ready, allowing the control to be connected to any computer
network. Network connectivity allows press operations to be viewed remotely via the
SmartView utility and e-mail messages, containing diagnostics and error log information,
to be sent from the SmartPAC 2.
• SmartPAC 2 Servo upgrades and enhancements can be installed quickly and easily.
Upgrades can be either downloaded from a Wintriss web site via an email with a link or
mailed to you on a USB disk.
SmartPAC 2 Servo Options
When configured with the DiProPAC option, SmartPAC 2 Servo can monitor up to 32 die
protection sensors, allowing detection of malfunctions such as stock buckling, misfeeds, and
improper part ejection.
Info Center, another SmartPAC 2 Servo option, enables die setup sheets and other plantspecific press information to be displayed on the SmartPAC 2 screen. This option allows you
to store information needed throughout the plant on a central server, where it is available to
operators via SmartPAC 2’s Ethernet connectivity. In order to make use of Info Center
functionality, SmartView (see Appendix D) must be installed. Documentation of the Info
Center option is available at
www.smartpac2.com/SmartView/InfoCenterSetupHelp.htm
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SmartPAC 2 Servo Front Panel
Programming and operation of SmartPAC 2 Servo is accomplished via the SmartPAC 2 Servo
front panel, which is shown in Figure 1-1. A brief description of each panel component is
provided below.
SmartPAC 2 Servo
TOOL NUMBER
DEMO TOOL 2
DEMO PRESS
6160
PART CNTR
CAMBIE
AL ESPANOL
0
PRESS ANGLE 180
F2
POWER
USE THE CURSOR KEYS
TO MAKE SELECTIONS.
PRESS ENTER TO
ACCESS SELECTION.
180
F1
F3
ENABLE SENSORS
COUNTERS
DIE PROTECTION
CAM SWITCH
TOOL INFORMATION
RAM POSITION
ERROR/EVENT LOG
LOAD NEW TOOL
MESSAGING
TOGGLE HOT KEYS 1
F4
F5
F6
F7
F8
1
2
3
4
5
6
7
8
9
CLEAR
0
.
PROG
RUN
ENTER
HELP
RESET
Figure 1-1. SmartPAC 2 Servo Front Panel
Display
Program/Run key switch
Keyboard
Introduction
Used with the keyboard to make and adjust settings, load tool
numbers, and view diagnostic messages. The display, which
measures 10.4 in. (264 mm) diagonally, is a color liquid crystal
display (LCD).
Allows Program mode to be locked so settings cannot be
changed by the press operator. Key must be set to “Run” to
operate the press. Minor adjustments, including loading an
existing tool, can be made in Run mode.
Consists of cursor keys and a numeric keypad (described
below) that are used with the display to make settings.
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Cursor keys
Number keys
Function keys
HELP key
ENTER key
RESET key
SmartPAC 2 Servo User Manual
Enable you to select a display item with the highlight bar. Also
allow you to select alphabetic characters and special symbols
when naming the press, tools, cam channels, and sensors.
Additional functions are described in Chapter 3 (see page 3-4).
Enable you to input numeric values such as counter presets or
tool numbers
Eight keys labelled “F1” to “F8” that perform specific tasks.
Functions performed by pressing the key are displayed to the
left of the key label. Function keys can also be programmed as
“Hot keys” that take the user directly to desired screens.
Enables you to access a help screen that provides information
about the display you are looking at.
When you press this key, SmartPAC 2 accepts the menu item
you have selected or the number you have keyed in.
You press this key when you are done with a programming or
other procedure. Also resets SmartPAC 2 after fault or event
messages appear on the display.
Detailed instructions on how to use the keyboard and display are provided in Chapter 3.
SmartPAC 2 Servo Operation
SmartPAC 2 Servo is connected to a magnetostrictive linear transducer mounted on the press,
which reads the ram position. As the transducer moves up and down, its signals are
interpreted by SmartPAC 2 Servo’s electronics to determine the correct ram angle at every
point in the stroke. SmartPAC 2 Servo converts the signal from the transducer at any point in
its linear motion to a number corresponding to the position of the transducer (and ram) in
degrees.
SmartPAC 2 Servo Settings
You can make the following settings, using the keys on the SmartPAC 2 keyboard:
• Assign tool numbers. Settings for each tool are stored by tool number, which you
assign to identify and access the tool when you want to program or load it. You specify in
Initialization mode whether to use numeric or alphanumeric tool numbers in programming.
• Load settings by tool number. SmartPAC 2 saves all counter, cam switch, sensor (if
DiProPAC is installed), and other press settings in its electronic memory. To use tool
settings again, you recall them by selecting the tool number from the Tool Manager display.
SmartPAC 2 retains tool settings even when the power is off.
• Record tool information for each tool number. With this option you can record up
to 30 characters of information, such as installation notes, for each tool.
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• Protect settings with lockout and optional password security. Using SmartPAC
•
•
•
•
2’s Security Access Menu in Initialization mode, you can lock many of the settings in Run
mode, preventing anyone without access to the Program/Run key from altering Run
settings. You can also require that the user enter a password in order to change settings. To
prevent unauthorized changes to SmartPAC 2 Servo setup, you can require a special
password for access to the Main Initialization Menu.
Set counters. SmartPAC 2 provides counters to keep track of the number of strokes
made by the press during each job, the number of good parts produced, and other desired
statistical information. The stroke counter increments at each press cycle. The good parts
counter increments only when the die protection or tonnage monitoring option does not
generate a fault. Three batch counters can be set to either top-stop the press or signal
programmable limit switch (PLS) outputs when their presets are reached. The total hits
counter counts all hits on a tool, and keeps track of the last recorded number for the
previous job. With the optional Advanced counter mode, you can set the good parts
counter to give an accurate parts count when multiple parts are produced on each stroke or
when multiple strokes are required to produce one part.
Reset SmartPAC 2. You reset SmartPAC 2 whenever the press is stopped because of a
malfunction. The malfunction is described in a fault message, which displays on the
SmartPAC 2 Servo front panel when the fault occurs, making it easy to troubleshoot the
problem. See Chapter 7 for documentation of fault messages.
Review recent errors. SmartPAC 2’s Error/Event Log feature displays the 100 most
recent errors and events that have occurred at the press. Errors (i.e., incidents that cause the
press to stop) are shown along with the stroke count and ram angle at which the error
occurred. Events, such as tool changes, are displayed with the date, time, and stroke count.
The Error Log is accessible from the Main Run Menu.
Set timing for sensor inputs (DiProPAC Only). You can specify the portion of the
stroke during which you want installed sensors to monitor press operation. Up to 32
sensors can be programmed, allowing detection of malfunctions such as stock buckling,
misfeeds, die overload, and improper part ejection.
Sensors Available for DiProPAC
DiProPAC, the SmartPAC 2 die protection option, checks output from sensors monitoring the
die and sends a stop signal to the press when it detects a malfunction. Sensors can be mounted
on the press or die.
Any electro-mechanical sensor can be used with SmartPAC 2 Servo as long as it can switch
between an open state (i.e., sensor circuit to SmartPAC 2 open) and a closed state (i.e., sensor
circuit closed to ground or “grounded”). All types of NPN electronic sensors (e.g., proximity,
photoelectric, and fiberoptic sensors) can be used as can simple contact sensors and probes. If
you have questions about whether a certain sensor will work with SmartPAC 2 Servo, contact
Wintriss Controls.
Wintriss makes or sells a wide range of sensors. Those that can be used with SmartPAC 2
Servo with DiProPAC are shown below. Detailed application information is available. Many
sensors made by other manufacturers can also be used.
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SmartPAC 2 Servo User Manual
• Miniature fiberoptic photoelectric sensors—Thru-beam and reflective types are
•
•
•
•
•
•
•
•
available with adjustable sensitivity and the capability to detect objects as small as .0006 in.
(.015 mm). Require 12 to 24 Vdc power source.
Proximity sensors—Miniature electronic sensors that detect metal objects passing in front
of the sensor barrel. These sensors have no moving parts and are not affected by water or
oil. Require 12 to 24 Vdc power source.
Misfeed detectors—Designed to monitor non-working, spring-loaded pilot punch
position, stripper position, or other material location applications.
Short feed sensors—Used to ensure that material is contacted at the fully advanced
position.
Overload sensors—Used to prevent expensive die damage due to overload from slugging,
material thickness variations, broken tooling, etc.
Die overload sensors—Designed to detect minor changes in shut height.
Buckling sensor—Used to detect material buckle.
End of material sensor—Signals when material has run out.
Probes—Three types are available for diverse applications.
Programmable Cam Channels
!
DANGER
PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE
Use SmartPAC 2 Servo’s programmable cam switch to control auxiliary functions only. The
SmartPAC 2 programmable cam capability should never be used to provide timing signals for any
safety use including muting of light curtains.
Failure to comply with these instructions will result in death or serious injury.
With SmartPAC 2 Servo you received a separate assembly for wiring up to eight cam
channels to your equipment. (If you ordered the ProCamPAC 15 Linear option, you received
equipment that enables you to wire up to 15 channels.) The assembly contains the relays that
open and close on signals from SmartPAC 2 Servo to turn your equipment on and off.
Different types of relays can be used depending upon the voltages of your equipment and your
special needs. Refer to Chapter 2 for details on wiring the cam channels.
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SmartPAC 2’s Three Modes of Operation
SmartPAC 2 has three operating modes, each of which allows you to perform specific tasks.
• Initialization Mode. Used to create settings (e.g., linear sensor, global cams) that control
operation of SmartPAC 2 when any tool is loaded. Initialization settings generally only
need to be made once. Initialization mode is discussed in detail in Chapter 4.
• Program Mode. Used to create, modify, and load settings (e.g., sensor and cam timing,
counter presets) that control SmartPAC 2 Servo operation for a specific tool. You cannot
use this mode while the press is running. Instructions for using Program Mode are
provided in Chapter 5.
• Run Mode. Used to operate the press and make adjustments to programmed settings such
as sensor and cam timing. You can also load tool settings in Run mode. Run mode is
discussed in Chapter 6.
SmartPAC 2 Servo Specifications
SmartPAC 2 Servo specifications are shown in Table 1-1.
Table 1-1. SmartPAC 2 Servo Specifications
Equipment
Main enclosure: 12.76 x 11.53 x 5.28 in. (324 x 293 x 134 mm), NEMA 12,
shock mounted. Weight: 17.4 lbs.
Panel mount: 12.3 x 11.3 in. (312 x 287 mm)
MTS linear position transducer: Magnetostrictive; electrical stroke 6 to 48 in.
in 6-in. increments, 2.1 x 2.7 in., overall length 8.8 in. plus electrical stroke
Electrical
Input: 115/230 ± 10% Vac 50/60 Hz, 50 VA
Oper. Temp.
32° to 122° F (0° to 50° C)
Speed
300 SPM maximum
Accuracy
± 2/3°
Counters
Good parts, strokes, 3 batch with presets (7 digits)
Number-of-hits-on-tool counter: counts all hits on tool; resettable to 0 after
maintenance
Display
10.4 in. (264 mm) color active matrix TFT liquid crystal display (LCD)
Power LED
Memory
Allows storage of settings for 200 tools
Inputs/Outputs
Inputs for position transducer, remote reset, and setup mode and for USB,
PS/2 and Ethernet RJ-45 connectors
Outputs for top stop, emergency stop: ratings 0-4 A resistive @ 120V max
(AC or DC); Normally open–Held closed. Fault condition or power off opens
relay(s)
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SmartPAC 2 Servo User Manual
Table 1-1. SmartPAC 2 Servo Specifications (Cont.)
Communications
Connects via Ethernet to local area network; data viewed via the Internet using
SmartView remote viewing utility; allows backup of programmed tool settings
to a network drive.
Standard
Features
ProCamPAC provides up to 8 programmable cam switch output channels
(up to 15 channels with ProCamPAC 15 option)
Programmable cam output assembly: NEMA 12, holds up to 8 outputs
Enclosure: 9 x 11 x 3.5 in. (229 x 279 x 89 mm) shock-mounted
Relay SPDT 0-3 A resistive @ 240V
DC solid state SPST 2A @ 5-60 Vdc
AC solid state SPST 1A @ 70-250 Vac
Options
DiProPAC provides up to 32 die protection sensor inputs
Power for electronic sensors (NPN only): 15 Vdc min., 100 mA total
DiPro Sensor Interface, DSI 2*: 5.88 x 5.41 x 3.42 in. (149 x 137 x 87 mm)
DiProPAC sensor-disabled output: open collector, 8 mA max.
AutoSetPAC* 10.25 x 12 x 4 in. (260 x 305 x 102 mm)
2 or 4 strain link inputs
Ability to store high, low, and repeatability setpoints with tool number
Displays, adjusts, recalculates “auto” setpoints and displays actual load
Displays and saves load signatures
SFI* ServoFeed Interface integrates servofeed
RamPAC* 10.25 x 12 x 4 in. (260 x 305 x 102 mm)
Automatically sets shut height and counterbalance and cushion pressures
SBR Provides capability to back up tool settings to a Windows laptop PC.
Requires purchase of SBR software.
USB Disk Backup Enables backup of programmed tool settings to USB disk
Info Center With this option Setup sheets and other press information stored
on a central server can be displayed on networked SmartPAC 2s
Bilingual* (English/Spanish) status/adjust menus
Preventive Maintenance (PM) Monitor Tracks selected press functions
requiring scheduled maintenance and alerts the user when maintenance is
due
PLC Interface Enables SmartPAC 2 to transmit additional tool settings to a
Programmable Logic Controller for press automation and auxiliary functions
ShopFloorConnect Asset Utilization Software (SFC) or Line Efficiency
Tracking Software (LETS) Provides capability for production information
from SmartPAC 2 to be downloaded to SFC or LETS data collection software
for generation of OEE and other reports. Requires purchase of SFC or LETS
software.
3rd Party Comms This option allows SmartPAC 2 to transmit real-time and
status information to external software for reporting and other tasks
* Consult product user manual. DSI 2: #1121900; AutoSetPAC: #1101600; SFI: #1102500;
RamPAC: #1115200; Bilingual (English/Spanish): #1130600.
1-8
Introduction
Chapter 2. Installation
!
DANGER
ELECTRIC SHOCK OR HAZARDOUS ENERGY
Disconnect main power before installation.
• Remove all power to the press, press control, and other equipment used with the press.
• Remove all fuses and “tag out” per OSHA 1910.147 Control of Hazardous Energy (Lockout/
Tagout).
• Ensure that installation is performed by qualified personnel.
• Complete all installation procedures before connecting to the AC power source.
Failure to comply with these instructions will result in death or serious injury.
!
DANGER
PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE
Use SmartPAC 2 Servo’s programmable cam switch to control auxiliary functions only. The
SmartPAC 2 programmable cam capability should never be used to provide timing signals for any
safety use including muting of light curtains.
Failure to comply with these instructions will result in death or serious injury.
NOTICE
OPTIONAL DIPROPAC MODULE INCLUDED IN MANUAL
When you order your SmartPAC 2 Servo, you may include the DiProPAC die protection option.
This manual includes instructions for installing and using this option. Remember that it is an
option and might not be included in your system.
If you ordered SmartPAC 2 Servo with other optional modules such as AutoSetPAC load monitor
or RamPAC shut height, counterbalance, and cushion control, refer to the user manual for that
option for complete details on its installation and use.
Installation
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SmartPAC 2 Servo User Manual
Before You Start
NOTICE
READ INSTALLATION INSTRUCTIONS BEFORE STARTING INSTALLATION
If you install SmartPAC 2 yourself, read this installation chapter carefully, plan your installation, and
figure out what steps you will follow before you start drilling holes, running conduit, or cutting wires.
NOTICE
LEARN TO USE SMARTPAC 2 SERVO BEFORE INSTALLING ON A PRESS
If you have not used SmartPAC 2 Servo before, learn how to initialize and program it before
installing it on a press. On the bench, wire the linear transducer to SmartPAC 2 Servo (see
page 2-11), connect the transducer to a DC power source (see page 2-14), and wire AC power
(see page 2-15). You can then access all the menus and make settings. See Chapter 3 for
instructions on using the keyboard and displays, Chapter 4 for using Initialization mode, Chapter 5
for using Program mode, and Chapter 6 for using Run mode.
This chapter describes how to install SmartPAC 2 Servo and some of its options. It is
organized in the following sections:
• Installation Guidelines, page 2-3
• Connecting Wires to Terminal Block Connectors, page 2-5
• Terminating Cable Shields, page 2-5
• Checking the Press, page 2-6
• Mounting the SmartPAC 2 Control Enclosure, page 2-7
• Installing SmartPAC 2 as a Panel Mount, page 2-8
• Installing the MTS Linear Transducer, page 2-10
• Wiring the Transducer to DC Power, page 2-14
• Connecting AC Wiring, page 2-15
• Connecting Stop Circuits, page 2-16
• Connecting to Network, page 2-18
• Replacing ProCamPAC, page 2-18
• Adding or Upgrading DiProPAC, page 2-20
• Connecting DiPro Sensor Interface to SmartPAC 2, page 2-23
• Connecting Programmable Cam Channels, page 2-25
• Turning on Power to SmartPAC 2 Servo, page 2-33
• Verifying Installation of DiProPAC and ProCamPAC, page 2-34
• Final Checkout, page 2-35
• Wiring Setup Mode Circuit, page 2-32
• Wiring a Remote Reset Switch (Optional), page 2-32
• Wiring a Sensor-Disabled Output (Optional), page 2-32
• Wiring a Press-in-Motion Signal (Optional), page 2-32
• Wiring Tables for SmartPAC 2 Servo Options, page 2-38
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Installation Guidelines
Observe the following guidelines when installing SmartPAC 2 Servo, referring to Figure 2-1,
page 2-4 when necessary.
• Separate high- and low-voltage wires
Never run wires for 120V and for lower voltages (e.g., 24V, 60V) inside the same conduit.
Run flexible, liquid-tight conduit for high voltage lines (120V power, relay circuits) to the
upper right-hand corner of the SmartPAC 2 enclosure. Run one or two low voltage
conduits for the transducer and communications control wires into the lower left-hand
corner of SmartPAC 2 Servo. If you have top-stop and emergency-stop circuits that are
24V or a voltage other than 120V, you must run them separately from the high-voltage
wiring.
The AC power supply wires to SmartPAC 2 Servo should be run separately from the DC
control wires going to the ProCamPAC Output Assembly. Never use the SmartPAC 2
power terminals as a junction point to provide power for external devices. In most cases,
the AC power supply wires should be connected directly to the press control cabinet. Do
not use the ProCam output enclosure as a junction box for the AC control wires. Provide a
separate junction box for this purpose.
Communications wiring should be run separately in its own conduit. Communications
wiring will be installed if SmartPAC 2 is connected to a ServoFeed Interface (SFI™),
AutoSetPAC, RamPAC, SBR, LETS/SFC, or other equipment.
• Provide NEMA 12 conduit and connections
Because SmartPAC 2 is rated NEMA 12 (i.e., protected against dust and oil), you must use
conduit of the same rating and make proper connections to ensure that the enclosure is
NEMA-12-protected.
• Properly ground SmartPAC 2
The ground wire from SmartPAC 2 should be connected to the main ground point of the
press control system. This ground point may be in the area where the control transformer is
grounded. Finding a good place for a ground is sometimes difficult, but the location should
be close to where the press receives its ground.
• Correctly terminate all cable shields
Terminate all cable shields to the studs provided in the enclosure or to a good grounding
location (see Terminating Cable Shields, page 2-5).
• Install suppressors across inductive loads
All relays, solenoids, or other inductive loads that are controlled by SmartPAC 2 must be
suppressed. Suppressors should be installed across the load and as close to the load as
possible. See Figure 2-16, page 2-31. Never install a suppressor across relay contacts. If
you do, the suppressor may fail shorted, and the equipment controlled by that relay will
remain energized. Additional suppressors (part number 2238801) can be obtained from
Wintriss Controls.
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Transducer
ProCamPAC
output
assembly
DiPro
Sensor
Interface
SmartPAC 2 Servo
Wintriss Press Automation Control
F1
F2
POWER
Main
Valve
Control
F3
F4
F5
F6
F7
F8
1
2
3
4
5
6
7
8
9
CLEAR
0
.
PROG
ENTER
HELP
RESET
RUN
Connections for AC wiring,
top stop wiring and emergency
stop wiring should be made
inside the press control.
Figure 2-1. Installation Overview
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Connecting Wires to Terminal Block Connectors
NOTICE
CONNECTOR WIRING
The connector can plug into the receptacle on the PC board in only one direction. Before wiring
the connector, mark its left and right ends when it is plugged in to make sure you wire the correct
pin numbers.
Connect wires to terminal block connectors as follows:
1. To connect a wire, find the correct terminal and loosen the screw over it by turning it
counterclockwise (see Figure 2-2).
2. Strip the correct wire for this terminal 1/4 in. (6.4 mm) from end.
3. Insert bare wire into the terminal 90% of the way. Tighten the screw. The metal tooth
inside will clamp down on the bare wire for a tight connection. Make sure that the metal
tooth is clamped down on the bare part of the wire, not on the insulation.
4. Connect all wires. Double-check connections when done.
5. Plug the connector firmly into the receptacle on the PC board. The connector can fit into
the receptacle in only one direction.
Tighten screw to clamp
wire in terminal
Insert wire here
Figure 2-2. Attaching Wires to Connector
Terminating Cable Shields
NOTICE
TERMINATE BOTH ENDS OF SHIELD
Be sure to terminate cable shields at both ends (for example, at SmartPAC 2 and DSI 2).
Your SmartPAC 2 Servo has ground studs on the inside of the enclosure for terminating cable
shields at their point of entry.
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SmartPAC 2 Servo User Manual
Drain wire
Strip cable jacket
as far as end of
conduit fitting
Secure drain wire
under nut on
ground stud
Figure 2-3. Connecting Shield Drain Wire to Ground Stud
For each shielded cable, perform the following steps, referring to Figure 2-3.
1. Strip the cable jacket as far as the end of the conduit fitting.
2. Cut the drain wire to a length that allows it to wrap at least once around the nearest
grounding stud. Loosen the nut on the stud, wrap the drain wire clockwise around the
stud, and tighten down the nut.
3. Connect the rest of the wires in the cable to the terminal block.
Checking the Press
Before starting the installation, remove the die from the press and run the press in all its
operating modes–Inch, Single-stroke, and Continuous. Make sure the press has working topstop and emergency-stop circuits. Verification that the press operates and stops properly is
extremely important because SmartPAC 2 Servo will be connected to the press stop circuits.
Do not forget to mark on your electrical prints where you connect SmartPAC 2. Move the
press ram to its programmed Upper Limit (see page 5-50).
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Mounting the SmartPAC 2 Control Enclosure
NOTICE
If your SmartPAC 2 Servo is a panel mount version, go to the next section, page 2-8, for mounting
instructions.
NOTICE
PLACE SMARTPAC 2 AT A CONVENIENT HEIGHT
SmartPAC 2 Servo should be installed at a convenient height for all users. Ideally, the top edge of
the unit should be approximately at chin level. Experiment to determine a good height for all users
before mounting.
To mount the SmartPAC 2 enclosure, follow the steps below, referring to Figure 2-4.
14.2 REF
(360)
Dimensions: inches
(mm)
1.00
(25.4)
TYP
.310
(7.9)
8 places
10.00
(254.0)
SmartPAC 2 Servo
F1
F2
POWER
F3
13.25
(336.6)
F4
F5
12.51
(317.8)
F6
F7
F8
1
2
3
4
5
6
7
8
9
CLEAR
0
.
PROG
RUN
ENTER
HELP
RESET
Enclosure depth approx. 5.5 inches (140 mm). However, you must allow clearance of
approximately 18 inches (460 mm) from mounting surface to fully open the enclosure’s door.
Figure 2-4. SmartPAC 2 Servo Mounting Dimensions: Enclosure
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1. Determine a convenient location for the enclosure. Ideally, the enclosure should be
mounted where operators and setup personnel can easily see the readouts and reach the
keyboard. Make sure that all cables can reach the enclosure. Leave enough room to open
the door at least 120°. The enclosure can be mounted on a pedestal, pendant, or the press
itself.
2. Drill and tap (if necessary) mounting holes, using a No. 7 drill and 1/4–20 tap, then mount
the enclosure, using the enclosed shock mounts. Shock mount studs are 1/4–20.
Installing SmartPAC 2 as a Panel Mount
If you have received the panel-mount configuration of SmartPAC 2 Servo, follow the steps
below to install the panel mount in your enclosure. The panel mount is usually installed from
the outside of the enclosure. Be sure to allow at least 6 in. (152 mm) of clearance behind the
panel mounting plane to leave enough room for the electronics.
1. Determine a convenient location within your enclosure or console for mounting
SmartPAC 2 Servo. Ideally, SmartPAC 2 should be mounted where operators and setup
personnel can easily see the readouts and reach the keyboard.
2. Cut out a hole in your enclosure, and drill and tap twelve holes for #10-32 screws,
referring to Figure 2-5, page 2-9 for mounting and “cutout” dimensions.
3. Prop the panel mount near the cutout location. You can do this by connecting ty wraps
from two of the left holes on the panel to the corresponding holes on the enclosure or
console, creating hinges.
4. Perform wiring connections as shown in the following sections. Make sure all cables will
reach the connectors on the back of the panel mount.
5. When final checkout procedures have been completed (see page 2-35), install the panel
mount in your enclosure or console, using twelve #10-32 screws.
2-8
Installation
SmartPAC 2 Servo User Manual
1131400
NOTE:
SmartPAC and SmartPAC 2
both use the same size cutout:
9.5 x 11 inches. The top 9 holes
are in the same location.
12.30
(312.4)
SmartPAC 2
F1
F2
POWER
F3
BRAKE
WARNING
F4
F5
11.30
(287.0)
F6
If you are replacing a SmartPAC
with a SmartPAC 2, drill three
additional holes at the locations
shown for the bottom three holes.
Allow 6 inches (153 mm)
minimum clearance behind
the panel
F7
F8
INCH
SINGLE
STROKE
1
CONT
2
3
4
5
6
7
8
9
CLEAR
0
.
OFF
PROG
RUN
ENTER
Dimensions:
Inches (mm)
HELP
RESET
Panel
0.35
(8.9)
TYP
5.50
(139.7)
0.35
0.35
(8.9)
(8.9)
TYP
TYP
10.65
(270.5)
Cutout
0.35
(8.9)
TYP
4.50
(114.3)
9.00
(228.6)
8.65
(105.4)
10.35
(261.6)
11.00
(279.4)
Figure 2-5. SmartPAC 2 Servo Mounting and Cutout Dimensions: Panel Mount
Installation
2-9
1131400
SmartPAC 2 Servo User Manual
Installing the MTS Linear Transducer
Make sure to install a magnetostrictive linear transducer (see page 1-4 for a description of
transducer operation) that is at least as long as or longer than the sum of the maximum stroke
length of your press and the maximum shut-height adjustment. If you have ordered a Balluff
rather than an MTS transducer, refer to Appendix A for installation instructions.
CAUTION
It is important that the transducer cable be facing up. If the cable is facing down, the transducer will
not work properly.
Failure to comply with these instructions could result in property damage.
Mounting the Transducer
NOTICE
Not all Servo presses are the same. Each installation will be different. The following installation
procedure is an example.
Once you have thought out your design and gathered the parts, mount the magnetostrictive
linear transducer by performing the following steps, referring to Figure 2-1, page 2-4 for
suggested mounting location and Figure 2-6, page 2-11 for mounting dimensions:
1. Make sure the press is at Bottom Dead Center (BDC) and at the Lower Limit of its Shut
Height adjustment.
2. Using a marking pen, mark the upper and lower limits of the area identified as the sensor’s
“Max. electrical stroke” in Figure 2-6.
3. Fabricate a bracket that will fit the length of the transducer and its mounting feet.
Make sure the bracket mounting holes are elongated or oval-shaped so the transducer can
be moved up and down during fine-tuning of the transducer’s mounting position.
4. Fabricate a second bracket to hold the sliding magnet connecting rod.
5. Mount the bracket for the transducer on the press.
6. Mount the transducer on the bracket, leaving the screws loose to allow adjustment of
transducer position.
7. Mount the bracket for the magnet connecting rod on the ram.
8. Connect the magnet to the transducer by sliding it into the mating grooves from the
bottom of the unit. Make sure the magnet is positioned within the transducer’s electrical
range (i.e., within the marks you made in step 2) and that the bump on the magnet is facing
the sensor’s electronics housing when the press moves up and down (see Figure 2-6). If
the magnet is not positioned within the transducer’s electrical range, it will not work
properly.
9. Once the magnet is secure, tighten down the transducer.
2-10
Installation
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1131400
Dimensions:
Inches (mm)
0.21 (5.5)
dia. for
M5 or #10
screw
(2 places)
2.6
(66)
Electronics
housing
Bump
2.48
(63)
0.47
(12)
1.92
(49)
0.36
(9)
2.05
1.77 (52)
(45)
Dead zone
Max. electrical
stroke
Sliding
magnet,
highest/
lowest
positions
0.07
(2)
1.97
(50)
1.77
(45)
M5
Male
2.68
(68)
0.36
(9)
2 places
Physical length
Top View
3.2
(82)
Dead zone
Side
view
Figure 2-6. MTS Linear Transducer Dimensions
Wiring the Transducer
To wire the transducer to the SmartPAC 2 Servo board, perform the following steps:
1. Plug the connector on the transducer cable into the transducer if it is not already
connected, twisting the locknut so the connection is tight. The connector plugs into the
transducer only one way.
2. Run the transducer cable through 1/2-in. conduit from the transducer to one of the
knockouts on the bottom left of the SmartPAC 2 enclosure.
3. Measure and cut the transducer wires so they comfortably reach TB402 on the
ProCamPAC board. See Figure 2-7, page 2-12, below, for the location of the ProCamPAC
board on the SmartPAC 2 Servo board and Figure 2-8, page 2-13 for the location of
TB402 on the ProCamPAC board.
Installation
2-11
SmartPAC 2 Servo User Manual
JP102
DiProPAC 16
board
K101
K102
1
TB105
S101
TB402
1
K102
TB403
60-250
ETHERNET LEDS
LINK
ACTIVITY
K101
1
TX
RX
+15V
POS SEN 12-60
GND
Z CAM
REM RST
GND
LOCKOUT
IN/SETUP
OP STA 2
OP STA 1
TX
RX
ETHERNET
TB101 RESOLVER
1
1
READ
WRITE
AUX I/O
TB107
TX
RX
USB
TB104
PACNET
SPECIAL
1
SFI
TX
RX
TX
RX
TX
RX
TX
RX
TX
RX
TB103
MODULE
WPC
COMPACT
FLASH
ACCESS LED
F103
TB553
302 303 304 305 306
ProCamPAC 8
Linear board
1
F102
F101
292 293 294 295 296 297 298 299 300 301
SPARE 1
-12V
+5V
POWER
LEDS
TB404
A B
TB554
T STOP
TB401
E STOP
1
282 283 284 285 286 287 288 289 290 291
260 261 262 263 264 265 266 267 268 269 270
1
TB102
1
1
TB106
SPARE 2
1
SPARE 3
+12V
+3.3V
1131400
1
1
Figure 2-7. SmartPAC 2 Servo Board with ProCamPAC and DiProPAC Boards Installed
2-12
Installation
SmartPAC 2 Servo User Manual
1131400
1
1
260 261 262 263 264 265 266 267 268 269 270
260 261 262 263 264 265 266 267 268 269 270
TB451
TB451
Cam channel 1-8
wiring connections
Cam channel 1-8
wiring connections
TB404
TB404
1
1
1
1
1
1
Cam channel 9-15
wiring connections
TB403
TB402
TB403
TB402
TB452
1
271 272 273 274 275 276 277 278 279 280 281
Figure 2-8. ProCamPAC Linear Boards, Location of Components:
8-Channel (Left), 15-Channel (Right)
4. Unplug the connector from TB402, and attach transducer wires as shown in Figure 2-9
and Table 2-1, page 2-14, and Figure 1 (8-channel ProCamPAC) or 2 (15-channel
ProCamPAC) at the back of the manual. Refer to Connecting Wires to Terminal Block
Connectors, page 2-5 if you need additional help.
NOTICE
The connector can plug into the ProCamPAC board in only one direction. Before wiring the
connector, mark its left and right ends when it is plugged in to make sure you wire the
correct pin numbers.
5. Double-check connections, then plug the connector back into TB402. It plugs in only one
way.
Installation
2-13
1131400
SmartPAC 2 Servo User Manual
76
32
1
Numbers match numbered
slots on socket
.
Wht
Brn
Grn
Yel
Gry
Pnk
54
Blu tion
c
onne
Connect the shield to
the enclosure next to
the conduit entry point.
No C
ld
Shie
Figure 2-9. MTS Linear Transducer Pinout
Table 2-1. MTS Linear Transducer Wiring
Pin # on TB402
ProCamPAC Linear Board
Wire Color *
Shield
(terminate to ground stud
nearest entry to enclosure)
1 (+DATA)
Pink
2 (-DATA)
Grey
3 (+CLK)
Yellow
4 (-CLK)
Green
5 (+24VDC)
Brown
6 (GND)
White
* Blue is not used.
Wiring the Transducer to DC Power
The magnetostrictive linear transducer requires a DC power source. Your SmartPAC 2 Servo
may already have a small DC power supply installed on the side and wired to the
ProCamPAC.
If your unit does not have the small DC power supply installed and you plan to use your own
24 VDC 0.5 A power supply, connect it to TB403 on the ProCamPAC Linear board as shown
in Table 2-2, page 2-15 and Figure 1 (8-channel ProCamPAC Linear) or 2 (15-channel
ProCamPAC Linear) at the back of the manual. See Figure 2-8 for the location of TB403 on
ProCamPAC Linear boards.
2-14
Installation
SmartPAC 2 Servo User Manual
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Table 2-2. Linear Transducer Wiring: DC Power
Pin # on TB403
ProCamPAC Linear Board
1 (24 VDC)
2 (GND)
Connecting AC Wiring
!
WARNING
ELECTRIC SHOCK HAZARD
• Do not connect the AC power source until you are done with all other installation procedures.
• Turn off and disconnect power from the machinery SmartPAC 2 is connected to before making
any wiring connections. This includes power to the machine control and motor.
Failure to comply with these instructions could result in death or serious injury.
Run the AC power wires through a “high-voltage” conduit (see Installation Guidelines,
page 2-3) along with the wiring for emergency-stop and top-stop circuits. No. 16 wire (No.
14, if local codes require it) with a minimum 75° C temperature rating is recommended for
these circuits. Bring the conduit into the top right knockout of the SmartPAC 2 enclosure.
Then, to wire the AC input terminal block, follow these steps:
1. Find the AC terminal block at the top right corner of the back wall of the enclosure (see
Figure 2-10, page 2-16).
For a panel mount unit, the terminal block is mounted to the back of the faceplate near the
top right corner of the SmartPAC 2 Servo PC board.
2. Determine how you will bring wiring from your 115 Vac power source (or 230V source, if
applicable) to the unit. These wires should be connected directly to the press control
transformer at the press control. For 115 Vac, you need three wires–high (black), neutral
(white) and ground (green). For 230 Vac, wires are black and red with green or green/
yellow for ground.
3. Connect the AC input wires and ground wire as shown in Figure 2-10 and Figure 3 at the
back of the manual. Make your ground connection as follows:
• SmartPAC 2 Enclosure: Connect your ground (green or green/yellow) wire to the set
screw terminal on the inside of the enclosure. To connect to the set screw terminal, strip
the ground wire about 1/4 in. (6.4 mm) from end, loosen the screw on the terminal, slide
the wire in the hole, and tighten the screw to secure the wire in place.
• SmartPAC 2 Panel Mount: Connect the ground wire to the ground stud on the face
plate below the AC input terminal block.
4. Connect AC wires to the power source only after all installation procedures have been
completed and you are ready to perform final checkout tests (see page 2-35).
Installation
2-15
1131400
SmartPAC 2 Servo User Manual
Ground
L2
(Neutral)
L1
(High)
Terminal block
Setscrew
terminal
Figure 2-10. Wiring AC to Terminal Block, Inside Enclosure, Top Right
!
WARNING
ELECTRIC SHOCK HAZARD
Do not connect the AC power source until you are done with all other installation procedures.
Failure to comply with these instructions could result in death or serious injury.
Connecting Stop Circuits
You need four wires to connect SmartPAC 2 Servo to your press control stop circuits, two for
the emergency-stop circuit and two for the top-stop circuit. You can wire these circuits at
your press control. Refer to your press control manual or other electrical prints.
To make wiring connections, perform the following steps:
1. Run the stop circuit wires to SmartPAC 2 Servo through flexible liquid-tight conduit to the
enclosure. Because SmartPAC 2 is rated NEMA 12 (protected against dust and oil), you
must use conduit of the same rating and make proper connections to ensure that the
enclosure is NEMA-12-protected.
2. Locate connector TB102 on the SmartPAC 2 Servo board (see Figure 2-11, page 2-17) and
unplug it from its socket. Connect the wires for the stop circuits to TB102 pin locations,
as shown in Table 2-3, page 2-17 and Figure 3 at the end of the manual.
3. Plug the connector back into its socket. Double-check connections to make sure that you
didn’t wire the connector backwards (see Connecting Wires to Terminal Block Connectors,
page 2-5).
2-16
Installation
SmartPAC 2 Servo User Manual
1131400
TB102
Battery Backed Up
RAM Device
ETHERNET
POSITION
SENSOR LED
DS103
1
1
212 213 214 215 216 217 218
READ
WRITE
E-STOP
LEDS Tx5
Rx5
DS101
TB101 RESOLVER
USB
Tx6
Rx6
245 246 247 248 249 250 251 252 253 254
AUX I/O
USB PORT
LEDS
TB107
ZERO CAM
LED DS102
PS/2
Tx8
Rx8
TB104
PACNET
SPECIAL
1
SFI
Tx2
Rx2
Tx1
Rx1
Tx4
Rx4
Tx3
Rx3
Tx7
Rx7
TB103
MODULE
321 322 323 324 325 326 327 328 329 330
INPUT
CHECK
LED
S101
TB105
1
TB106
310 311 312 313 314 315 316 317 318 319 320
SLAVE
INPUT
CHECK
SWITCH
WPC
MASTER
E-STOP
RELAYS
TOP
STOP
RELAY
SPARE 1
JP101
BATTERY
+
K102
SPARE 2
INPUT CHECK
FUSE
K101
SPARE 3
ETHERNET LEDS
LINK
ACTIVITY
COMPACT
FLASH
COMPACT
FLASH
ACCESS LED
TOP STOP
LED DS106
K102
HIGH
SPEED
TOP STOP
FUSE
F103
+15V
POS SEN 12-60
GND
Z CAM
REM RST
GND
LOCKOUT
IN/SETUP
OP STA 2
OP STA 1
LOW
F102
F101
Boot Loader
Serial # xxxxxxxx
-12V
+5V
JP102
A B
T STOP
POWER
LEDS
E-STOP
FUSE
205 206 207 208 209 210
E STOP
1
K101
DiPro
60-250
+12V
+3.3V
ProCam
1
1
224 225 226 227 228 229 230 231 232 233 234
235 236 237 238 239 240 241 242 243 244
Figure 2-11. SmartPAC 2 Servo Board: Location of Components
Table 2-3. Stop Circuit Wiring Connections: TB102
Circuit
SmartPAC 2
TB102
Pin Locations
E-stop
207
E-stop
208
Top-stop
209
Top-stop
210
4. Connect top-stop and E-stop circuit wires at the press control or other box into which you
are tying them.
NOTICE
Be sure to number all wires in a way consistent with your press’s electrical prints.
5. Make all the necessary conduit connections to ensure NEMA 12 protection.
Installation
2-17
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SmartPAC 2 Servo User Manual
Connecting to Network
Before you can connect SmartPAC 2 Servo to a computer network, your network
administrator must make the necessary connections and settings.
The Ethernet cable is plugged into the Ethernet connector on the SmartPAC 2 Servo board
(see Figure 2-11, page 2-17).
NOTICE
SETTING STATIC IP ADDRESS
SmartPAC 2 comes from the factory set up for a Dynamic Host Configuration Protocol (DHCP)
network, which automatically assigns IP addresses. If your network requires static IP addresses,
have your network administrator call Wintriss Tech. Support for assistance in setting up SmartPAC
2 with a static IP address. See CHANGE NETWORK SETTINGS, page 4-34.
Replacing ProCamPAC
!
WARNING
ELECTRIC SHOCK HAZARD
Turn off and disconnect power from SmartPAC 2 and from the machinery it is connected to before
making any wiring connections. This includes power to the machine control and motor. Do not
connect the AC power source until you are done with all other installation procedures.
Failure to comply with these instructions could result in death or serious injury.
CAUTION
DAMAGE TO BOARD FROM STATIC DISCHARGE
Ground yourself before touching circuit boards or chips by touching a large metal object such as
the press. Static electricity can destroy electronic components. Failure to comply with these
instructions could result in property damage.
NOTICE
INSTALL PROCAMPAC LINEAR BOARD IN CORRECT LOCATION
Install the ProCamPAC Linear board in the location shown in Figure 2-7, page 2-12. If you install
the board in the wrong location, SmartPAC 2 Servo will not recognize that ProCamPAC is installed.
Eight- and 15-channel configurations of ProCamPAC are interchangeable. When the ProCamPAC
Linear board is installed in the correct location, SmartPAC 2 recognizes whether it is an 8- or 15channel board.
To replace an existing ProCamPAC Linear board, do the following:
1. Turn off power to the SmartPAC 2 Servo.
2. On the SmartPAC 2 Servo board, locate the ProCamPAC board (see Figure 2-7,
page 2-12).
2-18
Installation
SmartPAC 2 Servo User Manual
1131400
CAUTION
DAMAGE TO BOARD FROM STATIC DISCHARGE
Ground yourself before touching circuit boards or chips by touching a large metal object
such as the press. Static electricity can destroy electronic components.
Failure to comply with these instructions could result in property damage.
3. Making sure you are grounded, remove the connector(s) attached to the board.
Connectors are wired to the following components (see Figure 1 or 2 at the back of the
manual):
• TB402–DSI 2
• TB403–Magnetostrictive linear transducer
• TB404–Unused
• TB451 and TB452–ProCamPAC output assembly
4. Remove the four screws that hold the board to the standoffs, and put them aside.
5. Mark the board to identify it so you don’t re-install it by mistake.
6. Remove the board by pulling it straight up from the SmartPAC 2 Servo board and out of
its connector.
7. Making sure that you are still grounded, install the new board by plugging it into the J111
connector (see Figure 2-11, page 2-17). The connector is keyed, so you can only plug in
the board in one direction.
8. When the board is properly seated, screw it down to the four standoffs, using the screws
you removed in step 4.
9. Reinstall the connector(s) you removed in step 3.
You will not be able to reinstall connector TB452 if you are replacing a 15-channel with
an 8-channel ProCamPAC. There is no mating connector for TB452 on the ProCamPAC 8
Linear board. In that case, make sure to disconnect the wires from TB452 and from the
equipment to which it is connected.
10. If you have installed a 15-channel board in place of an 8-channel board, remove connector
TB452 and wire it to the ProCamPAC Output assembly, following the procedure in
Connecting Programmable Cam Channels, page 2-25. Plug the TB452 connector back
into the ProCamPAC 15 Linear board when you are finished.
11. Verify that you have installed the board(s) properly by performing the Verifying
Installation of DiProPAC and ProCamPAC procedure, page 2-34. You need to complete
this procedure before you can use SmartPAC 2 Servo.
Installation
2-19
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SmartPAC 2 Servo User Manual
Adding or Upgrading DiProPAC
!
WARNING
ELECTRIC SHOCK HAZARD
Turn off and disconnect power from SmartPAC 2 and from the machinery it is connected to before
making any wiring connections. This includes power to the machine control and motor. Do not
connect the AC power source until you are done with all other installation procedures.
Failure to comply with these instructions could result in death or serious injury.
CAUTION
DAMAGE TO BOARD FROM STATIC DISCHARGE
Ground yourself before touching circuit boards or chips by touching a large metal object such as
the press. Static electricity can destroy electronic components.
Failure to comply with these instructions could result in property damage.
NOTICE
INSTALL DIPROPAC BOARD IN CORRECT LOCATION
Install the DiProPAC board in the location shown in Figure 2-7, page 2-12. If you install the board
in the wrong location, SmartPAC 2 Servo will not recognize that DiProPAC is installed.
Eight-, 16-, and 32-channel configurations of DiProPAC are interchangeable. When the DiProPAC
board is installed in the correct location, SmartPAC 2 recognizes whether it is an 8-, 16-, or 32channel board.
NOTICE
MAKE SURE TO CLEAR TABLES AFTER INSTALLING DIPROPAC 32
If you are installing a DiProPAC 32 board, you must clear some of the SmartPAC 2 memory tables;
otherwise, your SmartPAC 2 will not operate properly. After installing the board, clear the tables by
accessing the Diagnostics Menu from the SmartPAC 2 Main Initialization Menu (see Figure 4-1,
page 4-1) and selecting the CLEAR TABLES item (see Figure 4-27, page 4-35). On the Clear
Tables Utility screen, select DIPRO 32, and when the red warning window displays, press the
CLEAR key to confirm that you want to continue with the Clear Tables process.
The following instructions describe how to add die protection capabilities to a basic
SmartPAC 2 Servo or upgrade your existing die protection capabilities. DiProPAC is
available as an 8-sensor, 16-sensor, or 32-sensor board. Wiring instructions for the
DiProPAC board are provided starting on page 2-23.
Replacing an Existing Board
To replace an existing DiProPAC board, do the following:
1. Turn off power to the SmartPAC 2 Servo.
2. On the SmartPAC 2 Servo board, locate the DiProPAC board (see Figure 2-7, page 2-12).
2-20
Installation
SmartPAC 2 Servo User Manual
1131400
CAUTION
DAMAGE TO BOARD FROM STATIC DISCHARGE
Ground yourself before touching circuit boards or chips by touching a large metal object
such as the press. Static electricity can destroy electronic components.
Failure to comply with these instructions could result in property damage.
3. Making sure you are grounded, remove the connector(s) attached to the board (see
Figure 2-12).
Connector TB554 (and TB555 if it is wired) go(es) to DSI 2. Connector TB453 is used for
auxiliary outputs. See Figure 4 or 5 at the back of the manual.
1
1
282 283 284 285 286 287 288 289 290 291
1
282 283 284 285 286 287 288 289 290 291
TB554
282 283 284 285 286 287 288 289 290 291
TB554
Wiring connector for
sensor inputs 1-8
(also DiProPAC 16 and 32)
TB553
LEDs for
sensor inputs 9-16
(also DiProPAC 32)
TB553
TB553
1
LEDs for
sensor inputs 17-24
LEDs for
sensor inputs 25-32
1
Wiring connector for
sensor inputs 17-24
Wiring connector for
sensor inputs 25-32
302 303 304 305 306
Wiring connector for
sensor inputs 9-16
(also DiProPAC 32)
292 293 294 295 296 297 298 299 300 301
302 303 304 305 306
Wiring connector for
auxiliary outputs
(also DiProPAC 16 and 32)
292 293 294 295 296 297 298 299 300 301
302 303 304 305 306
LEDs for
sensor inputs 1-8
(also DiProPAC 16 and 32)
TB554
1
1
180 181 182 183 184 185 186 187 188 189
TB555
190 191 192 193 194 195 196 197 198 199
DiProPAC 8
DiProPAC 16
DiProPAC 32
Figure 2-12. DiProPAC Boards (8-, 16-, and 32-Sensor): Location of Components
4. Remove the four screws that hold the board to the standoffs, and put them aside.
5. Mark the board to identify it so you don’t re-install it by mistake.
6. Remove the board by pulling it straight up from the SmartPAC 2 Servo board and out of
its connector.
7. Making sure that you are still grounded, install the new board by plugging it into the J112
connector (see Figure 2-11, page 2-17). Connectors are keyed, so you can only plug in the
board in one direction.
8. When the board is properly seated, screw it down to the four standoffs, using the screws
you removed in step 4.
Installation
2-21
1131400
SmartPAC 2 Servo User Manual
9. Reinstall the connector(s) you removed in step 3.
If you are upgrading from an 8- to a 16-sensor DiProPAC or from a 16- to a 32-sensor
DiProPAC, make sure you plug the connector(s) into the correct terminal block(s). TB554
and TB555 pin assignments for the different boards are as follows (see Figure 2-12):
• DiProPAC 8: Sensors 1-8 to TB554 upper
• DiProPAC 16: Sensors 1-8 to TB554 upper, sensors 9-16 to TB554 lower
• DiProPAC 32: Sensors 1-8 to TB554 upper, sensors 9-16 to TB554 lower
10. If you have installed a board with an additional connector (i.e., a 16-sensor board in place
of an 8-sensor board, or a 32-sensor board in place of a 16-sensor board), wire that
connector or those connectors to the DiPro Sensor Interface, following the instructions in
Connecting DiPro Sensor Interface to SmartPAC 2, page 2-23.
11. Verify that you have installed the DiProPAC board properly by performing the Verifying
Installation of DiProPAC and ProCamPAC procedure, page 2-34. You need to complete
this procedure before you can use SmartPAC 2 Servo.
Installing a New Board
To install a new DiProPAC board, do the following:
1. On the SmartPAC 2 Servo board, find the location where the DiProPAC board will be
installed (see Figure 2-7, page 2-12).
CAUTION
DAMAGE TO BOARD FROM STATIC DISCHARGE
Ground yourself before touching circuit boards or chips by touching a large metal object
such as the press. Static electricity can destroy electronic components.
Failure to comply with these instructions could result in property damage.
2. Making sure that you are grounded, install the new board by plugging it into the J112
connector (see Figure 2-11, page 2-17). Connectors are keyed, so you can only plug in the
board in one direction.
3. When the board is properly seated, screw it down to the four standoffs, using the screws
that came with the kit.
4. Remove the connector(s) from the board.
Connector TB554 (and TB555 if it is wired) go(es) to DSI 2. Connector TB453 is used for
auxiliary outputs. See Figure 4 or 5 at the back of the manual.
TB554 and TB555 pin assignments for the different boards are as follows (see
Figure 2-12, page 2-21):
• DiProPAC 8: Sensors 1-8 to TB554 upper
• DiProPAC 16: Sensors 1-8 to TB554 upper, sensors 9-16 to TB554 lower
• DiProPAC 32: Sensors 1-8 to TB554 upper, sensors 9-16 to TB554 lower, sensors 17-24
to TB555 upper, and sensors 25-32 to TB555 lower
2-22
Installation
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5. Wire the TB554 and TB555 connectors to the DiPro Sensor Interface, following the
instructions in Connecting DiPro Sensor Interface to SmartPAC 2, page 2-23.
6. Plug the connector(s) back into their sockets on the board.
7. Verify that you have installed the DiProPAC board properly by performing the Verifying
Installation of DiProPAC and ProCamPAC procedure, page 2-34. You need to complete
this procedure before you can use SmartPAC 2 Servo.
Connecting DiPro Sensor Interface to SmartPAC 2
To connect your DiPro die protection sensors through the DiPro Sensor Interface (DSI) 2,
refer to Table 2-4, below, to wire sensors 1-8, Table 2-5, page 2-24 to wire sensors 9-16,
Table 2-6, page 2-24 to wire sensors 17-24, and Table 2-7, page 2-25 to wire sensors 25-32.
Wiring diagrams (Figure 4 for sensors 1-16, Figure 5 for sensors 17-32) are provided at the
back of the manual. Terminate cable shields to ground studs close to the point of entry into
the enclosure. Refer to the DSI 2 manual for more information.
NOTICE
DSI 2 NOT COMPATIBLE WITH LOW-IMPEDANCE SENSORS
If any of your sensors are low-impedance types, they must be wired directly to DiProPAC.
Low-impedance sensors cannot be wired to DSI 2.
Table 2-4. DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 1-8
Wire color*
1st DSI 2 (TB2)
Pin #
Pin Designation
DiProPAC (TB554)
Pin #
Pin Designation
Brown
1
SENSOR 1
282
SENSOR 1
Red
2
SENSOR 2
283
SENSOR 2
Orange
3
SENSOR 3
284
SENSOR 3
Yellow
4
SENSOR 4
285
SENSOR 4
Green
5
SENSOR 5
286
SENSOR 5
Blue
6
SENSOR 6
287
SENSOR 6
Violet
7
SENSOR 7
288
SENSOR 7
Gray
8
SENSOR 8
289
SENSOR 8
No connection
290
Sensor power
9
GND
291
GND
10
GND
No connection
11
+5 VDC
No connection
Black
Shield
Terminate drain wire to ground
stud
Terminate drain wire to ground
stud
* Your colors may be different
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Table 2-5. DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 9-16
Wire color*
2nd DSI 2 (TB2)
Pin #
Pin Designation
DiProPAC (TB554)
Pin #
Pin Designation
Brown
1
SENSOR 1
292
SENSOR 9
Red
2
SENSOR 2
293
SENSOR 10
Orange
3
SENSOR 3
294
SENSOR 11
Yellow
4
SENSOR 4
295
SENSOR 12
Green
5
SENSOR 5
296
SENSOR 13
Blue
6
SENSOR 6
297
SENSOR 14
Violet
7
SENSOR 7
298
SENSOR 15
Gray
8
SENSOR 8
299
SENSOR 16
No connection
300
Sensor power
9
GND
301
GND
10
GND
No connection
11
+5 VDC
No connection
Black
Shield
Terminate drain wire to ground
stud
Terminate drain wire to ground
stud
* Your colors may be different.
Table 2-6. DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 17-24
Wire color*
3rd DSI 2 (TB2)
Pin #
Pin Designation
DiProPAC (TB555)
Pin #
Pin Designation
Brown
1
SENSOR 1
180
SENSOR 17
Red
2
SENSOR 2
181
SENSOR 18
Orange
3
SENSOR 3
182
SENSOR 19
Yellow
4
SENSOR 4
183
SENSOR 20
Green
5
SENSOR 5
184
SENSOR 21
Blue
6
SENSOR 6
185
SENSOR 22
Violet
7
SENSOR 7
186
SENSOR 23
Gray
8
SENSOR 8
187
SENSOR 24
No connection
188
Sensor power
9
GND
189
GND
10
GND
No connection
11
+5 VDC
No connection
Black
Shield
Terminate drain wire to ground
stud
Terminate drain wire to ground
stud
* Your colors may be different
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Table 2-7. DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 25-32
Wire color*
4th DSI 2 (TB2)
Pin #
Pin Designation
DiProPAC (TB555)
Pin #
Pin Designation
Brown
1
SENSOR 1
190
SENSOR 25
Red
2
SENSOR 2
191
SENSOR 26
Orange
3
SENSOR 3
192
SENSOR 27
Yellow
4
SENSOR 4
193
SENSOR 28
Green
5
SENSOR 5
194
SENSOR 29
Blue
6
SENSOR 6
195
SENSOR 30
Violet
7
SENSOR 7
196
SENSOR 31
Gray
8
SENSOR 8
197
SENSOR 32
No connection
198
Sensor power
9
GND
199
GND
10
GND
No connection
11
+5 VDC
No connection
Black
Shield
Terminate drain wire to ground
stud
Terminate drain wire to ground
stud
* Your colors may be different.
NOTICE
If there are extra wires in the cable, cut them off close to the end of the cable jacket.
Connecting Programmable Cam Channels
!
DANGER
PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE
Use SmartPAC 2 Servo’s programmable cam switch to control auxiliary functions only. The
SmartPAC 2 programmable cam capability should never be used to provide timing signals for any
safety use including muting of light curtains.
Failure to comply with these instructions will result in death or serious injury.
CAUTION
BOARD DAMAGE OR SHORT CIRCUIT WHEN MOUNTED WITHOUT ENCLOSURE
• Mount the cam output assembly in a clean area where it will be safe from damage.
• Provide at least 0.5 in. (12.7 mm) clearance between the back of the Cam Outputs board and
any metal surface.
Failure to comply with these instructions could result in property damage.
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The ProCamPAC Output Assembly allows you to wire up to fifteen cam channels to your
equipment. The assembly contains the relays that control the timing signals for your press.
Different types of relays can be used, depending on the voltages of your equipment and your
special needs.
To mount the ProCamPAC Output Assembly and wire it to the ProCamPAC board inside the
SmartPAC 2 Servo control, follow these instructions:
1. Select a convenient location for running conduit from the ProCamPAC Output Assembly
to the equipment that it will control.
2. Mount the output enclosure, using the mounting holes on the flanges as shown in
Figure 2-13, page 2-27.
3. Select the relays to be used with each channel. Relays should already be plugged into the
Cam Outputs board (see Figure 2-14, page 2-28), each relay labelled with its type (i.e.,
standard or solid state).
Standard relays can only be plugged into the slots labeled K301 through K305, K307,
K309, and K311, which are channels 1-8. Optional solid state relays can only be plugged
into slots labeled K306, K308, K310, and K312, which are channels 5-8.
Do not mix standard and solid state relays in channel locations 5-8. For example, if you
plug a solid state relay into channel 5 (location K306), you cannot plug a standard relay
into location K305. See Figure 2-14.
Example
Say you wish to use three standard relays and one solid state relay. You would install the
three standard relays in channels 1 through 3, and the solid state relay in channel 5,
skipping the channel 4 output for all wiring and programming.
To remove a relay, pull the plastic retention clip away from the relay and pull the relay
straight out of its socket. When re-inserting the relay, make sure that the pins line up with
the socket holes, then press in firmly.
4. Locate the 12-conductor cable(s) for wiring the ProCamPAC board (see Figure 2-8,
page 2-13 for layouts of 8- and 15-channel boards) to terminal block TB301 inside the
ProCamPAC Output enclosure. If you are wiring an 8-channel ProCamPAC Linear, one
cable is supplied (for channels 1-8). If you are wiring a 15-channel board, two cables are
supplied, one for channels 1 through 8, the other for channels 9 through 15.
5. Remove the appropriate connector(s) from its socket on the ProCamPAC Linear board
(TB451 for an 8-channel ProCamPAC Linear, TB451 and TB452 for a 15-channel
ProCamPAC Linear). Connect wires from the 12-conductor cable(s) to the pin locations
on the appropriate terminal blocks, as shown in Table 2-8, page 2-29 (for the 8-channel
option) or Table 2-8 and Table 2-9, page 2-29 (for the 15-channel option). See also
figures 1 (8-channel unit) and 2 (15-channel unit) at the end of the manual.
6. Plug the connector(s) back into its socket.
7. Run the cable(s) through conduit to TB301 in the ProCamPAC Output enclosure, using
the knockouts directly above the connector.
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6.00
(152.4)
Cam output
enclosure
0.312 (7.9) dia.
4 places
10.00
(254.0)
10.75
(273.1)
3.50
(88.9)
XX.XX = inches
(XX.X) = mm
8.00
(203.2)
6.00
(152.4)
Cam output
board
TB301
Connections to control
DS301
Sockets for solid state relays
only (Channels 5 through 8)
CH8 CH7 CH6 CH5 CH4 CH3 CH2 CH1
5.50
(139.7)
Sockets for
standard relays
(Channels 1
through 8)
TB302
TB303
NOTE:
For channels 5-8,
plug in standard or
solid state, but not both
CHAN 8 CHAN 7 CHAN 6 CHAN 5
CHAN 4 CHAN 3 CHAN 2 CHAN 1
Terminals for connecting wires to equipment
Clearance hole
for #6 screw
(4 places)
Figure 2-13. ProCamPAC Output Assembly
Installation
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SmartPAC 2 Servo User Manual
Connection to
press control
TB301
DS301
Solid State Relays
Channels 5-8
Use only one relay
(mechanical or solid state)
for each channel
K311
K309
Relay 6
K307
Relay 5
K305
Relay 4
K304
Relay 3
K303
Relay 2
K302
LEDs for channels
Relay 1
K301
Mechanical
Relays
Fuses
TB302
TB303
CHAN 8 CHAN 7 CHAN 6 CHAN 5
Counter
on - 200o
off - 250 o
CHAN 4 CHAN 3 CHAN 2 CHAN 1
Cam 4
Cam 3
Cam 2
Cam 1
Connect to loads
to be controlled
Figure 2-14. Cam Outputs Board
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Table 2-8. ProCamPAC Linear to Cam Output Assembly TB301 Wiring, Cams 1-8
Wire
ProCamPAC Linear TB451
(Pin #)
1st Cam Output Board
TB301 (Pin #)
CHAS (1)
White
Relay Pwr (270)
A (3)*
Black
Gnd (269)
B (2)*
Red
+5 (268)
+5 Vdc (4)
Tan
Ch 8 (267)
Ch 8 (5)
Pink
Ch 7 (266)
Ch 7 (6)
Gray
Ch 6 (265)
Ch 6 (7)
Blue
Ch 5 (264)
Ch 5 (8)
Yellow
Ch 4 (263)
Ch 4 (9)
Orange
Ch 3 (262)
Ch 3 (10)
Purple
Ch 2 (261)
Ch 2 (11)
Brown
Ch 1 (260)
Ch 1 (12)
* Note that the pin numbers for A and B are out of order
Table 2-9. ProCamPAC Linear to Cam Output Assembly TB301 Wiring, Cams 9-15
Wire
ProCamPAC Linear TB452
(Pin #)
2nd Cam Output Board
TB301 (Pin #)
CHAS (1)
White
Relay Pwr (281)
A (3)*
Black
Gnd (280)
B (2)*
Red
+5 (279)
+5 Vdc (4)
Unused
Unused
Pink
Ch 15 (277)
Ch 7 (6)
Gray
Ch 14 (276)
Ch 6 (7)
Blue
Ch 13 (275)
Ch 5 (8)
Yellow
Ch 12 (274)
Ch 4 (9)
Orange
Ch 11 (273)
Ch 3 (10)
Purple
Ch 10 (272)
Ch 2 (11)
Brown
Ch 9 (271)
Ch 1 (12)
* Note that the pin numbers for A and B are out of order
8. Remove the TB301 connector from its socket, and connect wires from the 12-conductor
cable(s) as shown in Table 2-8 (for 8-channel ProCamPAC Linear) or Table 2-8 and
Table 2-9 (for a 15-channel ProCamPAC Linear). A wire from CHAS to a lug on the
ProCamPAC Output enclosure should already be connected (unless you bought the board
assembly only).
9. Plug the connector(s) back into its socket.
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SmartPAC 2 Servo User Manual
10. To connect the relays to your equipment, use connectors TB302 and TB303 (see
Figure 2-15).
TB302
TB303
CHAN 8 CHAN 7
CHAN 6
CHAN 5
N/C C N/O N/C C N/O N/C C N/O N/C C N/O
CHAN 4 CHAN 3
CHAN 2
CHAN 1
N/C C N/O N/C C N/O N/C C N/O N/C C N/O
Figure 2-15. Connector TB302 and TB303 for Wiring Relays to Equipment
Specific connections depend on the type of relay you use. For 120 Vac relays, you can
connect wires from your equipment to “C” and either the N/O or N/C side of the relay. If
you connect to N/O, the equipment will be on for the number of degrees set in SmartPAC
2 Servo. If you connect to N/C, the equipment will be on except for the number degrees
set. Generally, you should use the N/O terminal so that equipment is off except when you
use SmartPAC 2 to turn it on. Use the N/C terminal only if it is more practical to do the
reverse.
All solid state relays work only when the C and the N/O terminals are connected. Polarity
must be correct for DC solid state relays (refer to Table 2-10.)
Table 2-10. Connections to Relays
Module
How To Connect
Type
Electro-mechanical
Relay
One wire to C, one wire to N/O or N/C, polarity does not
matter
SPDT
DC Solid State
– to C, + to N/O
SPST
AC Solid State
One wire to C, one wire to N/O, polarity does not matter
SPST
!
WARNING
INCORRECT SUPPRESSOR INSTALLATION MAY CAUSE RELAYS TO REMAIN ENERGIZED
Ensure that suppressors are correctly installed. They must not be installed across the relay
contacts inside the ProCamPAC Output enclosure. If a suppressor is installed across the relay
contacts and it fails shorted, the equipment controlled by that relay will remain energized.
Failure to comply with these instructions could result in death or serious injury.
11. To reduce electrical noise and to extend the life of the relays, do the following:
a. AC loads: Install arc suppressors across each inductive load (motors, coils, etc.) that is
connected to a cam relay (see Figure 2-16, page 2-31). Suppressors are supplied with
each relay. Install the suppressors across the load or as close to the load as possible.
Attach suppressors by connecting leads across existing terminals or junction points.
b. DC loads: Install a diode across each DC load, such as relays, solenoids and PLC
inputs (see Figure 2-17, page 2-31).
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Relay
Power
in
RIGHT
c
n/o
Power
Return
Suppressor
Relay
Power
in
ACCEPTABLE
not recommended
c
n/o
Power
Return
Power
Return
Suppressor
Relay
Power
in
WRONG
c
n/o
Power
Return
Suppressor
Figure 2-16. Installing Suppressors Across an AC Load
Relay
+ DC IN
C
N/O
– DC RETURN
IN4001 or equivalent
Figure 2-17. Installing a Diode Across a DC Load
Installation
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SmartPAC 2 Servo User Manual
Wiring Setup Mode Circuit
SmartPAC 2 Setup mode allows you to disable green sensors and parts/batch counters, using a
remote switch. Typically, the Setup mode circuit is enabled when Inch mode is selected on
your main control. When you inch the press, SmartPAC 2 will not stop the press when a fault
condition is detected. The Setup mode terminal can be wired to an extra contact on the Inch
switch of your main control, or you can use an external switch to activate the circuit. If you
intend to use the Setup mode circuit, plan how you will run your wiring for this connector now
so you do not have to disconnect conduit or rerun wires through conduit later.
For Setup mode, you must provide contact closure when the main control is in Inch mode.
Connect a wire from SmartPAC 2 terminal block TB107, terminal #252 (SETUP) to one side
of a normally open switch (see Figure 2-11, page 2-17, Table 2-16, page 2-39, and Figure 3 at
the end of the manual). Connect the other side of the switch to GND (TB107, terminal #250).
Refer to your electrical prints or the manual for your control to plan your wiring.
Wiring a Remote Reset Switch (Optional)
Like the Setup mode terminal, the Remote Reset terminal can be wired to a normally open
switch to activate the circuit. Be sure to plan how you will run your wiring for this connector
so that you do not have to disconnect conduit or re-run wires through conduit later. Connect a
wire from SmartPAC 2 TB107, terminal #249 (REM RES) to a normally open switch (see
Figure 2-11, page 2-17, Table 2-16, page 2-39, and Figure 3 at the end of the manual).
Connect another wire from the switch to GND (TB107, terminal #250). SmartPAC 2 is reset
with a momentary connection to ground.
Wiring a Sensor-Disabled Output (Optional)
You can wire a Sensor-disabled Output such as a warning light to a customer-supplied solidstate relay to warn personnel that the die protection capability, if installed, is disabled.
Connect the positive input wire from your 12Vdc solid-state relay to terminal #302 (Relay
Pwr) on TB553 on the DiProPAC board (see Figure 2-12, page 2-21 and Figure 4 or 5 at the
back of the manual). Connect the negative input wire from the relay to terminal #306 (Aux 1)
on TB553. You cannot use more than 8 mA for your relay.
Wiring a Press-in-Motion Signal (Optional)
If you plan to program any of your cam channels as a DSV ON output type (see Setting DSV
ON Channel Timing, page 5-46), you must wire the input check circuit inputs #205 (A) and
#206 (B) on TB102 on the SmartPAC 2 Servo board (see Figure 2-11, page 2-17, Table 2-11,
page 2-38, and Figure 3 at the back of the manual). To activate this circuit, you must apply 12
to 250 V to these inputs when the press is in motion.
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Turning on Power to SmartPAC 2 Servo
Figure 2-18. SmartPAC 2 Startup Screen
NOTICE
For help in using the SmartPAC 2 keyboard and display, see Chapter 3.
NOTICE
If you turn the Program/Run key and nothing happens, press RESET repeatedly until SmartPAC 2
changes modes. Before turning the Program/Run key, make sure SmartPAC 2 is in the Main
menu for the mode it is in. If it is not, press RESET repeatedly until the Main menu appears. Then
turn the Program/Run key.
To turn on power to SmartPAC 2 Servo, do the following:
1. Make sure there is no die in the press.
2. Turn the Program/Run key to PROG.
3. Power up the SmartPAC 2 Servo.
The green Power LED on the SmartPAC 2 front panel illuminates, a red SmartPAC 2
screen appears for a few seconds, then the display goes off and the amber LED beneath the
Power LED flashes at approximately two-second intervals while SmartPAC 2 completes
its startup routine. This can take up to one minute. Eventually, the Main Program Menu
appears (see Figure 2-19, page 2-34).
NOTICE
• If an error message displays when SmartPAC 2 starts up, press RESET.
• If the error message continues to appear after your press RESET, find the message in Chapter
7 and follow the instructions for correcting the problem. If you cannot find the error message or
cannot fix the problem, contact Wintriss Tech. Support.
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Figure 2-19. Main Program Menu
4. If the SmartPAC 2 display remains off, do the following:
• If the green Power LED on SmartPAC 2 does not illuminate
Turn off power to SmartPAC 2, and recheck all power connections. Check that the
connectors are correctly seated on both ends of the cables between the SmartPAC 2
board and the display. Power up SmartPAC 2 again. If the display remains off, contact
Wintriss Tech. Support.
• If the green Power LED illuminates, but the display remains off
Power down SmartPAC 2, and check that the connectors are correctly seated on both
ends of the cables between the SmartPAC 2 board and the display. Power up SmartPAC
2 again. If the display remains off, contact Wintriss Tech. Support.
Verifying Installation of DiProPAC and ProCamPAC
If you installed DiProPAC and/or replaced ProCamPAC on SmartPAC 2 Servo, you need to
verify that the installation was done correctly and that these items are available. Do the
following:
1. With the Main Program Menu on the SmartPAC 2 display, press the 1 and CLEAR keys at
the same time to display the Main Initialization Menu (see Figure 2-20, page 2-35).
2. Move the highlight bar to INSTALLED OPTIONS, and press ENTER. The Installed
Options screen, shown in Figure 2-21, page 2-35 displays.
Check to see that DiProPAC and/or ProCamPAC are displayed in the list.
• If DiProPAC and/or ProCamPAC are in the list, go to the next section.
• If you do not see one or both of the items, go to Adding or Upgrading DiProPAC,
page 2-20 and/or Replacing ProCamPAC, page 2-18 and verify that you performed the
installation properly. Check that the board or boards are plugged into the correct
connectors. If you still cannot fix the problem, call Wintriss Tech. Support.
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Figure 2-20. Main Initialization Menu
F1
F2
F3
F4
F5
F6
F7
F8
Figure 2-21. Installed Options Screen
Final Checkout
Before using SmartPAC 2 Servo, you need to make a few test press runs to ensure that your
unit is working properly. To perform final checkout, follow these instructions. Do not
proceed to the next step or group of steps until the item you are testing checks out.
Set Up a “Test” Tool
1. Create a tool number and program counter settings (see Creating a New Tool, page 5-3,
TOOL NAME or TOOL ID, page 5-8, and COUNTERS, page 5-9). If you are not familiar
with how to use the SmartPAC 2 keyboard and displays, see Chapter 3.
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SmartPAC 2 Servo User Manual
2. Program Upper Limit and Lower Limit settings on the Ram Position screen (see
page 5-50).
3. Load the tool number (see Loading a Tool, page 5-5), and enter Run mode (see Entering
and Exiting Run Mode, page 6-2).
Check Stroke Limits
4. Inch the press. Verify that the ram moves accurately between programmed Upper and
Lower limits (see RAM POSITION, page 5-50).
5. Run the press in Single-stroke, and reconfirm that the ram moves accurately between
programmed limits.
6. Run the press in Auto or Continuous, if available, and reconfirm ram limits.
7. Change the stroke length from your Servo control, program new Upper and Lower limits
to match these settings, and verify that the ram moves accurately between the new limits.
Check the Top-stop Circuit
8. Set the stroke counter preset to a small value (e.g., 10), referring to COUNTERS, page 5-9;
then, run the press in Continuous mode until the preset value is reached. Check to make
sure that the press top-stops and that a message indicating that the preset was reached is
displayed (see Chapter 7 for counter preset messages).
• If the press top-stopped correctly, go to step 9.
• If the press did not top-stop and SmartPAC 2 displayed a message, there is a wiring
problem in your top-stop circuit. Recheck all wiring and trace the cause of the problem.
Check the Emergency-stop Circuit
9. Turn the Program/Run key switch to PROG, and press RESET until the Main Program
Menu (see Figure 2-19, page 2-34) displays. Try stroking the press. Since SmartPAC 2
Servo’s E-stop relays are always open in Program mode, the ram should not move.
• If the ram does not move, go to step 10.
• If the ram moves, there is a wiring problem in your emergency-stop circuit. Recheck all
wiring and trace the cause of the problem.
Check Cam Channels
10. Create some test settings for your cam channels in Program mode (see CAM SWITCH,
page 5-39), load the tool settings, and switch to Run mode to run the press. Ensure that
the equipment (feed, blow off, lube, etc.) controlled by each channel is operating
appropriately according to the settings you made.
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Test Complete
11. If you get to this step, SmartPAC 2 Servo is working correctly. Clear any error messages
by pressing RESET, then delete the test tool. You can now create a tool in SmartPAC 2
Servo, program settings for it, load it, and begin to make parts using your new SmartPAC
2 Servo.
What Next?
To program and use your SmartPAC 2 Servo, follow the instructions in the remaining
chapters of this manual. Go to Chapter 4 to make Initialization settings for your SmartPAC 2.
Installation
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Wiring Tables for SmartPAC 2 Servo Options
Table 2-11. Stop and Input Check
Circuit (TB102) Wiring
Pin #
Signal
Pin #
Signal
Port
205
Input check A
224
+RXD3
206
Input check B
SPECIAL
PORT (3)
207
E-stop
225
–RXD3
“
208
E-stop
226
TXD3
“
209
Top-stop
227
+TXD3
“
210
Top-stop
228
–TXD3
“
229
GND
“
230
+RXD4
PACNET
PORT (4)
231
–RXD4
“
232
TXD4
“
233
+TXD4
“
234
–TXD4
“
Table 2-12. SFI Port (1) and Module
Port (2) (TB103) Wiring
2-38
Table 2-13. Special Port (3) and PACNet
Port (4) (TB104) Wiring
Pin #
Signal
Port
235
+RXD1
SFI PORT (1)
236
–RXD1
“
237
TXD1
“
238
+TXD1
“
239
–TXD1
“
240
GND
“
241
+RXD2
MODULE
PORT (2)
242
–RXD2
“
243
+TXD2
“
244
–TXD2
“
Table 2-14. Spare 1 Port (5) and WPC
Port (6) (TB105) Wiring
Pin #
Signal
Port
330
–TXD6
WPC PORT
(6)
329
+TXD6
“
328
–RXD6
“
327
+RXD6
“
326
GND
“
325
–TXD5
SPARE 1
PORT (5)
324
+TXD5
“
323
TXD5
“
322
–RXD5
“
321
+RXD5
“
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Table 2-15. Spare 3 Port (7) and Spare 4
Port (8) (TB106) Wiring
Table 2-16. Aux I/O (TB107) Wiring
Pin #
Signal
Pin #
Signal
Port
245
+15 V
320
–TXD8
SPARE 2
PORT (8)
246
POSITION SENSOR
319
+TXD8
“
247
GND
318
TXD8
“
248
ZERO
317
–RXD8
“
249
REMOTE RESET
316
+RXD8
“
250
GND
315
GND
“
251
LOCKOUT
314
–TXD7
SPARE 3
PORT (7)
252
SETUP
253
OP STA 2
313
+TXD7
“
254
OP STA 1
312
TXD7
“
311
–RXD7
“
310
+RXD7
“
Installation
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SmartPAC 2 Servo User Manual
Installation
Chapter 3. Keyboard, Displays and
Operating Modes
This chapter shows you how to use the SmartPAC 2 Servo keyboard and displays and
introduces you to SmartPAC 2’s three operating modes. The keyboard and the screen on
which the displays appear are located on the SmartPAC 2 Servo front panel, which is shown
in Figure 3-1.
It is a good idea to learn how to use SmartPAC 2 Servo before you install it. Set up the unit on
a bench and wire a power cord, a DC power source, and a transducer to it, then try making
settings on the displays. SmartPAC 2 Servo is easy to use. The instructions on each display
tell you which key to press in order to proceed to the next step.
SmartPAC 2 Servo
TOOL NUMBER
DEMO TOOL 2
DEMO PRESS
6160
PART CNTR
CAMBIE
AL ESPANOL
0
PRESS ANGLE 180
F2
POWER
USE THE CURSOR KEYS
TO MAKE SELECTIONS.
PRESS ENTER TO
ACCESS SELECTION.
180
F1
F3
ENABLE SENSORS
COUNTERS
DIE PROTECTION
CAM SWITCH
TOOL INFORMATION
RAM POSITION
ERROR/EVENT LOG
LOAD NEW TOOL
MESSAGING
TOGGLE HOT KEYS 1
F4
F5
F6
F7
F8
1
2
3
4
5
6
7
8
9
CLEAR
0
.
PROG
RUN
ENTER
HELP
RESET
Figure 3-1. SmartPAC 2 Servo Front Panel
This chapter covers the following topics:
• SmartPAC 2 Keyboard, next page
• SmartPAC 2 Servo Display Layout in Run Mode, page 3-12
• Selecting an Item on a Display, page 3-13
• SmartPAC 2 Operating Modes, page 3-14
• Screen Capture, page 3-22
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SmartPAC 2 Keyboard
The SmartPAC 2 keyboard, as shown in Figure 3-2, is composed of number keys, cursor keys,
function keys, and HELP, CLEAR, ENTER, and RESET keys. There is also a Program/Run
key switch. Use of the keys and key switch is explained in the following sections.
1
2
3
4
5
6
7
8
9
CLEAR
0
.
F1
ENTER
key
HELP key
F2
PROG
RUN
ENTER
F4
HELP
F5
RESET
Cursor
keys
Number keys
F3
F6
Program/Run
Key Switch
F7
RESET
key
F8
CLEAR
key
Function
keys
(F keys)
Figure 3-2. SmartPAC 2 Keyboard
Number Keys
The number keys, shown in Figure 3-3, are used to input numeric values, such as counter
presets or tool numbers. They are used in conjunction with entry windows–numeric,
alphabetic, and alphanumeric–which display when you select items on SmartPAC 2 Servo
screens (see Figure 3-4 and Figure 3-5, page 3-3)
SmartPAC 2 Servo
CAMBIE
AL ESPANOL
F1
F2
POWER
Number keys
F3
F4
F5
F6
F7
F8
1
2
3
4
5
6
7
8
9
CLEAR
0
.
PROG
RUN
ENTER
HELP
1
2
3
4
5
6
7
8
9
CLEAR
0
.
RESET
Figure 3-3. Number Keys
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Figure 3-4. Numeric Entry Window (Left); Alphabetic Entry Window (Right)
Figure 3-5. Alphanumeric Entry Window
To enter a number in an entry window, simply key in the individual digits of the number,
using the number keys. In Numeric Entry windows, press ENTER; in Alphabetic or
Alphanumeric Entry windows, press F6. The window closes, and the number you entered
(and, in the case of alphabetic or alphanumeric entry, accompanying letters or symbols)
appears on the SmartPAC 2 screen next to the item you selected.
You can also use the cursor keys to enter information on these entry screens (see Cursor Keys,
page 3-4). The CLEAR key is used to delete entered information (see CLEAR Key, next
page). To cancel a numeric entry operation, press RESET (see RESET Key, page 3-9).
The number keys are also used to execute several functions. Pressing the 8 and 0 keys at the
same time saves a screen capture of the current display (see page 3-22). Pressing 2 and 0
simultaneously on a selected Run mode screen programs the next function key you press as a
Hot key for that screen (see page 6-3). Pressing the decimal point (.) key on the Main Run
Menu opens a window in the upper right corner of the screen displaying the ram angle in large
characters (see page 6-6). This window carries over to other Run mode screens on which a
prominent ram angle display is useful such as angle adjustment screens for cams and die
protection sensors. These keys and their functions are summarized in Table 3-1.
Table 3-1. Number Key Functions
Key/Key Combination
Function
8 and 0
Capture screen
2 and 0
Program Hot key
Decimal point (.)
Display ram angle on Main Run Menu
and selected Run mode screens
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CLEAR Key
The CLEAR key, shown in Figure 3-6, is used to delete digits or characters in a SmartPAC 2
entry window (see Figure 3-4 and Figure 3-5). You also use the CLEAR key as directed in
other procedures, such as deleting a tool.
SmartPAC 2 Servo
CAMBIE
AL ESPANOL
F1
F2
POWER
F3
F4
CLEAR key
F5
F6
F7
CLEAR
F8
1
2
3
4
5
6
7
8
9
CLEAR
0
.
PROG
RUN
ENTER
HELP
RESET
Figure 3-6. Clear Key
Cursor Keys
The cursor, or arrow, keys, shown in Figure 3-7, are used to
• Move the highlight bar over an item you want to select on a SmartPAC 2 display
• Increase or decrease numeric values in SmartPAC 2 entry windows and screens
• Move the highlight box over a letter you want to enter in a SmartPAC 2 entry window
• Set the Ready signal for sensors and timing for cams
SmartPAC 2 Servo
CAMBIE
AL ESPANOL
F1
F2
POWER
HELP key
F3
F4
F5
F6
F7
F8
1
2
3
4
5
6
7
8
9
CLEAR
0
.
PROG
HELP
RUN
ENTER
HELP
RESET
Cursor (arrow)
keys
Figure 3-7. Cursor Keys
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Using Cursor Keys to Move the Highlight Bar
The cursor keys control the movement of the highlight bar that you use to select items on a
SmartPAC 2 Servo screen, such as the CAM SWITCH item on the SmartPAC 2 Servo Run
Menu shown in Figure 3-8.
Figure 3-8. Highlighted Item on Run Menu
Pressing the Up () and Down () cursor keys moves the highlight bar up and down the list
of items. When the highlight bar rests on the item you want to select, press ENTER.
The highlight bar moves one item up or down for each depression of the appropriate key. If
you hold down the key, the highlight bar moves until you release it.
If there is only one column of items displayed, the highlight bar wraps to the top of the list
when you press the Down () cursor key with the bar on the last item. The highlight bar
moves to the bottom of the list when you press the Up () cursor key with the bar on the first
item.
If there is more than one column of items, the highlight bar will move from the bottom of one
column to the top of the column to the right of it when you press the Down () cursor key
with the bar on the last item in the first column. You can also use the Left () and Right ()
cursor keys to move between columns on the same level.
When there are more columns than can be displayed on the screen (the tool list in Tool
Manager, for example, can have up to nine columns), pressing the Left () and Right ()
cursor keys will move you to the hidden columns. The highlight bar wraps to an item in the
leftmost column when the Right () cursor key is pressed with the bar in the rightmost
column. Likewise, the bar wraps to the rightmost column when the Left () cursor key is
pressed with the highlight bar in the leftmost column.
Using Cursor Keys to Increase or Decrease Numeric Values
The Up () and Down () cursor keys can be used to increase and decrease numeric values
displayed in SmartPAC 2 entry windows (see Figure 3-4 and Figure 3-5) and on some
SmartPAC 2 screens. To increase the value, press the Up () cursor; to decrease the value,
press the Down () cursor. The displayed value increases or decreases one unit for each
depression of the appropriate key. If you hold down the key, the value continues to increase
or decrease until you release it.
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Using Cursor Keys to Highlight Letters in Entry Windows
You can use Up (), Down (), Left (), and Right () cursor keys to move the highlight
box from one letter (including symbols and the space character) to another in alphabetic and
alphanumeric entry windows (see Figure 3-4 and Figure 3-5). When the letter you want is
highlighted, you press ENTER to accept that letter. To accept an entire alphabetic or
alphanumeric entry, press function key F6.
In the alphanumeric entry window (see Figure 3-5), you can press the F2 key to change
between upper- and lower-case letters. For more information about alphanumeric mode, see
Tool Number Mode, page 4-4.
Using Cursor Keys to Set Timing
You can use the cursor keys to set timing for your programmable cam switch and optional
sensors, setting the ram angle and position at which you want a cam channel or Ready signal
to turn on and off. For detailed instructions on using die protection sensors and cams, see DIE
PROTECTION (Optional), page 5-16 and CAM SWITCH, page 5-39.
Timing settings are made on a ram angle clock that appears on Die Protection and Cam
Switch screens in Program and Run modes. When these screens are displayed, the cursor
keys move two cursors around this diagram, one cursor controlling the angle at which the
sensor or cam turns on, the other controlling the angle at which the sensor or cam turns off.
The two cursors define the endpoints of a highlighted arc that indicates graphically the
duration of the On signal. The four cursor keys function in the following manner:
• Right () cursor key increases the On setting, moving the On cursor clockwise.
• Left () cursor key decreases the On setting, moving the On cursor counterclockwise.
• Up () cursor key increases the Off setting, moving the Off cursor clockwise.
• Down () cursor key decreases the Off setting, moving the Off cursor counterclockwise.
The following steps illustrate how the cursor keys are used to set timing for a cam channel in
Program mode.
1. Before On/Off settings have been made for a cam channel, On and Off ram angles are both
0°, as shown in Figure 3-9, page 3-7. The “dwell” (i.e., the number of degrees during
which the channel is On) is 0°. The ram position (in inches) at which the cam turns on and
off is also displayed.
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 3-9. Cam Channel Timing: On=0°, Off=0°
2. To set the On angle, you use the Left () and Right () cursor keys. Press and hold
down the Right () cursor key to move the On cursor clockwise around the ram angle
diagram until you reach 239°. The On angle is shown in the window in the center of the
ram angle clock; the ram On position is displayed in the ON POS = field. Your display
should look like the one shown in Figure 3-10. If you overshoot the On angle you want,
simply press the Left () cursor key to move the On cursor counterclockwise. Notice that
the dwell has changed to 121° (i.e., 360°-239°), indicating that the cam channel is on for
121°. The dwell angle is shown graphically by the highlighted arc on the ram angle clock.
NOTICE
Zero degrees (0°) and 360° are located at the same point in the ram angle diagram.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 3-10. Cam Channel Timing: On=239°, Off=0°
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3. To set the Off angle, you use the Up () and Down () cursor keys. With the cam
channel timing set as in Figure 3-10, press the Down () cursor key and hold it down
until the Off cursor, moving counterclockwise, reaches 270° as shown in the window
inside the ram angle diagram. The ram Off position is shown in the OFF POS = field. The
channel timing display should look like the one shown in Figure 3-11. If you overshoot
the desired Off angle, press the Up () cursor key to move the Off cursor clockwise.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 3-11. Cam Channel Timing: On=239°, Off=270°
HELP Key
The HELP key, shown in Figure 3-12, provides information about the current SmartPAC 2
display. Pressing HELP takes you to a Help screen that instructs you how to use the display
and explains key terms you need to know.
SmartPAC 2 Servo
CAMBIE
AL ESPANOL
F1
F2
POWER
HELP key
F3
F4
F5
F6
F7
F8
1
2
3
4
5
6
7
8
9
CLEAR
0
.
PROG
HELP
RUN
ENTER
HELP
RESET
Cursor (arrow)
keys
Figure 3-12. HELP Key
3-8
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ENTER Key
The ENTER key, shown in Figure 3-13, is used to complete selection of an item on a
SmartPAC 2 display. After you have highlighted the item with the cursor keys (see Cursor
Keys, page 3-4), pressing the ENTER key displays the SmartPAC 2 Servo screen for that
item. You also use the ENTER key for other functions, such as to accept a number you have
keyed in, to start loading settings for a tool, etc.
SmartPAC 2 Servo
CAMBIE
AL ESPANOL
F1
F2
POWER
F3
F4
ENTER
key
F5
F6
F7
F8
1
2
3
4
5
6
7
8
9
CLEAR
0
.
PROG
ENTER
RUN
ENTER
HELP
RESET
Figure 3-13. ENTER Key
NOTICE
SELECT = HIGHLIGHT + ENTER
When this manual instructs you to select an item, you should highlight the item and press ENTER.
RESET Key
The RESET key, shown in Figure 3-14, page 3-10, has two functions: to exit from the current
display and return to the previous display and to reset SmartPAC 2 when an error is generated
or a counter preset is reached.
When RESET is used to exit from a display, a screen message indicates the conditions under
which RESET should be pressed (e.g., PRESS RESET WHEN DONE or PRESS RESET TO
CANCEL).
When RESET is used to reset SmartPAC 2, the message documenting the error or indicating
that the counter preset has been reached disappears, and you can once again run the press.
Keyboard, Displays, Etc.
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SmartPAC 2 Servo
CAMBIE
AL ESPANOL
F1
F2
POWER
RESET
key
F3
F4
F5
F6
F7
RESET
F8
1
2
3
4
5
6
7
8
9
CLEAR
0
.
PROG
RUN
ENTER
HELP
RESET
Figure 3-14. RESET Key
Program/Run Key Switch
The Program/Run key switch, shown in Figure 3-15, is used to move between Program and
Run modes (see SmartPAC 2 Operating Modes, page 3-14).
• When you turn the key switch to PROG, SmartPAC 2 enters Program mode
• When you turn the key switch to RUN, SmartPAC 2 enters Run mode
SmartPAC 2 Servo
CAMBIE
AL ESPANOL
F1
F2
POWER
F3
F4
F5
F6
Program/Run
key switch
PROG
RUN
F7
F8
1
2
3
4
5
6
7
8
9
CLEAR
0
.
PROG
RUN
ENTER
HELP
RESET
Figure 3-15. Program/Run Key Switch
The switch has a removable key so that access to Run mode can be controlled.
NOTICE
SmartPAC 2 changes from Run to Program mode or from Program to Run when the display shows
the Main menu in the mode you are leaving. If you turn the key and nothing happens, press
RESET repeatedly until you see the new mode appear on the display.
3-10
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Function Keys
The function keys, shown in Figure 3-16, are used to perform specific tasks on SmartPAC 2
Servo screens. Located on the SmartPAC 2 Servo panel along the right edge of the LCD,
these eight keys, F1 through F8, are assigned different functions on each SmartPAC 2 display.
Specific functions are shown in a rectangular label on the LCD just to the left of the function
key number label. When a function key has no label, no function has been assigned to that
key on that screen. Screen messages may instruct you to press specific function keys to
perform certain tasks. In most of the screens in Run mode, the F8 key has been assigned the
function of returning you to the Main Run Menu.
F1
SmartPAC 2 Servo
F1
F2
POWER
F3
F4
F5
F6
F7
F8
1
2
3
4
5
6
7
8
9
CLEAR
0
.
PROG
RUN
ENTER
HELP
RESET
F2
F3
F4
F5
Function
keys
F6
F7
F8
Figure 3-16. Function Keys
In Run mode, you can program function keys as “Hot” keys to give you quick access to
frequently-used screens. See Hot Keys, next, for more information.
Hot Keys
Hot keys, shown in Figure 3-17, page 3-12, are function keys you program to take you
directly to Run mode screens you use frequently. When a function key is programmed as a
Hot key, a description of the screen to which the key is linked appears in the label to the left of
the function key number on the Main Run Menu. When you press that function key,
SmartPAC 2 goes to that screen. For detailed instructions on how to use Hot keys, see
page 6-3.
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TOOL NUMBER
DEMO TOOL 2
DEMO PRESS
6160
PART CNTR
0
PRESS ANGLE 180
USE THE CURSOR KEYS
TO MAKE SELECTIONS.
PRESS ENTER TO
ACCESS SELECTION.
180
ENABLE SENSORS
COUNTERS
DIE PROTECTION
CAM SWITCH
TOOL INFORMATION
RAM POSITION
ERROR/EVENT LOG
LOAD NEW TOOL
MESSAGING
TOGGLE HOT KEYS 1
CAMBIE
AL ESPANOL
F1
VIEW SENSOR
SUMMARY
F2
VIEW GLOBAL
CAM SUMMARY
F3
ADJ SENSOR
PART EJECTION
F4
ADJUST CAM
SPRAY LUBE
F5
TONNAGE
PLAN VIEW
F6
VIEW RAM
POSITION
F7
SHOW
CAM TIMING
F8
Use F1 - F8 as Hot keys
If you have the Bilingual Option,
F1 is reserved for changing
language and cannot be used
as a Hot key.
Descriptive labels
for Hot keys
Figure 3-17. Hot Keys Programmed on Main Run Menu
Example
You frequently need to adjust the timing for the cam channel that controls part blowoff. For
convenience, you set up a Hot key to take you directly from the Main Run Menu to the adjust
screen for that cam channel.
You can use all the function keys, F1 through F8, as Hot keys.
NOTICE
If you have the Bilingual Spanish/English option, F1 is reserved for switching between languages
in Run mode and cannot be used as a Hot key.
Hot keys are identified by the red frame around their descriptive labels. If your SmartPAC 2
Servo does not have the bilingual option installed, you can have two sets of Hot keys, making
a total of sixteen. To switch from one set to the other, highlight “TOGGLE HOT KEYS 1,”
and press ENTER. “TOGGLE HOT KEYS 2” replaces “TOGGLE HOT KEYS 1” on the
menu, and the other set of Hot key labels appears.
SmartPAC 2 Servo Display Layout in Run Mode
The layout of the SmartPAC 2 Servo display in Run mode is shown in Figure 3-18, page 3-13.
At the top of the display is a status box that contains information such as the press name and
the press speed or angle. Below the status box is the Run window, which contains menu
items, instructions, graphics, and other elements. Along the right edge of the display are the
eight function keys with descriptive labels shown for active keys. If any function keys have
been programmed as Hot keys (see page 3-11), their labels have a red border.
You progress from menu to menu in Run mode by use of the ENTER and RESET keys, as
instructed on the display. You navigate in the same way in Initialization and Program modes.
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TOOL NUMBER
DEMO TOOL 2
Status box
Instructions
DEMO PRESS
6160
PART CNTR
PRESS ANGLE
USE THE CURSOR KEYS
TO MAKE SELECTIONS.
PRESS ENTER TO
ACCESS SELECTION.
Ram angle
readout
180
0
CAMBIE
AL ESPANOL
180
F1
F2
F3
ENABLE SENSORS
COUNTERS
DIE PROTECTION
CAM SWITCH
TOOL INFORMATION
RAM POSITION
ERROR/EVENT LOG
LOAD NEW TOOL
MESSAGING
TOGGLE HOT KEYS 1
F4
F5
F6
F7
F8
Ram angle clock
Run window
Menu
Descriptive labels for
Function keys and Hot keys
Figure 3-18. SmartPAC 2 Servo Display, Run Mode
Selecting an Item on a Display
To select an item on a SmartPAC 2 display, highlight the item you want, using the cursor keys
(see page 3-5), and press ENTER. Figure 3-19 shows the Main Run Menu with the “CAM
SWITCH” item highlighted. SmartPAC 2 goes to the display you have selected, on which
you can select another item or make a setting. Screen messages tell you how to proceed on
each display.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 3-19. Main Run Menu with “CAM SWITCH” Highlighted
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SmartPAC 2 Operating Modes
SmartPAC 2 has three modes of operation: Initialization mode, Program mode, and Run
mode. The Main, or top, menu for each mode is shown in Figure 3-20 along with a physical
description of the display, a summary of what you can do in that mode, and a reference to the
chapter in which that mode is documented. Table 3-2, page 3-15 provides more detail about
what you can do in each mode, instructs you in how to enter and exit the mode, and refers you
to other sections of the manual.
NOTICE
To exit any mode, be sure you are in the Main menu, shown in Figure 3-20. If you are not in the
Main menu, press RESET repeatedly until the Main menu appears.
Initialization Mode (Chapter 4)
Program Mode (Chapter 5)
white text on dark blue display
settings for the press
black text on light green display
settings for individual tools
Run Mode (Chapter 6)
black text on light blue display
live screens; some adjustments possible “on the fly”
Figure 3-20. SmartPAC 2 Operating Modes, Showing Main Menus
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Table 3-2. Initialization, Program and Run Modes: Entry and Exit Procedures
Mode
Initialization
Make settings that control
operation of SmartPAC 2 with
all tools.
You use Initialization mode
extensively when you install a
new SmartPAC 2. You will use
this mode only occasionally
after you set up SmartPAC 2
and the press is running.
How to Enter This Mode
Turn Program/Run key to
PROG.* Then press the “1”
and “CLEAR” keys
simultaneously and hold down
a few seconds until the Main
Initialization Menu appears.
How to Exit This Mode
To switch to Program mode:
Press RESET.
_______________________
To switch to Run mode:
Turn the Program/Run key to
RUN.*
See page 3-16 and Chapter 4.
White text on dark blue display.
Program
From Run mode:
To switch to Run mode:
Create, modify and load
settings for individual tools that
control SmartPAC 2 operation
when that tool is loaded.
Turn the Program/Run key to
PROG.*
Turn the Program/Run key to
RUN.*
_________________________
_________________________
See page 3-18 and Chapter 5.
From Initialization mode:
Black text on green display.
Go to the Main Initialization
Menu, and
Press RESET.
To switch to Initialization mode:
Press the “1” and “CLEAR”
keys simultaneously and hold
down a few seconds until the
Main Initialization Menu
appears.
—or—
Turn the Program/Run key to
RUN and then back to PROG.*
Run
Run the press. In this mode
you can adjust counters, cams,
sensors and other functions
while the press is running.
Turn the Program/Run key to
RUN.*
To switch to Program mode:
Turn the Program/Run key to
PROG.*
See page 3-20 and Chapter 6.
Black text on light blue display.
* If you turn the key and nothing happens, press RESET repeatedly until SmartPAC 2 changes
modes. Before you turn the Program/Run key, make sure SmartPAC 2 is in the Main (or top) menu
for the mode it is in. If it is not, press RESET repeatedly until the Main menu appears.
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Initialization Mode
Initialization mode allows you make settings that control the operation of SmartPAC 2 with
any tool. (Settings for individual tools are made in Program mode–see page 3-18.)
Initialization mode is used extensively when you install a new SmartPAC 2, but you will
likely use it only occasionally after SmartPAC 2 is set up and the press is running.
The Main Initialization Menu is shown in Figure 3-21. Figure 3-22, page 3-17 shows you
how to navigate through the SmartPAC 2 Servo menus in Initialization mode.
Figure 3-21. Initialization Mode Main Menu
See Chapter 4 for detailed instructions on how to use SmartPAC 2 Servo in Initialization
mode.
NOTICE
For help with an item on the Main Initialization Menu, press the HELP key when that screen is
displayed.
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POSITION SENSOR MODE
INITIALIZATION MODE MAIN MENU
RESOLVER MOTION MODE
ANGLE WHEEL ROTATION
POSITION SENSOR
INSTALLED OPTIONS
PRESS NAME
SELECT CAM NAMES
SET GLOBAL CAMS
TOOL NUMBER MODE
COUNTER SETUP MODE
PROGRAM ON/OFF ANGLES
COUNTER INCREMENT MODE
PROGRAM TIMED OUTPUT
select channel
F5 - VIEW GLOBAL CAM SUMMARY
CUSTOM SENSOR NAMES
SENSOR ENABLE MODE
LINEAR SENSOR
SENSOR ENABLE MODE
SETUP MODE
PROGRAM DSV ON
DELETE CHANNEL SETTINGS
SENSOR RESOLUTION
OFFSET VALUE
ZERO VALUE
UPPER LIMIT
TOOL INFORMATION
SECURITY ACCESS
set access privileges
UNITS
F1 - CHANGE PASSWORDS
F6 - SAVE UPPER LIMIT
SETUP NETWORK
F7 - SAVE ZERO POSITION
DIAGNOSTICS
RESOLVER
COMMUNICATIONS
INPUT STATUS
ANALOG STATUS
OUTPUT STATUS
E-MAIL FUNCTION
SMARTVIEW FUNCTION
SET UP E-MAIL
CHANGE NETWORK SETTINGS
PRESS TYPE
SET CLOCK
MEMORY CHECKSUM
TOOL TABLES
CLEAR TABLES
SHOW SBC ERRORS
SAVE TO USB DISK
menu item
UPDATE FIRMWARE
Function Key
Figure 3-22. Navigation Example: Initialization Mode
Press ENTER to go in direction of arrow. Press RESET to return to previous menu.
This illustration includes some optional features. Your menus may be different.
Keyboard, Displays, Etc.
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Program Mode
Program mode allows you to create, copy, modify and delete tool settings as well as enable or
disable sensors. The Main Program Menu is shown in Figure 3-23. Figure 3-24, page 3-19
shows you how to navigate through the SmartPAC 2 Servo menus in Program mode.
Figure 3-23. Program Mode Main Menu
See Chapter 5 for detailed instructions on how to use SmartPAC 2 Servo in Program mode.
NOTICE
For help with an item on the Main Program Menu, press the HELP key when that screen is
displayed.
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STROKES
BATCH 1
GOOD PARTS
BATCH 2
BATCH 1
BATCH 3
BATCH 2
COUNTER INCREMENT ANGLES
BATCH 3
F2 - ADVANCED MODES
TOTAL HITS
F2 - SET COUNTER MODES
PARTS/STROKE
STROKES/PART
TOOL NAME
COUNTERS
DIE PROTECTION
CAM SWITCH
BATCH 1 PRE-LOAD COUNT
BATCH 2 PRE-LOAD COUNT
BATCH 3 PRE-LOAD COUNT
AUTO BATCH PRE-LOAD
TOOL INFORMATION
select sensor
RAM POSITION
F6 - VIEW SENSOR SUMMARY
F5 - LOAD THIS TOOL
SENSOR NAME
ENABLE COUNT
PROGRAM MODE MAIN MENU
GO TO THE TOOL MANAGER
SENSOR ENABLE/DISABLE & STATUS
select
tool
F4 - EDIT TOOL
SENSOR TYPE
F5 - LOAD TOOL
STOP TYPE
F6 - DELETE TOOL
READY WINDOW
F7 - NEW TOOL
F8 - COPY TOOL
select cam channel
F5 - VIEW GLOBAL CAM SUMMARY
SENSOR ON/OFF STATUS
F6 - VIEW CAM SUMMARY
F4 - NEXT/PREV 8 SENSORS
F5 - DISABLE/ENABLE ALL SENSORS
PROGRAM ON/OFF ANGLES
PROGRAM TIMED OUTPUT
PROGRAM DSV ON
DELETE CHANNEL SETTINGS
UPPER LIMIT
menu item
LOWER LIMIT
Function Key
STAGE MODE
CURVE TYPE
F4 - CLEAR LIMITS
F5 - SET UPPER LIMIT
F6 - SET LOWER LIMIT
Figure 3-24. Navigation Example: Program Mode
Press ENTER to go in direction of arrow. Press RESET to return to previous menu.
This illustration includes some optional features. Your menus may be different.
Keyboard, Displays, Etc.
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Run Mode
Run mode is the mode you use to run the press. The Main Run Menu, shown in Figure 3-25,
displays the ram stroke on a ram angle clock diagram in the lower left corner of the display.
When the press is running in Continuous mode, the press speed in strokes per minute is
displayed in the center of the clock diagram. When the press is stopped or running in Inch or
Single-stroke, the ram angle is displayed inside the clock.
If security access settings in Initialization mode permit, you may be able to make adjustments
to programmed settings in Run mode, such as changes to die protection settings, cam timing,
etc.
Figure 3-26, page 3-21 shows you how to navigate through the SmartPAC 2 Servo menus in
Run mode.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 3-25. Run Mode Main Menu
See Chapter 6 for detailed instructions on how to use SmartPAC 2 Servo in Run mode.
NOTICE
For help with an item on the Main Run Menu, press the HELP key when that screen is displayed.
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SmartPAC 2 Servo User Manual
RUN MODE MAIN MENU
ENABLE SENSORS
COUNTERS
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STROKES
select sensor
GOOD PARTS
F6 - VIEW SENSOR SUMMARY
BATCH 1
F7 - SHOW SENSOR STATUS
BATCH 2
BATCH 3
TOTAL HITS
F4 - CHG REFERENCE ANGLE
F5 - UPDATE THE SENSOR ARC
DIE PROTECTION
CAM SWITCH
select cam channel
TOOL INFORMATION
F5 - VIEW GLOBAL CAM SUMMARY
RAM POSITION
F6 - VIEW CAM SUMMARY
F7 - SHOW CAM TIMING
ERROR/EVENT LOG
LOAD NEW TOOL
F5 - LOAD TOOL
MESSAGING
TOGGLE HOT KEYS 1
F3 - SELECT RECIPIENT
F7 - SELECT ARC
F4 - SELECT MESSAGE
UPPER LIMIT
F5 - SEND MESSAGE AND EXIT
LOWER LIMIT
menu item
F6 - EXIT WITHOUT SENDING
F4 - CLEAR LIMITS
Function Key
F7 - CLEAR RECIPIENTS
F5 - SET UPPER LIMIT
F6 - SET LOWER LIMIT
Figure 3-26. Navigation Example: Run Mode
Press ENTER to go in direction of arrow. Press RESET to return to previous menu.
This illustration includes some optional features; your menus may be different.
Keyboard, Displays, Etc.
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Screen Capture
SmartPAC 2 allows you to save a copy of one or more SmartPAC 2 screens to aid in
troubleshooting or maintain records of tool settings such as cam on/off angles. Your screen
capture options depend on your SmartPAC 2 Main firmware version, which you can easily
determine by accessing the Installed Options screen (see page 4-6.)
If the SmartPAC 2 Main version is earlier than V 5.3.1, refer to Screen Capture in SmartPAC
2 Main Versions Earlier than V 5.3.1, below. If your version of SmartPAC 2 Main is V 5.3.1
or later, refer to Screen Capture in SmartPAC 2 Main Versions V 5.3.1 and Later, page 3-24.
Screen Capture in SmartPAC 2 Main Versions Earlier than V 5.3.1
If the SmartPAC 2 Main version is earlier than Version 5.3.1, all screen captures are saved to
SmartPAC 2 memory, each new screen capture overwriting the previous one. You can e-mail
the current screen capture in memory to a selected recipient if the SmartPAC 2 is connected to
a computer network and recipient e-mail addresses have been set up in SmartView. You can
also save the screen capture to a USB disk inserted in the SmartPAC 2 USB connector.
Saving a Screen Capture to SmartPAC 2 Memory
To save a copy of a SmartPAC 2 screen to SmartPAC 2 memory, do the following:
1. On the SmartPAC 2 front panel, access the screen you want to capture.
2. Press the 8 and 0 (zero) keys simultaneously for a second or two until the message
“Capturing Screen...” in very small letters appears at the top right of the display.
The captured screen remains in SmartPAC 2 memory until the next screen capture is
performed, the new screen capture overwriting the old one.
E-Mailing a Screen Capture
E-mail provides a convenient way of sharing screen captures with individuals responsible for
troubleshooting your SmartPAC 2 (e.g., Wintriss Tech. Support) or maintaining a record of
tool settings. In order to use e-mail, your SmartPAC 2 must be connected to a computer
network and e-mail addresses of recipients configured in SmartView (see page D-14). To
e-mail a copy of the screen currently residing in SmartPAC 2 memory (see Saving a Screen
Capture to SmartPAC 2 Memory, above), do the following:
1. Access the Run mode Main Menu (see Figure 6-1, page 6-1), and select MESSAGING. A
screen displays with the headings “From:,” “To:,” and “Message:” at the top and a window
with a list of e-mail recipients beneath. The “From:” slot is filled with the e-mail address
that has been configured for your SmartPAC 2 (see page D-2).
2. Highlight the recipient you want, using the Up () or Down () cursor key, then press
F3 (Select Recipient). The recipient you selected appears in the “To:” slot.
3. Press F4 (Select Message) to display a list of available messages, highlight the “Screen
Capture” item, and press F4 again. “Screen Capture” appears in the “Message:” slot.
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4. Press F5 (Send Message and Exit). The message “Sending Message” appears beneath the
message window, and you are returned to the Main Run Menu.
Refer to MESSAGING, page 6-26 for additional information about sending e-mail messages.
Saving a Screen Capture to a USB Disk
You can save a copy of the current screen residing in SmartPAC 2 memory to a USB disk
inserted in the USB connector on the SmartPAC 2 processor board. A USB disk allows you to
transfer the screen capture to another computer when your SmartPAC 2 is not networked. The
error/event log (see page 6-23) and other information maintained in a special SmartPAC 2
buffer are saved along with the screen capture. To save this information, do the following:
CAUTION
POWER DOWN SMARTPAC 2 BEFORE INSERTING USB DISK
Do not insert a USB disk into the USB connector while SmartPAC 2 is running. The USB disk
could touch a component on the SmartPAC 2 board, resulting in a short circuit and damage to the
board. Always power down SmartPAC 2 before inserting a USB disk.
Failure to comply with these instructions could result in property damage.
1. Power down the SmartPAC 2.
2. Open the SmartPAC 2 enclosure or console.
3. Locate the USB connector, J121, on the SmartPAC 2 board (see Figure 2-11, page 2-17),
then carefully insert the USB disk into the USB connector.
NOTICE
The USB disk can be inserted into the USB connector only one way. Do not attempt to
force the USB disk into the connector.
4. Shut the enclosure or console door, and power up the SmartPAC 2.
5. Access the Main Initialization Menu (see Figure 4-1, page 4-1), select DIAGNOSTICS,
and when the Diagnostics Menu (see Figure 4-27, page 4-35) displays, select SAVE TO
USB DISK. The following messages appear in succession:
PLEASE WAIT WHILE THE DATA IS BEING TRANSFERRED TO THE USB DISK.
THIS MAY TAKE UP TO ONE MINUTE TO COMPLETE . . .
THE USB DISK TRANSFER HAS FINISHED AND WAS SUCCESSFUL. PRESS THE
RESET KEY AND THEN REMOVE THE USB DISK DEVICE.
6. When the second message appears, press RESET to return to the Diagnostics Menu.
7. Power down the SmartPAC 2, and remove the USB disk.
The screen capture is saved to a folder on the USB disk named UpLoadnnnnnnnn, where
nnnnnnnn is the serial number of the SmartPAC 2. The screen capture itself is named
ScreenCapturennnnnnnn.gif. There are additional files in the UpLoad folder.
Keyboard, Displays, Etc.
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Screen Capture in SmartPAC 2 Main Versions V 5.3.1 and Later
If you are running SmartPAC 2 Main Version 5.3.1 or later, screen captures can be saved to
SmartPAC 2 memory as in earlier versions or, if a properly configured USB disk is inserted in
the SmartPAC 2 USB connector when the capture is made, you can save one or more screen
captures directly to the USB disk. If you choose to continue saving screen captures to
SmartPAC 2 memory, you can still copy the screen capture to an e-mail message or to a USB
disk as described in Screen Capture in SmartPAC 2 Main Versions Earlier than V 5.3.1, above.
Saving Multiple Screen Captures to a USB Disk
To save one or more screen captures to a USB disk, do the following:
CAUTION
POWER DOWN SMARTPAC 2 BEFORE INSERTING USB DISK
Do not insert a USB disk into the USB connector while SmartPAC 2 is running. The USB disk
could touch a component on the SmartPAC 2 board, resulting in a short circuit and damage to the
board. Always power down SmartPAC 2 before inserting a USB disk.
Failure to comply with these instructions could result in property damage.
1. At your PC, create a folder named “Capture” in the root directory of the USB disk.
2. Power down the SmartPAC 2, and open the SmartPAC 2 enclosure or console.
3. Locate the USB connector, J121, on the SmartPAC 2 board (see Figure 2-11, page 2-17),
then carefully insert the USB disk into the USB connector.
NOTICE
The USB disk can be inserted into the USB connector only one way. Do not attempt to
force the USB disk into the connector.
4. Shut the enclosure or console door, and power up the SmartPAC 2.
5. On the SmartPAC 2 front panel, access one of the screens you want to capture.
6. Press the 8 and 0 (zero) keys simultaneously for a second or two until the message “USB
Capturing Screen...” in very small letters appears at the top right of the display.
7. Repeat steps 5 and 6 for additional screens. The number of screens you can capture is
limited only by the capacity of your disk.
8. When you are finished, open the enclosure or console, and remove the USB disk.
Captured screens are saved to a folder in the Capture folder named “Capturennnnnnnn,”
where nnnnnnnn is the SmartPAC 2 serial number. Screen capture files are named using a
prefix that stands for the operating mode in which the screen functions (i.e., INIT, PROG,
and RUN) followed by the date and time of the capture (e.g., INIT-02212007102234).
The date is expressed in mmddyyyy (month/day/year) format, the time in hhmmss (hours/
minutes/seconds) military format. All screen captures are saved as .gif files.
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Keyboard, Displays, Etc.
Chapter 4. Initialization Mode
This chapter shows you how to make settings in SmartPAC 2 Initialization mode.
Initialization settings, which are entered via the Main Initialization Menu (see Figure 4-1),
control operation of SmartPAC 2 Servo for all tools. (You make settings for individual tools
in Program mode–see Chapter 5).
Figure 4-1. Main Initialization Menu
(Includes some options. Your display may look different.)
The following sections cover setting up the linear transducer, controlling security access,
setting communications parameters, and other operations. It also documents functions related
to programmable cams and die protection, such as entering custom cam channel and sensor
names and setting global cams.
If you have SmartPAC 2 options installed, you will also make Initialization settings for them.
Refer to the user manuals for the options you have purchased for instructions.
Entering and Exiting Initialization Mode
NOTICE
SELECT = HIGHLIGHT + ENTER
When this manual instructs you to select an item, you should highlight the item, and press ENTER.
Follow the instructions shown in Table 4-1, page 4-2 to enter and exit Initialization mode.
See Figure 3-22, page 3-17 for help in navigating in Initialization mode.
Initialization Mode
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Table 4-1. Instructions for Entering and Exiting Initialization Mode
To Enter Initialization Mode
To Exit Initialization Mode
1. Turn Program/Run key to PROG.*
To switch to Program mode:
2. Press the “1” and “CLEAR” keys
simultaneously and hold down a few
seconds until the Main Initialization Menu
appears.
Press RESET.
____________________________________
To switch to Run mode:
Turn the Program/Run key to RUN.*
* If you turn the key and nothing happens, press RESET repeatedly until SmartPAC 2 changes modes. Make sure SmartPAC
2 is in the Main (or top) menu for the mode it is in before you turn the Program/Run key. If SmartPAC 2 is not in a top-level
menu, press RESET repeatedly until the Main menu appears.
The first display you see in Initialization mode is the Main Initialization Menu (see
Figure 4-1). From this menu, you can access all the Initialization mode displays.
The following sections show you how to use the selections available on the Main Initialization
Menu to set initialization parameters for SmartPAC 2 Servo with DiProPAC.
NOTICE
SET THE INTERNAL CLOCK IN SMARTPAC 2
When you initialize your SmartPAC 2, be sure to set the clock to the correct date and to your local
time according to the instructions in SET CLOCK, page 4-38.
POSITION SENSOR
(INITIALIZATION – POSITION SENSOR)
This item allows you to select the format (i.e., numeric or alphanumeric) to be used in entering
tool numbers, specify whether counters are to be incremented in Inch mode during setup, and
make other settings. Parameters are set on the screen shown in Figure 4-2, page 4-3. The
following sections show you how to set each parameter
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Figure 4-2. Position Sensor Screen
Position Sensor Mode
(INITIALIZATION – POSITION SENSOR)
SmartPAC 2 Servo does not use a position sensor, and this item is set to “DISABLED” by
default. If POSITION SENSOR MODE has been inadvertently set to “ENABLED,” the
“Position sensor incorrect” message will display (see page 7-3 for details). To correct this
problem, do the following:
1. On the Position Sensor screen and with the POSITION SENSOR MODE setting selected,
press ENTER to toggle the setting from “ENABLED” to “DISABLED.”
2. Press RESET when you are done.
Resolver Motion Mode (Normal Motion – Link Motion)
(INITIALIZATION – POSITION SENSOR)
SmartPAC 2 Servo does not use a resolver. Leave this option set to “NORMAL MOTION,”
its default setting. The setting has no affect on the operation of your press.
Angle Wheel Rotation (Clockwise – Counterclockwise)
(INITIALIZATION – POSITION SENSOR)
Leave this item set to “CW” (Clockwise), its default setting.
Initialization Mode
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Tool Number Mode
(INITIALIZATION – POSITION SENSOR)
NOTICE
Before you set up your SmartPAC 2, decide which tool number mode you will use, numeric or
alphanumeric. Set up your SmartPAC 2 in that mode, and do not change tool number modes
afterward.
This item enables you to select which format–Numeric or Alphanumeric–is used to enter tool
numbers in SmartPAC 2. In Numeric mode, tool numbers are limited to 7 digits and contain
only numbers. Alphanumeric tool “numbers” can contain 20 characters, including both letters
and numbers. Other differences between the two tool number modes are shown in Table 4-2.
Table 4-2. Numeric and Alphanumeric Tool Number Modes
Numeric Tool Number Mode
Alphanumeric Tool Number Mode
Tool Number: numbers only
Tool Number: letters, numbers, symbols
7 digits, max.
20 characters, max.
Tool Manager: Sorts tool numbers numerically
Tool Manager: Sorts tool numbers
alphanumerically
Tool Name:
Tool ID:
Optional, entered by user
Alphanumeric (letters, numbers and symbols)
Automatically assigned by SmartPAC 2; assigned
consecutively, starting with “1”
20 characters, max.
Numeric
Editable by user (must be unique)
7 digits, max.
To set tool number mode, do the following:
1. Press ENTER to toggle between NUMERIC and ALPHANUMERIC.
2. When the setting you want is displayed, press RESET.
Once you select a mode and program a tool, do not change tool number mode.
Counter Setup Mode
(INITIALIZATION – POSITION SENSOR)
This item allows you to enable or disable counter setup mode if you have made the
appropriate wiring connections to make SmartPAC 2 “setup mode ready” (see Wiring Setup
Mode Circuit, page 2-32.) To set this parameter, do the following:
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1. Press ENTER to toggle between two settings:
• “IS INCREMENTED IN ALL MODES”–Parts and batch counters will increment on
every stroke no matter what mode (i.e., Inch, Single-stroke, or Continuous) you are in.
• “NOT INCREMENTED IN SETUP MODE”–The Parts counter and batch counters
whose increment mode is programmed as GOOD PARTS will not increment when you
are in Inch mode.
NOTICE
The Strokes counter will increment regardless of the mode you are in.
2. When the setting you want is displayed, press RESET.
Counter Increment Mode
(INITIALIZATION – POSITION SENSOR)
This item, which is provided for SFC (see Appendix F) or LETS (see Appendix G) customers,
allows you to specify whether the Good Parts counter increments during a fault condition.
The default setting, NO INC FAULT, prevents the counter from incrementing when there is a
fault. To set this parameter, do the following:
1. Press ENTER to toggle between two settings:
• “NO INC FAULT”–The Parts counter and batch counters whose increment mode is
programmed as GOOD PARTS will increment on every stroke except when there is a
fault condition. This is the default setting.
• “INC ALWAYS”–The Parts counter and batch counters whose increment mode is
programmed as GOOD PARTS will increment on every stroke even if a fault condition
is present.
2. When the setting you want is displayed, press RESET.
INSTALLED OPTIONS
(INITIALIZATION – INSTALLED OPTIONS)
This item enables you to view the options that are installed on your SmartPAC 2 Servo (see
Figure 4-3, page 4-6), including the number of cam channels and sensors.
Initialization Mode
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 4-3. Installed Options Screen
Your screen will look different.
If you have ordered the alternate language option, this screen also provides a function key, F3
(Select Language), that allows you to select the language in which you want SmartPAC 2
Servo screens displayed. When you press F3, the screen shown in Figure 4-4 displays.
Figure 4-4. Select Language Screen
To select a language, highlight one of the three items, and press RESET. You are returned to
the Installed Options screen.
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PRESS NAME
(INITIALIZATION – PRESS NAME)
NOTICE
You can use a separate computer keyboard to enter the press name. See page 4-39.
This item enables you to name the press on which SmartPAC 2 Servo is installed. When you
select PRESS NAME, the Alphabetic Entry window opens (see Figure 4-5), allowing you to
enter the characters for the press name you want, using any combination of alphabetic
characters, numbers and symbols.
Figure 4-5. Alphabetic Entry Window
To enter a press name in the Alphabetic Entry window, do the following:
1. To key in letters and symbols, highlight each character, using the Up (), Down (), Left
(), and Right () cursor keys, then press ENTER. Pressing the CLEAR key clears the
text.
To key in numbers, use the numeric keypad, then press ENTER.
2. To accept your entry, press F6. To cancel your selection, press RESET.
SELECT CAM NAMES
(INITIALIZATION – SET CAM NAMES)
NOTICE
CAM NAMES ENTERED IN INITIALIZATION APPLY TO ALL TOOLS
The names you assign to cam channels in Initialization apply to all tools. If, for example, you
“custom-name” Channel 1 as “Bypass 3,” then Channel 1 is “Bypass 3” for every tool loaded.
This item allows you to assign descriptive names to each of your cam channels. You can
name up to 15 channels, depending on your SmartPAC 2 Servo configuration (i.e., standard
8-channel or optional 15-channel ProCamPAC). Do the following to assign cam channel
names:
Initialization Mode
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1. Select SELECT CAM NAMES on the Main Initialization Menu. The Cam Channel Name
Menu, shown in Figure 4-6, displays. The first time you access this screen, all channels
are named “UNNAMED.”
Figure 4-6. Cam Channel Name Menu
Your display may look different.
2. Select a channel. The screen shown in Figure 4-7 displays.
Figure 4-7. Cam Channel Name Selection Screen
3. Select from the list of names the name that best describes the function of the selected cam
channel. You are returned to the Cam Channel Name Menu with the name you selected
displayed to the right of the selected channel.
To view names that appear below the MORE NAMES line, press the Down () cursor
key. A new name appears each time you press the Down () cursor. When you have
cycled through the complete list, the highlight bar returns to “UNNAMED,” the first item.
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4. If none of the names in the list seem suitable but you still want to name the cam channel,
you can select “CUSTOM NAME.” If you do so, the Alphabetic Entry window (see
Figure 4-5, page 4-7) displays.
NOTICE
You can use a separate computer keyboard to enter cam channel names. See page 4-39.
5. Key in a “custom” cam channel name, following the directions in the Alphabetic Entry
window, then press F6 to accept your entry. You are returned to the Cam Channel Name
Menu with the “custom” name you selected displayed to the right of the selected channel.
To cancel your selection, press RESET.
6. When you are finished naming channels, press RESET to return to the Main Initialization
Menu.
NOTICE
Cam channel names do not replace channel numbers. They simply provide a way to
identify channel numbers by their function.
SET GLOBAL CAMS
(INITIALIZATION – SET GLOBAL CAMS)
!
DANGER
PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE
Use SmartPAC 2 Servo’s programmable cam switch to control auxiliary functions only. The
SmartPAC 2 programmable cam capability should never be used to provide timing signals for any
safety use including muting of light curtains.
Failure to comply with these instructions will result in death or serious injury.
NOTICE
Set as global cams only cam channels that perform identically regardless of the tool installed.
NOTICE
CHANNELS 6, 7 AND 8 CANNOT BE USED FOR GLOBAL CAMS
You can set any channel as a global cam except channels 6, 7 and 8.
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This item allows you to make settings for selected cam channels that apply to all tools
programmed on your SmartPAC 2 Servo. These cam channels are called “global” cams; they
are used to program events that remain the same on all tools. The global cam feature
eliminates the need to program the same cam information for multiple tools and ensures that
the cam always operates in the same way.
To program a global cam, do the following:
NOTICE
If you want to name the cam channel, do so before you program it as a global cam. Enter the cam
name as instructed in SELECT CAM NAMES, page 4-7.
1. Select SET GLOBAL CAMS on the Main Initialization Menu. The Global Cams menu,
shown in Figure 4-8, displays. An asterisk (*) indicates the channels that are already
programmed as global cams.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 4-8. Global Cams Menu
Asterisk (*) Indicates Global Cams
2. Select the cam you want to program. The Global Cam Timing Type screen, shown in
Figure 4-9, page 4-11 displays.
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Figure 4-9. Global Cam Timing Type Screen
3. Select the type of cam timing you want to program for this channel, referring to CAM
SWITCH, page 5-39 for instructions. Note that Auto Advance is not available as a cam
timing option for SmartPAC 2 Servo.
4. When you have finished programming the global cam, press RESET.
CUSTOM SENSOR NAMES (Optional)
(INITIALIZATION – CUSTOM SENSOR NAMES)
This item, which appears on the Main Initialization Menu only when DiProPAC is installed,
allows you to create “custom” names for up to 32 die protection sensors. The custom names
you create in Initialization provide the options available to you in Program mode when you
select names for your sensors. You create custom names on the Custom Sensor Names
screen, which is shown in Figure 4-10, page 4-12.
NOTICE
You can use a separate computer keyboard to enter custom sensor names. See page 4-39.
NOTICE
Custom Name entries 17-32 display sequentially, one at a time as you move the highlight bar
down past the CUSTOM 16 item.
Custom names do not have to be entered in the sequence that you use to name sensors. Sensor
1 can be assigned Custom Name 32, Sensor 2 Custom Name 15, Sensor 3 Custom Name 5, etc.
See page 5-23 for instructions in assigning custom names to sensors.
Initialization Mode
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Figure 4-10. Custom Sensor Names Screen
To create a custom name, do the following:
1. Select CUSTOM SENSOR NAMES on the Main Initialization Menu. The Custom
Sensor Names screen displays.
2. Select the item for which you want to create a custom name (e.g., CUSTOM 1, CUSTOM
2, etc.). The Alphabetic Entry window (see Figure 4-5, page 4-7) displays.
3. Key in the custom name, following the directions in the Alphabetic Entry window, then
press F6 to accept your entry. You are returned to the Custom Sensor Names screen with
the custom name you created displayed to the right of the selected item number. To cancel
your selection, press RESET.
4. Repeat steps 2 and 3 for each item you want to name. To access CUSTOM 17 through
CUSTOM 32 items, move the highlight bar down past “CUSTOM 16.” Additional
Custom Name entries display sequentially, one at a time.
5. Press RESET when you are done to return to the Main Initialization Menu.
SENSOR ENABLE MODE (Optional)
(INITIALIZATION – SENSOR ENABLE MODE)
The SENSOR ENABLE MODE item, which appears on the Main Initialization Menu only
when DiProPAC is installed, allows you to select the way in which your die protection sensors
are enabled. This item also allows you to enable Setup mode if this feature has been wired
during installation. You make these settings on the Die Protection Mode Selection Menu (see
Figure 4-11, page 4-13).
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Pressing ENTER toggles to
AUTO BY TOOL
AUTO BY SENSOR
Figure 4-11. Die Protection Mode Selection Menu
Selecting Sensor Enable Mode
You can select one of three modes for enabling die protection sensors:
• MANUAL ENABLE. When this option is selected, sensors are not automatically
re-enabled after the press is restarted following a setup or other procedure in which the
sensors have been temporarily disabled. You must enable or disable sensors manually in
Program and Run modes (see SENSOR ENABLE/DISABLE & STATUS (Optional),
page 5-52 and DISABLE (ENABLE) SENSORS, page 6-7).
• AUTO BY TOOL. When this option is selected, DiProPAC automatically re-enables all
sensors programmed for a specific tool whenever the press is restarted. You specify in
Program mode the number of strokes to allow after the press starts before DiProPAC
re-enables all sensors for the tool (see Setting the “Auto Enable by Tool” Counter Value,
page 5-21).
• AUTO BY SENSOR. When this option is selected, DiProPAC automatically re-enables
each sensor programmed for a specific tool, sensor by sensor. You specify in Program
mode for each sensor the number of strokes to allow after the press is restarted before
DiProPAC re-enables that sensor (see Setting the “Auto Enable by Sensor” Counter Value,
page 5-24).
To select a Sensor Enable mode, do the following:
1. Select SENSOR ENABLE MODE on the Main Initialization Menu. The Die Protection
Mode Selection Menu displays (see Figure 4-11).
2. With the highlight bar on the SENSOR ENABLE MODE item, press ENTER until the
setting you want is displayed.
3. Press RESET to return to the Main Initialization Menu.
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Enabling Setup Mode
Setup mode allows you to run the press in Inch without incrementing the good parts and batch
counters or triggering a fault condition in the green sensors. This mode, as its name indicates,
is used during setup. You enable Setup mode by selecting the Inch setting.
NOTICE
To enable Setup mode, your inch-selector switch must be wired to the Setup mode input, terminal
#252 on TB107 (see Wiring Setup Mode Circuit, page 2-32).
To enable Setup mode, do the following:
1. Select SENSOR ENABLE MODE on the Main Initialization Menu. The Die Protection
Mode Selection Menu displays.
2. Move the highlight bar to the SETUP MODE item.
3. Press ENTER to toggle the setting from DISABLED to INCH.
4. Press RESET to return to the Main Initialization Menu.
LINEAR SENSOR
(INITIALIZATION – LINEAR SENSOR)
NOTICE
Make sure to select a transducer that is at least as long as or longer than the sum of the maximum
stroke length of your press and the maximum shut-height adjustment.
This item enables you to set up the magnetostrictive linear transducer for use with your press.
You set the resolution for the sensor, the sensor’s zero value, the maximum Upper Limit in the
sensor’s range, the offset to apply to the sensor’s upper and lower limits, and the units in
which Upper Limit, Lower Limit, and Offset Value are measured. You make these settings on
the Linear Sensor Setup screen, which is shown in Figure 4-12, page 4-15.
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 4-12. Linear Sensor Setup Screen
Table 4-3 explains the settings displayed on the Linear Sensor Setup screen and, where
applicable, provides available options.
Table 4-3. Linear Sensor Setup Screen Field Definitions
Field
Settings
SENSOR
RESOLUTION
The smallest change the sensor can detect in its
measurement range. There are three linear sensor
resolution options (displayed in micrometers, μM), which
are dependent on the length of the sensor:
6- and 12-in. sensors
18- and 24-in. sensors
30-, 36-, 42-, and 48-in. sensors
OFFSET VALUE
5 μM
10 μM
20 μM
A value added to the Upper Limit and Lower Limit readings
on the Ram Position screen in Program (see page 5-50)
and Run (see page 6-22) modes that reflects the shut
height opening of your press. This corrected reading is
used for all displays and settings.
The magnetostrictive transducer reports absolute distance,
the transducer’s lowest position reporting zero, the highest
position the instrument’s maximum range. The absolute
distance must be modified by the Offset Value to represent
the true length of the ram’s vertical movement.
To determine the Offset Value, measure the shut height
opening of your press, using a dial gage if you want a
precise display. From this value subtract the reading
displayed in the Lower Limit field on the Ram Position
screen in either Program or Run mode when the press has
been inched to its lowest position. The formula is
Offset Value = Shut height opening – Lower Limit value
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Table 4-3. Linear Sensor Setup Screen Field Definitions (Cont.)
Field
Settings
ZERO VALUE
The number of counts representing the sensor’s output at
its zero position. For an MTS sensor, this value should be
at least 1,000 counts. For a Balluff sensor, this item should
be set to zero (0).
UPPER LIMIT
The highest value you can program as the Upper Limit on
the Ram Position screen in Program (see page 5-50) and
Run (see page 6-22) modes. This value should be set to
the ram’s position at Top Dead Center (TDC) and at the
Upper Limit of its Shut Height adjustment. The Upper Limit
can be less than the maximum range of the linear sensor.
UNITS
The units in which the sensor’s Upper Limit, Lower Limit,
and Offset Value are measured. There are two options:
IN
MM
Inches
Millimeters
To enter linear sensor Initialization settings, perform the following steps:
1. Select LINEAR SENSOR on the Main Initialization Menu. The Linear Sensor Setup
screen displays.
2. With the highlight bar on the SENSOR RESOLUTION item, press ENTER until the
setting you want is displayed, referring to Table 4-3 for available options.
NOTICE
DO NOT enter the OFFSET VALUE field until you have set the Zero Value and Upper
Limit.
3. Move the highlight bar to the ZERO VALUE item.
4. Set the ZERO VALUE field in one of the following ways:
• If you are using a Balluff sensor, this item should be set to zero (0). To change the
setting, press ENTER, and when the Numeric Entry window displays (see Figure 3-4,
page 3-3), key in zero, using the numeric keypad, and press ENTER. Your entry
displays in the ZERO VALUE field.
• If you are using an MTS sensor, position the ram at Bottom Dead Center (BDC) and at
the Lower Limit of its Shut Height adjustment, then press F7 (Save Zero Position).
That position, in counts, is displayed in the ZERO VALUE field.
The displayed value should be greater than 1,000 counts. If it isn’t, the magnet is
positioned outside the sensor’s range. Move the transducer down so that the magnet is
positioned within the sensor’s range, then press F7 again.
5. Move the highlight bar to the UPPER LIMIT item.
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6. Set the UPPER LIMIT value in one of the following ways:
• Switch to Run mode (see page 6-2 for instructions), Inch the ram to Top Dead Center
(TDC) and adjust the Shut Height to its Upper Limit, return to this screen, and press F6
(Save Upper Limit). The absolute reading reported by the linear sensor displays in the
UPPER LIMIT field.
• Press ENTER, and when the Numeric Entry window displays (see Figure 3-4,
page 3-3), key in the value you want, using the numeric keypad or the Up () and
Down () cursor keys, and press ENTER. The value you specified displays in the
UPPER LIMIT field.
7. Move the highlight bar to the OFFSET VALUE item.
NOTICE
With firmware versions V9.08 or higher, there is no limit for the Offset Value.
8. Press ENTER, key in the value you want in the Numeric Entry window, and press
ENTER. The value you specified displays in the OFFSET VALUE field.
9. Move the highlight bar to the UNITS item.
10. Press ENTER until the setting you want is displayed, referring to Table 4-3 for available
options.
11. When you are finished, press RESET to return to the Main Initialization Menu.
TOOL INFORMATION
(INITIALIZATION – TOOL INFORMATION)
The TOOL INFORMATION item on the Main Initialization Menu allows you to set up a
name, unit of measurement, and number of decimal places for up to six items you wish to
document for each tool. You enter specific values and up to thirty characters of special
information for each tool in Program and Run modes (see TOOL INFORMATION, page 5-48
and TOOL INFORMATION, page 6-20).
NOTICE
Tool Information screens only maintain information about the tool. They do not control any aspect
of press operation.
NOTICE
This feature is not available if you have the optional PLC interface installed.
To set up items you wish to document for each tool, do the following:
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1. Select TOOL INFORMATION on the Main Initialization Menu. The Tool Information
Setup screen, shown in Figure 4-13, displays.
Figure 4-13. Tool Information Setup Screen
2. Highlight the NAME 1 item, and press ENTER. The Tool Information Name screen,
shown in Figure 4-14, displays.
Figure 4-14. Tool Information Name Screen
3. Move the highlight bar to the name you want, using the cursor keys, and press ENTER.
You are returned to the Tool Information Setup screen with the name you selected
displayed.
4. If you want to use a name that is not in the list, select the “CUSTOM” item.
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5. When the Alphabetic Entry window (see Figure 4-5, page 4-7) displays, key in a custom
name of up to 12 characters, following the directions on the screen, then press F6 to accept
your entry. You are returned to the Tool Information Setup screen with your custom name
displayed. To cancel your selection, press RESET.
NOTICE
You can use a separate computer keyboard to enter tool information names. See
page 4-39.
6. Highlight the UNS 1 item, and press ENTER. The Tool Information Units Selection
screen, shown in Figure 4-15, page 4-19, displays.
Figure 4-15. Tool Information Units Selection Screen
7. Move the highlight bar to the abbreviation for the unit you want, using the cursor keys,
and press ENTER. (See Table 4-4, page 4-20 for an explanation of abbreviations.) You
are returned to the Tool Information Setup screen with your Units selection displayed.
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Table 4-4. Tool Information Setup Screen: Abbreviations for Units
On-screen
Abbreviation
Units
On-screen
Abbreviation
Units
IN
Inches
METERS
Meters
FT
Feet
FT/MIN
Feet per minute
MM
Millimeters
FT/SEC
Feet per second
CM
Centimeters
MM/SEC
Millimeters per second
PSI
Pounds per square inch
MM/MIN
Millimeters per minute
BAR
Bars
GALS
Gallons
LBS
Pounds
QTS
Quarts
TONS
Tons
GRAMS
Grams
OUNCES
Ounces
SPM
Strokes per minute
DEG. F
Degrees Fahrenheit
FPM
Feet per minute
DEG. C
Degrees Celsius
MPM
Meters per minute
8. If you want to specify a unit that is not in the list, select the “CUSTOM” item. When the
Alphabetic Entry window displays, key in a unit of up to 6 characters. To accept your
entry, press F6. You are returned to the Tool Information Setup screen with the unit you
created displayed.
9. Highlight the zero (0) on the first line in the PLACES column, and press ENTER. When
the Numeric Entry window displays (see Figure 3-4, page 3-3), key in a value, using the
numeric keypad or the Up () and Down () cursor keys, then press ENTER.
For numeric values, you can select up to four decimal places. For YES/NO items, enter
eight (8) for the number of places. Table 4-5 provides additional information about
decimal place formats.
Table 4-5. Tool Information Setup Screen: Decimal Places and Formats
No. of
Places
0
Example
Whole numbers: press speed
(SPM)
1
4-20
Digits to Left of
Decimal Point
Digits to Right of
Decimal Point
Up to seven (7)
None (0)
0 to
9,999,999
Up to five (5)
One (1)
0.0 to
99,999.9
Range
2
Die location (mm)
Up to four (4)
Two (2)
0.00 to
9,999.99
3
Pass line height (inches)
Up to three (3)
Three (3)
0.000 to
999.999
4
Precise values: material
thickness
Up to two (2)
Four (4)
0.0000 to
99.9999
8
Yes or No designation
Not applicable
Not applicable
NO (0)
YES (1)
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NOTICE
Do not change the number of decimal places on the Tool Information Setup screen after
you have entered values for specific tools in Program or Run mode. If you change the
number of decimal places, entered values will be changed by a factor of ten for each
decimal place added or removed.
10. Repeat steps 2-9 for other Tool Information items you want to set up. A Tool Information
Setup screen with sample entries filled in is shown in Figure 4-16.
Figure 4-16. Tool Information Setup Screen with Sample Entries
11. When you are finished, press RESET to return to the Main Initialization Menu.
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SECURITY ACCESS
(INITIALIZATION – TOOL INFORMATION)
The SECURITY ACCESS item on the Main Initialization Menu allows you to control user
access to SmartPAC 2 Servo operating modes and settings. You set user access on the
Security Access Menu, which is shown in Figure 4-17.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 4-17. Security Access Menu
For most items on the Security Access Menu, you can specify three types of access:
• PROGRAM AND RUN MODES. Allows users to change settings in both Program and
Run modes. This access type is the least secure.
• PROGRAM MODE ONLY. Allows users to change settings only in Program mode (i.e.,
when the Program/Run key is in the PROG position). To prevent users from entering
Program mode, you should remove the Program/Run key with the switch in the RUN
position.
• PASSWORD REQUIRED. Allows users to change settings only after they have entered a
password. This access type is the most secure.
The following items on the Security Access Menu allow you to select other access options
(see Table 4-6, page 4-23 for a complete list of security access settings):
• CHANGE COUNTS and CHG GOOD PRTS CNT. These items allow you to specify NO
CHANGES ALLOWED, which prevents changes to actual counter values for strokes, good
parts, total hits, and batch counters (CHG COUNTS) or for good parts only (CHG GOOD
PRTS CNT). This setting is applicable in either Program or Run mode.
• INIT. PASSWORD. This item allows you to require a password for user access to the Main
Initialization Menu. To require a password, select MUST BE USED. Otherwise, select
NOT REQUIRED.
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• LOAD MONITOR. This item has four options: ALLOW RECALC/ADJUST, ALLOW
RECALC ONLY, NO RECALC/ADJUST, and PASSWORD REQUIRED.
• CHG TOOL TEMPLATE. This item has two options: PASSWORD REQUIRED and
PASSWORD NOT REQUIRED.
Table 4-6. Security Access Settings
Optional modules included; your menu may be different
Security Access Menu Item
Security Access Settings
LOAD TOOL #
PROGRAM AND RUN MODES
PROGRAM MODE ONLY
PASSWORD REQUIRED
DELETE TOOL #
PROGRAM MODE
NOT ALLOWED
PASSWORD REQUIRED
SET CNTR PRESET
PROGRAM AND RUN MODES
PROGRAM MODE ONLY
PASSWORD REQUIRED
CHANGE COUNTS
PROGRAM AND RUN MODES
PROGRAM MODE ONLY
PASSWORD REQUIRED
NO CHANGES ALLOWED
CHG GOOD PRTS CNT
PROGRAM AND RUN MODES
PROGRAM MODE ONLY
PASSWORD REQUIRED
NO CHANGES ALLOWED
RESET MODE
PROGRAM AND RUN MODES
PROGRAM MODE ONLY
PASSWORD REQUIRED
CHG TOOL TEMPLATE
PASSWORD REQUIRED
PASSWORD NOT REQUIRED
ADJ DIPRO SENS
PROGRAM AND RUN MODES
PROGRAM MODE ONLY
PASSWORD REQUIRED
DISABLE SENSORS
PROGRAM AND RUN MODES
PROGRAM MODE ONLY
PASSWORD REQUIRED
TURN OFF SENSORS
ALLOWED
NOT ALLOWED
PASSWORD REQUIRED
ADJUST CAMS
PROGRAM AND RUN MODES
PROGRAM MODE ONLY
PASSWORD REQUIRED
ADJUST FEED
PROGRAM AND RUN MODES
PROGRAM MODE ONLY
PASSWORD REQUIRED
LOAD MONITOR
ALLOW RECALC/ADJUST
ALLOW RECALC ONLY
NO RECALC/ADJUST
PASSWORD REQUIRED
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Table 4-6. Security Access Settings (Cont.)
Optional modules included; your menu may be different
ADJ. TOOL INFO
PROGRAM AND RUN MODES
PROGRAM MODE ONLY
PASSWORD REQUIRED
ADJ RAM POSITION
PROGRAM AND RUN MODES
PROGRAM MODE ONLY
PASSWORD REQUIRED
INIT. PASSWORD
NOT REQUIRED
MUST BE USED
When you attempt to access a menu that is password-protected, SmartPAC 2 displays a
window (see Figure 4-18) that asks you to enter your password.
ENTER YOUR PASSWORD
USE THE KEYPAD TO ENTER NUMBERS.
USE THE UP/DOWN CURSOR KEYS TO
INCREASE/DECREASE. PRESS ENTER
WHEN DONE. PRESS RESET TO CANCEL.
60599
Give this number to
Wintriss Tech. Support if
you forget your password.
Note: Your number may be
different.
Figure 4-18. “Enter Your Password” Screen
NOTICE
IF YOU FORGET OR DO NOT KNOW YOUR PASSWORD(S)
Call Wintriss Tech. Support at the telephone number on the cover of this manual. Give the Tech.
Support person the 5-digit number from the bottom of the “Enter your password” display.
Information about accessing menus in Program and Run modes is provided in chapters 5 and
6.
Setting Security Access
NOTICE
CHECK YOUR PASSWORDS
Make sure to check your passwords before changing any security access settings. Record the
passwords in a safe place. Refer to Changing Passwords, page 4-25.
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NOTICE
DO NOT ENABLE INIT. PASSWORD UNTIL YOU HAVE CHECKED YOUR PASSWORDS
Field upgraded SmartPAC 2s may have different passwords than those listed in this manual. If
you do not know the Initialization password and change the INIT. PASSWORD item to MUST BE
USED, you will not be able to access the Main Initialization Menu.
NOTICE
BE CAREFUL WHEN SETTING RESET MODE SECURITY ACCESS
If you select the PROGRAM MODE ONLY or PASSWORD REQUIRED setting for the RESET
MODE item, the operator will not be able to reset SmartPAC 2 in Run mode when the press stops
as the result of a malfunction.
If you want the operator to be able to reset the machine in Run mode following errors, select
PROGRAM AND RUN MODES as the Reset Mode setting.
If you want one person to be responsible for tracking faults, give that individual the Program/Run
key, and set Reset Mode access to PROGRAM MODE ONLY. When a fault occurs, that individual
can reset the press by turning the key switch to PROG and pressing the RESET key, then resume
press operation by turning the key back to RUN.
To make security access settings, do the following:
1. Select SECURITY ACCESS on the Main Initialization Menu to display the Security
Access Menu (see Figure 4-17). Note that the factory settings allow all actions to be
performed in both Program and Run modes.
2. To change the security access of an item, highlight the item, using the Up () and Down
() cursor keys, then press ENTER one or more times until the type of access you want
displays. Refer to Table 4-6 for help with selecting access options.
3. Press RESET to save your settings and return to the Main Initialization Menu.
Examples
You want to prevent the operator from loading a tool number in Run mode. To accomplish this,
set the security access for LOAD TOOL # to PROGRAM MODE ONLY. With this setting, a tool
can be loaded only when the Program/Run key is switched to PROG.
You want to give only certain individuals the ability to adjust cams. To accomplish this, set
ADJUST CAMS to PASSWORD REQUIRED, and give these individuals the password. With
security access set in this way, the cams cannot be adjusted without the user entering the
correct password.
Changing Passwords
SmartPAC 2 allows you to set up to four different passwords:
• General Password–Provides access to all SmartPAC 2 Servo menus and settings unless one
or more of the following specific passwords is also required
• Init. Password–Provides access to the Main Initialization Menu
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• PM Password–Provides access to the PM (Preventive Maintenance) Monitor setup in
Program mode (see Appendix B)
• Tool Template Password–Provides access to the Tool Template (see page 5-5)
Passwords must be numeric and can be from one to four digits in length.
NOTICE
DEFAULT PASSWORDS
Your SmartPAC 2 comes from the factory with all passwords set to the default password “1234.” If
you have upgraded your SmartPAC 2 in the field, your passwords may be different.
To change passwords, perform the following steps:
1. On the Security Access Menu (see Figure 4-17), press F1 (Change Passwords) to display
the Set Passwords Menu (see Figure 4-19).
Figure 4-19. Set Passwords Menu
2. Select the password you want to change. The window shown in Figure 4-20 displays.
Figure 4-20. “Enter a New Password” Window
3. Key in the new password, following the instructions in the window, and press ENTER.
You are returned to the Set Passwords Menu.
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BACKUP/RESTORE
This item, which displays on the Main Initialization Menu only when you have SmartPAC 2
version V5.32 or higher, enables you to back up and restore tools programmed on your
SmartPAC 2. Tools may be backed up to a network drive, or, if you have ordered the USB
Backup/Restore option (part no. 9679619), to a USB disk inserted in the SmartPAC 2 board.
You can back up as many as 200 tools per SmartPAC 2 as well as SmartPAC 2 Initialization
parameters.
Instructions for backing up tools to a network drive are provided on the SmartPAC2.com Web
site. Click on See a Demo, then on Backup Setup Online Manual. Instructions for backing up
tools to a USB disk are provided below.
Backing Up Tools to a USB Disk
The USB disk you use for backup must have at least 600 KB of free space in order to store all
tools and Initialization parameters on a SmartPAC 2. USB disks are available in a wide range
of capacities, and you should choose a device that will allow you to store backup information
for all your SmartPAC 2s. A USB disk that should meet most needs is available from Wintriss
(part no. 9679401).
Backup files are written to folders named “Backupnnnnnnnn,” where nnnnnnnn is the serial
number of the SmartPAC 2. Use of the serial number in the folder name allows SmartPAC 2–
and you–to identify the backup information pertaining to a particular control. Within folders,
there are at least two files, one for tool backups, named “nnnnnnnn-Tool,” the other for
Initialization backups, named “nnnnnnnn-Init.” Again, nnnnnnnn is the SmartPAC 2 serial
number.
When two or more backups have been performed on the same SmartPAC 2, two additional
files are maintained in the backup folder, named “nnnnnnnn-Tool.old” and “nnnnnnnnInit.old.” These files contain the next-most-recent tool and Initialization backups of the
SmartPAC 2 with the specified serial number.
To back up tools on a SmartPAC 2, do the following:
1. Make sure a USB disk with the necessary free space is installed in the USB connector in
the lower left corner of the SmartPAC 2 board (component J121 in Figure 2-11,
page 2-17).
2. Select the BACKUP/RESTORE item on the Main Initialization Menu. The Backup/
Restore Control Menu displays with the message
Please wait
Checking SmartPAC 2 tools...
appearing briefly at the top of the screen, followed by a message displaying the number of
tools that have been programmed on that SmartPAC 2 (see Figure 4-21, page 4-28).
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 4-21. Backup/Restore Control Menu
NOTICE
You can view the date and time of the last backup by pressing the F4 (Date Last Backup)
function key. The date and time display at the bottom of the screen.
3. To begin the backup process, press the F6 (Backup) function key.
NOTICE
If the SmartPAC 2 detects that the USB disk does not have enough free space to store the
tool and initialization backup information, a message like the following displays:
There is NOT enough space available
on USB Disk!
Please remove and free up approx
nnn.nK then try again
Press RESET to clear this message
The variable nnn.n is the number of kilobytes (KB) of free space required for the backup.
Press RESET to clear the message, then remove the USB disk, install another USB disk
with the required amount of free space, and press F6 (Backup) again.
If you want to re-use the original USB disk, you can insert it into a USB connector on your
computer, delete the files necessary to free up the required amount of space, re-install it in
the SmartPAC 2, and reinitiate the backup.
The message
Please wait...
appears briefly at the top of the screen, and the following message displays near the
bottom
USB Disk Detected (nnn Meg free)
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where nnn is the amount of disk space in megabytes available for storing backup
information.
As the backup proceeds, messages like the following display at the top of the screen
Backing up SmartPAC2 data for Tool nnnnnn
where nnnnnn is the tool number, followed by messages like
Backing up SmartPAC2 data for Init Group nn
where nn is the Initialization group number. Then the message
Transferring files...
displays briefly as backup files are written to the USB disk. When the backup is complete,
the following message displays:
Backup Finished!
4. Press RESET to return to the Main Initialization Menu.
Restoring Tools from a USB Disk
NOTICE
You should only need to perform a restore if the SmartPAC 2 tool and Initialization
programming has been corrupted or if the SmartPAC 2 board has been replaced. The
restore process overwrites programming for all your tools and Initialization setups with the
tool and Initialization settings saved during the most recent backup. In performing a
restore, you may lose information that has taken you considerable time to input.
To restore backed-up tools to a SmartPAC 2, do the following:
1. With the USB disk onto which tools have been backed up inserted in the USB connector
(see step 1 of the Backing Up Tools to a USB Disk procedure, page 4-27) and the Backup/
Restore Control Menu (see Figure 4-21) displayed, press the F5 (Restore) function key. A
window opens, asking you to confirm that you really want to restore tools to the
SmartPAC 2, as shown in Figure 4-22, page 4-30.
NOTICE
Make sure that you really want to restore the tool settings contained on the USB disk.
During the restore process, current tool programming will be overwritten by the backed-up
settings.
2. Press ENTER to continue with the restore.
The same sorts of messages display during the restore process as occurred during backup
(see step 3 of the Backing Up Tools to a USB Disk procedure, page 4-28). When the
restore is complete, the following message displays:
Finished Restore!
Press RESET to return to the Main Initialization Menu.
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 4-22. Backup/Restore Control Menu with Restore Confirmation Window Displayed
SETUP DATA COMMS (Optional)
(INITIALIZATION – SETUP DATA COMMS)
The SETUP DATA COMMS item, which appears on the Main Initialization Menu only when
firmware for Wintriss data collection software is installed, allows you to set communications
parameters for a Wintriss data collection software product. Communications settings are
made on the Set Communications Menu, which is shown in Figure 4-23. This screen is fully
documented starting on page F-7 for SmartPAC 2 users with the SFC firmware option. If you
have the LETS firmware option, refer to page G-7 for Set Communications Menu
documentation.
Figure 4-23. Set Communications Menu
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SETUP NETWORK
(INITIALIZATION – SETUP NETWORK)
NOTICE
• Your network administrator must connect SmartPAC 2 to your computer network before you can
use e-mail messaging or SmartView remote viewing utility. For e-mail, your network must have
a valid SMTP mail server.
• If your network requires static IP addresses, your network administrator should call Wintriss
Tech. Support. See CHANGE NETWORK SETTINGS, page 4-34.
The SETUP NETWORK item on the Main Initialization Menu allows you to set up
SmartPAC 2’s E-mail and SmartView functions and to make other settings necessary to
configure a SmartPAC 2 network. You make these settings on the Network Setup Utility
screen, which is shown in Figure 4-24.
Figure 4-24. Network Setup Utility Screen
E-MAIL FUNCTION
(INITIALIZATION – SETUP NETWORK – E-MAIL FUNCTION)
NOTICE
• Consult with your network administrator when setting up e-mail.
• Use the SmartView remote viewing utility (see next item) to set up e-mail messages and
recipients.
SmartPAC 2’s E-mail function allows you to send e-mails to individuals in your SmartPAC 2
Servo network and to other recipients, such as Wintriss Tech. Support, via the Internet. If you
plan to use E-mail, do the following to enable this function:
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1. Select SETUP NETWORK on the Main Initialization Menu to display the Network Setup
Utility screen.
2. With the highlight bar on E-MAIL FUNCTION, press ENTER to toggle the setting to
ENABLED.
3. Press RESET to return to the Main Initialization Menu.
If you don’t plan to use E-mail, set the E-MAIL FUNCTION item to DISABLED.
SMARTVIEW FUNCTION
(INITIALIZATION – SETUP NETWORK – SMARTVIEW FUNCTION)
NOTICE
Consult your network administrator when setting up SmartView.
SmartPAC 2’s SmartView function enables individuals in your SmartPAC 2 Servo network to
view the operation of each press in your pressroom from a remote location. (Information
about setup and operation of SmartView is provided in Appendix D.) If you plan to use
SmartView, do the following to enable this function:
1. With the highlight bar on the SMARTVIEW FUNCTION item on the Network Setup
Utility screen, press ENTER to toggle the setting to ENABLED.
2. Press RESET to return to the Main Initialization Menu.
If you don’t plan to use SmartView, set the SMARTVIEW FUNCTION item to DISABLED.
SETUP E-MAIL
(INITIALIZATION – SETUP NETWORK – SETUP E-MAIL)
NOTICE
• Consult your network administrator when setting up e-mail.
• Use SmartView remote viewing utility (see previous item) to set up e-mail messages and
recipients.
If you have enabled the SmartPAC 2 E-mail function, you should use the SETUP E-MAIL
item on the Network Setup Utility screen to enter E-mail settings. Settings are made on the
Setup E-mail screen, which is shown in Figure 4-25, page 4-33.
To set up E-mail, do the following:
1. Select SETUP E-MAIL on the Network Setup Utility screen. The Setup E-Mail screen
displays.
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 4-25. Setup E-mail Screen
2. With the highlight bar in the Mail Server: field, press ENTER. The Alphanumeric Entry
window, shown in Figure 4-26, displays with the default mail server shown at the top of
the window.
Figure 4-26. Alphanumeric Entry Window with Default Mail Server Displayed
3. Key in the name or IP address of your mail server, following the directions in the window,
then press F6 to save your entry and return to the Setup E-mail screen. Your entry is now
displayed in the Mail Server: field.
For help in filling in this and other items, refer to Table 4-7, page 4-34. You can also
consult your plant network administrator.
4. Select the next item (e.g., Mail Port:, Use Secure Login:, etc.), and repeat steps 2 and 3,
referring to Table 4-7 for help.
5. When you are done, press F2 (Apply Changes) to apply the changes you have made, then
press RESET to return to the Network Setup Utility screen.
NOTICE
You can use a separate computer keyboard to enter information. See page 4-39.
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Table 4-7. Setup E-mail Items
Item
Description
Examples
Mail Server
The name or IP address of the SMTP mail
server on your network
server.yourcompany.com
124.15.62.53
Mail Port
The port on the server used for mail.
Usually 25.
25
Use Secure
Login
Indicates whether a username and
password are required to log in to the
network
FALSE
TRUE
TRUE = Password required
FALSE = No password required
If the setting is “FALSE,” you don’t need to
enter a username or password.
Username
The username (if necessary) for logging in
to the network
username
joe_user
Password
The password (if necessary) for logging in
to the network
password
secret452
Email Error
Recipient
The e-mail address to which messages
issued when an e-mail fails to be delivered
are sent. SmartPAC 2 cannot receive
e-mail.
ErrorRecipient
@yourcompany.com
joe.user@yourcompany.com
E-mail From
Name
Name to be shown in the “From” field in the
e-mail header. Some networks require a
particular format of “From” name.
FromRecipient
@yourcompany.com
Press_14@yourcompany.com
Wintriss Email Addr
The e-mail address of Wintriss Tech.
Support. Use the default unless instructed
otherwise.
info@wintriss.com
After you enter settings on the Network Setup Utility screen, you use SmartView to complete
setting up the e-mail messages and recipients for your SmartPAC 2 (see Appendix D).
CHANGE NETWORK SETTINGS
(INITIALIZATION – SETUP NETWORK – CHANGE NETWORK SETTINGS)
This item is to be used only by your Information Technology or Information Systems person.
Call Wintriss Tech. Support for assistance in making advanced network settings.
NOTICE
SETTING STATIC IP ADDRESS
SmartPAC 2 comes from the factory set up for a Dynamic Host Configuration Protocol (DHCP)
network, which automatically assigns IP addresses. If your network requires static IP addresses,
have the person who supports your network call Wintriss Tech. Support for assistance in setting up
SmartPAC 2 with a static IP address.
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PRESS TYPE
(INITIALIZATION – SETUP NETWORK – PRESS TYPE)
Your entry for the PRESS TYPE item is used by the SmartView remote viewing utility (see
SMARTVIEW FUNCTION, page 4-32) to select the graphic it uses to illustrate the type of
press (i.e., straight side or gap frame) on which SmartPAC 2 is installed. This graphic appears
in the press information summary on the SmartView Main Page.
To set the press type, do the following:
1. With the highlight bar in the PRESS TYPE field, press ENTER to toggle between GAP
FRAME and STRAIGHT SIDE until the option you want is displayed.
2. Press RESET to return to the Main Initialization Menu.
DIAGNOSTICS
(INITIALIZATION – DIAGNOSTICS)
The DIAGNOSTICS item on the Main Initialization Menu gives you access to the
Diagnostics Menu (see Figure 4-27), which you use primarily when you are working with
Wintriss Tech. Support for initial setup or troubleshooting. This section documents only the
following items:
• COMMUNICATIONS, which allows you to run a communications loopback test
• SET CLOCK, which allows you to set SmartPAC 2’s internal clock to local time
• SAVE TO USB DISK, which allows you to save screen captures and other items to a USB
disk
• UPDATE FIRMWARE, which allows you to upload revised firmware to SmartPAC 2
Figure 4-27. Diagnostics Menu
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COMMUNICATIONS
(INITIALIZATION – DIAGNOSTICS – COMMUNICATIONS)
When you select the COMMUNICATIONS item on the Diagnostics Menu, the
Communications Data Viewer screen, shown in Figure 4-28, displays.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 4-28. Communications Data Viewer Screen
This screen allows you to verify communications between SmartPAC 2 and its installed
modules (e.g., SFI). When you press ENTER with the highlight bar resting on one of the
communications ports (e.g., PORT 1 (SFI)), the Transmit and Receive Data screen for that
communications port displays (see Figure 4-29).
You can view communications data in two screen formats: combined and split. Press ENTER
with the F1 key label showing “COMBINED TX AND RX” to view the combined format.
Press ENTER with F1 showing “SPLIT TX AND RX” to view the split format.
F1
F1
F2
F2
F3
F3
F4
F4
F5
F5
F6
F6
F7
F7
F8
F8
Figure 4-29. Transmit and Receive Data Screen: Combined View (Left), Split View (Right)
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In the “combined” view, Transmit and Receive data are shown together (see the left panel in
Figure 4-29), Transmit data being displayed as blue on a white background, Receive data
displayed as white on blue. This view shows the data as it is transmitted and received in real
time. Press F3 (Reset Buffer) to view the data starting at the beginning of the buffer.
In the “split” view, Transmit data is shown in the upper half of the screen, Receive data in the
lower half (see right panel in Figure 4-29). In this view, the data is always shown starting at
the beginning of the buffer.
Normal communications between SmartPAC 2 and the selected module (e.g., SFI) is
indicated by both Transmit and Receive data being displayed on the screen. If no data or only
partial data is displayed, SmartPAC 2 and the other module are not communicating properly.
If you want to examine transmitted or received data, press F2 (Stop/Start Buffer).
If the Transmit and Receive Data screen indicates a communications problem, you can
perform a “loopback test.” To do so, you connect (or jumper) the TXD (transmit) and RXD
(receive) lines, and then press F1 (Send Loopback Message) to check communications. In
effect, you are “receiving” the communications data that you are transmitting. This test is
useful when verifying the accuracy of Transmit and Receive hardware and wiring.
To perform a loopback test, follow these steps:
1. Wire loopback jumpers for the port or ports you want to check, following the wiring
diagram in Figure 6 at the end of the manual. Figure 6 shows loopback test wiring for
both RS232 and RS485 communications. Be sure to follow the correct diagram for your
system.
2. Select the port/module you want to test, such as “PORT 1 (SFI).” The Transmit and
Receive Data screen for that port displays.
3. Press F1 (Send Loopback Message) to start the test. The message “LOOP BACK
MESSAGE PORT X” displays, where X is the number of the port you selected.
If you need help performing the loopback test, contact Wintriss Tech. Support. Be prepared to
provide the following information: product name (e.g., SmartPAC 2 Servo); installed
options (e.g., DiProPAC, ProCamPAC, etc.); and firmware version number (e.g., Vs. 2.00).
You can determine the last two items by accessing the Installed Options screen (see
Figure 4-3, page 4-6).
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SET CLOCK
(INITIALIZATION – DIAGNOSTICS – SET CLOCK)
When you select the SET CLOCK item on the Diagnostics Menu, the Set the Clock screen,
shown in Figure 4-30, displays.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 4-30. Set the Clock Screen
On this screen you can set the date in month/day/year (mm/dd/yy) format and the time in
military hours/minutes (hh:mm) format (i.e., 1:30 p.m. = 13:30, 11:00 p.m. = 23:00). To do
so, perform these steps:
1. Highlight the segment of the date or time that you want to change, using the Left () and
Right () cursor keys, then press ENTER. The Numeric Entry window (see Figure 3-4,
page 3-3) displays.
2. Key in a value, using the numeric keypad or the Up () and Down () cursor keys, and
press ENTER. You are returned to the Set the Clock screen with your entry displayed in
the date or time segment you selected in step 1.
3. Repeat steps 1 and 2 for other date/time segments.
NOTICE
To stop the clock, press F1 (Stop the Clock). The F1 label changes to START THE
CLOCK. To restart the clock, press F1 (Start the Clock).
4. Press RESET when you are done to return to the Diagnostics Menu.
NOTICE
You will have to change the clock setting in the spring and fall when your local time
changes from Standard to Daylight Savings and from Daylight Savings to Standard.
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SAVE TO USB DISK
(INITIALIZATION – DIAGNOSTICS – SAVE TO USB DISK)
This item enables you to save the error/event log (see page 6-23), screen captures (see
page 3-22), and other data maintained in a special SmartPAC 2 buffer to a USB disk. Once
the data has been saved, you can remove the USB disk, transfer the information to a computer,
and e-mail it to Wintriss Tech. Support or to another recipient (see MESSAGING, page 6-26).
This function is useful if your SmartPAC 2 is not networked. To save information to a USB
disk, do the following:
1. Make sure a USB disk is installed in the USB connector on the SmartPAC 2 board (see
steps 1 through 4 of the Saving a Screen Capture to a USB Disk, page 3-23).
2. Access the Main Initialization Menu, select DIAGNOSTICS, and when the Diagnostics
Menu (see Figure 4-27) displays, select SAVE TO USB DISK. The following messages
appear in succession:
PLEASE WAIT WHILE THE DATA IS BEING TRANSFERRED TO THE USB DISK.
THIS MAY TAKE UP TO ONE MINUTE TO COMPLETE . . .
THE USB DISK TRANSFER HAS FINISHED AND WAS SUCCESSFUL. PRESS THE
RESET KEY AND THEN REMOVE THE USB DISK DEVICE.
3. When the second message appears, press RESET to return to the Diagnostics Menu.
4. Power down your SmartPAC 2, and remove the USB disk.
UPDATE FIRMWARE
(INITIALIZATION – DIAGNOSTICS – UPDATE FIRMWARE)
To update the firmware in your SmartPAC 2 Servo, refer to Appendix C.
Using a Computer Keyboard to Enter Names
When entering the name for your press and custom names for cams and sensors, you can use a
computer keyboard connected to SmartPAC 2. To connect the keyboard and use it to key in
names, proceed as follows:
1. Power down SmartPAC 2.
2. Plug the keyboard into the appropriate connector on the SmartPAC 2 board (see
Figure 2-11, page 2-17).
• Keyboard with a USB connector: Plug into the USB connector (J121).
• Keyboard with a PS/2 connector: Plug into the PS/2 connector (J120).
3. Power up SmartPAC 2.
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4. Select the name you want to enter (e.g., PRESS NAME), and when the Alphabetic Entry
window displays (see Figure 4-5, page 4-7), type your entry on the keyboard.
You can type any alphabetic or symbol character shown in the Alphabetic Entry window.
You can also enter numbers and use the backspace key and the space bar. As you type, the
characters appear at the top of the Alphabetic Entry window.
5. When you have finished typing, press F6 on the SmartPAC 2 Servo panel to accept your
entry.
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Chapter 5. Program Mode
This chapter shows you how to make settings in SmartPAC 2 Program mode. Program
settings, which are entered via the Main Program Menu (see Figure 5-1), control SmartPAC 2
Servo operation for an individual tool. (You make settings that control operation of all tools
in Initialization mode–see Chapter 4).
Figure 5-1. Main Program Menu
(Includes some options. Your display may look different.)
The following sections show you how to create, program, modify, delete, and load individual
tools. You are instructed how to enter tool names, set counters, program timing for cams, and
make settings for die protection sensors and other SmartPAC 2 options.
Once you have programmed and loaded a tool, you can switch to Run mode to run that tool on
your press (refer to Chapter 6). In Run mode, you can also make some adjustments to tool
settings.
If you need help using the SmartPAC 2 keyboard to input information on Program mode
displays, refer to Chapter 3.
Entering and Exiting Program Mode
NOTICE
SELECT = HIGHLIGHT + ENTER
When this manual instructs you to select an item, you should highlight the item, and press ENTER.
Follow the instructions shown in Table 5-1, page 5-2 to enter and exit Program mode. See
Figure 3-24, page 3-19 for help in navigating in Program mode
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Table 5-1. Instructions for Entering and Exiting Program Mode
To Enter Program Mode
To Exit Program Mode
From Run mode:
To switch to Run mode:
Turn the Program/Run key to PROG.*
Turn the Program/Run key to RUN.*
_________________________
_________________________
From Initialization mode:
To switch to Initialization mode:
Go to the Main Initialization Menu.
Press the “1” and “CLEAR” keys
simultaneously and hold down a few seconds
until the Main Initialization Menu appears.
Press RESET.
—or—
Turn the Program/Run key to RUN and then
back to PROG.*
* If you turn the key and nothing happens, press RESET repeatedly until SmartPAC 2 changes modes. Make
sure SmartPAC 2 is in the Main (or top) menu for the mode it is in before you turn the Program/Run key. If
SmartPAC 2 is not in a top-level menu, press RESET repeatedly until the Main menu appears.
The first display you see in Program mode is the Main Program Menu (see Figure 5-1). From
this menu, you can access the following screens or functions:
• Tool Manager screen (see next section)
• Sensor Enable/Disable and Status screen (see page 5-52)
NOTICE
For help with a Program mode screen, press the HELP key when that screen is displayed.
TOOL MANAGER
(PROGRAM – GO TO THE TOOL MANAGER)
The GO TO THE TOOL MANAGER item on the Main Program Menu enables you to create,
copy, delete and load tools. You perform these functions on the Tool Manager screen (see
Figure 5-2, page 5-3), which displays when you select GO TO THE TOOL MANAGER.
Once you have created a tool, you must program it before the tool can be loaded. You
program tools on the Tool Program Menu (see Figure 5-9, page 5-8), which you access from
the Tool Manager screen by pressing the F4 (Edit Tool) key.
The Tool Manager screen displays a list of the tools that have already been created.
(SmartPAC 2 has the capability to store settings for up to 200 tools.) The currently loaded
tool is highlighted. To copy, delete, program, or load a tool, select that tool and press the
appropriate function key (i.e., F8 (Copy Tool), F6 (Delete Tool), F4 (Edit Tool), or F5 (Load
Tool)). To create a new tool, press F7 (New Tool).
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-2. Tool Manager Screen
NOTICE
The Tool Manager screen sorts the tool list based on the setting for TOOL NUMBER MODE in
Initialization (see page 4-4).
• If the setting is NUMERIC, tools are sorted by tool number
• If the setting is ALPHA-NUMERIC, tools are sorted alphabetically by tool name
In the example shown in Figure 5-2, tools are sorted by tool number.
Creating a New Tool
(PROGRAM – GO TO THE TOOL MANAGER – select tool – F7-NEW TOOL)
To create a new tool, do the following:
1. On the Tool Manager screen, press F7 (New Tool). The Numeric Entry or Alphanumeric
Entry window (see Figure 5-3) displays, depending on whether you selected Numeric or
Alphanumeric tool number mode in Initialization.
Figure 5-3. Numeric Entry Window (Left); Alphanumeric Entry Window (Right)
2. Key in the desired tool number, following the directions displayed in the applicable
window.
3. Press ENTER after keying in a numeric tool number or F6 after keying in an
alphanumeric tool number. The window shown in Figure 5-4, page 5-4 displays.
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Figure 5-4. Copy Tool Template Window
4. If you want to copy the settings you have programmed for the Tool Template (see Copying
Tool Template to a New Tool, page 5-5), press ENTER. If you don’t want to copy the Tool
Template, press RESET. The Tool Program Menu displays (see Figure 5-9, page 5-8) with
the highlight bar on the TOOL NAME or TOOL ID item.
NOTICE
The first item on the Tool Program Menu is TOOL NAME if Numeric mode has been
specified for tool numbers in Initialization. The first item is TOOL ID if Alphanumeric mode
has been selected.
5. Create a name for the new tool if tool number mode is Numeric. Refer to TOOL NAME or
TOOL ID, page 5-8 for instructions.
6. Continue programming settings for the new tool, follow the directions in Tool Program
Menu, page 5-8. Then load the tool, referring to Loading a Tool, page 5-5 for instructions.
Copying an Existing Tool
(PROGRAM – GO TO THE TOOL MANAGER – select tool – F8-COPY TOOL)
If you want to copy the settings programmed for an existing tool to a new tool, perform the
following steps:
1. On the Tool Manager screen, highlight the tool whose settings you want to copy to the
new tool, and press F8 (Copy Tool). The Numeric Entry or Alphanumeric Entry window
(see Figure 5-3) displays, depending on whether you selected Numeric or Alphanumeric
tool number mode in Initialization.
NOTICE
If there are more tools in SmartPAC 2’s memory than can be displayed in two columns,
press the Left () or Right () cursor key to display the additional hidden column(s).
2. Key in the desired tool number, following the directions displayed in the applicable
window.
3. Press ENTER after keying in a numeric tool number or F6 after keying in an
alphanumeric tool number. The Tool Program Menu displays (see Figure 5-9, page 5-8)
with the highlight bar on the TOOL NAME or TOOL ID item.
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NOTICE
The first item on the Tool Program Menu is TOOL NAME if Numeric mode has been
specified for tool numbers in Initialization. The first item is TOOL ID if Alphanumeric mode
has been selected.
4. Create a name for the new tool if tool number mode is Numeric. Refer to TOOL NAME or
TOOL ID, page 5-8 for instructions.
5. Change settings for the new tool, as necessary, following the directions in Tool Program
Menu, page 5-8. Then load the tool, referring to Loading a Tool, page 5-5 for instructions.
Copying Tool Template to a New Tool
(PROGRAM – GO TO THE TOOL MANAGER – select Tool Template, # 9999999 –
F8-COPY TOOL)
Tool Template, which is assigned tool number 9999999, is a tool you can program with
settings common to two or more tools (see Tool Program Menu, page 5-8). When used with
the COPY TOOL (F3) function, Tool Template allows you to duplicate the same constellation
of settings across multiple tools. Tool Template is not used to run the press.
NOTICE
PASSWORD PROTECTION FOR TOOL TEMPLATE
To prevent unauthorized changes, you can set Security Access (page 4-22) so that a password is
required to change the Tool Template.
To copy Tool Template to a new tool, do the following:
1. On the Tool Manager screen, highlight TOOL # 9999999, TOOL TEMPLATE, and press
F8 (Copy Tool).
2. Perform steps 2 through 4 of the Copying an Existing Tool procedure, starting on page 5-4.
3. Load the new tool, referring to Loading a Tool (next section) for instructions.
Loading a Tool
(PROGRAM – GO TO THE TOOL MANAGER – select tool – F5-LOAD TOOL)
!
DANGER
ANCILLARY EQUIPMENT MAY OPERATE WHEN TOOL IS LOADED
Ensure that all personnel stand clear when you load a tool.
Failure to comply with these instructions will result in death or serious injury.
To load a tool, perform the following steps:
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1. On the Tool Manager screen, highlight the tool you want to load, and press F5 (Load
Tool). The warning window shown in Figure 5-6 displays,
ENTER YOUR PASSWORD
USE THE KEYPAD TO ENTER NUMBERS.
USE THE UP/DOWN CURSOR KEYS TO
INCREASE/DECREASE. PRESS ENTER
WHEN DONE. PRESS RESET TO CANCEL.
60599
If this display appears, you need to enter the general password to load the tool. Security
access is set in Initialization mode (see SECURITY ACCESS, page 4-22).
Figure 5-5. “Enter Your Password” Screen
NOTICE
You can also load tool numbers in Run mode, if allowed by security access, as long as the
press is stopped.
Figure 5-6. Load Tool Warning Window
2. Press ENTER to load the tool. A message should appear indicating that the tool is being
loaded.
NOTICE
If an error message displays, go to Chapter 7 and follow the instructions for correcting the
problem. If the error is not covered in Chapter 7, or you cannot fix the problem, call
Wintriss Tech. Support.
Changing Settings for a Loaded Tool
(PROGRAM – GO TO THE TOOL MANAGER – select tool – F4-EDIT TOOL)
!
DANGER
ANCILLARY EQUIPMENT MAY OPERATE WHEN TOOL IS LOADED
Ensure that all personnel stand clear when you load a tool.
Failure to comply with these instructions will result in death or serious injury.
To change settings for a loaded tool, do the following:
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1. With the currently loaded tool highlighted on the Tool Manager screen, press F4 (Edit
Tool).
ENTER YOUR PASSWORD
USE THE KEYPAD TO ENTER NUMBERS.
USE THE UP/DOWN CURSOR KEYS TO
INCREASE/DECREASE. PRESS ENTER
WHEN DONE. PRESS RESET TO CANCEL.
60599
If this display appears, you need to enter the general password to program the tool.
Security access is set in Initialization mode (see SECURITY ACCESS, page 4-22).
Figure 5-7. “Enter Your Password” Screen
2. Change settings for the tool, following the instructions in Tool Program Menu, page 5-8.
NOTICE
RELOAD CURRENTLY LOADED TOOL IF YOU CHANGE IT
If you change settings for a tool that is currently loaded, you should load the tool again
after you make the changes. If you do not re-load the tool, the old settings will be used
until you load the tool again.
3. When you have made your changes and “reset” out of the Tool Program Menu, the Load
Tool Warning window (see Figure 5-6) displays. Press ENTER to load the tool.
Deleting a Tool
(PROGRAM – GO TO THE TOOL MANAGER – select tool – F6-DELETE TOOL)
To delete a tool, perform the following steps:
1. On the Tool Manager screen, highlight the tool you want to delete, and press F6 (Delete
Tool). The window shown in Figure 5-8 appears, asking you to confirm that you want to
delete the tool.
Figure 5-8. Delete Tool Confirmation Message
2. Press the CLEAR key to continue the deletion process. A message displays indicating that
the tool has been deleted, and you are returned to the Tool Manager screen with the
deleted tool removed from the tool list.
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Tool Program Menu
The Tool Program Menu, which is shown in Figure 5-9, displays whenever you
• Create a new tool
• Copy settings from an existing tool (e.g., Tool Template) to a new tool
• Press the F4 (Edit Tool) function key on the Tool Manager screen with a tool selected.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-9. Tool Program Menu
(Includes some options. Your display may look different.)
The following sections show you how to make settings for each of the items on the menu.
NOTICE
For help with screens accessible from the Tool Program Menu, press the HELP key with that
screen displayed.
NOTICE
RELOAD CURRENTLY LOADED TOOL IF YOU CHANGE IT
If you change settings for a tool that is currently loaded, you should load the tool again after you
make the settings. If you do not re-load the tool, the old settings will be used.
TOOL NAME or TOOL ID
(PROGRAM – GO TO THE TOOL MANAGER – select tool – F4-EDIT TOOL – TOOL NAME/ID)
NOTICE
If tool number mode has been set to Numeric in Initialization, this menu item is captioned TOOL
NAME. If tool number mode has been set to Alphanumeric, this item is captioned TOOL ID. See
Tool Number Mode, page 4-4.
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This item on the Tool Program Menu allows you to assign a name to a tool created with a
numeric tool number. To do so, perform the following steps:
NOTICE
If you have selected alphanumeric tool number mode in Initialization (see Tool Number Mode,
page 4-4), a tool ID is automatically generated by the system. You can view this number by
selecting the TOOL ID item on the Tool Program Menu. There is no reason to change the tool ID.
1. On the Tool Program Menu, select TOOL NAME. The Alphabetic Entry window
displays (see Figure 5-10).
Figure 5-10. Alphabetic Entry Window
2. Key in a tool name, following the instructions in the Alphabetic Entry window, then press
F6.
3. When you are finished, press RESET to return to the Tool Program Menu.
COUNTERS
(PROGRAM – GO TO THE TOOL MANAGER – select tool – F4-EDIT TOOL – COUNTERS)
NOTICE
For help with the Counters screen and screens accessible from it, press the HELP key when the
applicable screen is displayed.
This item on the Tool Program Menu allows you to set the counters that maintain counts of
press strokes and good parts and initiate various actions when a preset number of strokes has
been reached. Settings are made via the Counters screen (see Figure 5-11, page 5-10).
Program Mode
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-11. Counters Screen
SmartPAC 2 uses the following counters:
• Strokes counter: Counts the number of strokes made by the press during a job. When a
user-programmed preset value has been reached, SmartPAC 2 top-stops the press and
displays a message (see Counter Preset Reached Messages, page 7-2). The counter resets
to zero (0) when the message has been cleared.
• Good Parts counter: Counts the number of strokes made by the press during a job unless a
tonnage monitor, die protection, or process monitor (i.e., ProPAC) fault occurs during a
stroke. SmartPAC 2 top-stops the press and displays a message (see page 7-2) when the
programmed preset value has been reached. When the message has been cleared, the
counter resets to zero (0).
• Total Hits counter: Counts the number of hits on the programmed tool during all jobs.
The Total Hits count is incremented by the Strokes counter whenever the tool is loaded.
When the programmed preset has been reached, a flashing message displays in the Status
Box in Run mode. This counter can be used to indicate when die maintenance is required.
• Batch counters (3): Incremented by the Strokes or Good Parts counter, depending on the
user-programmed setting. Each batch counter can be set to initiate one of three actions
when the programmed preset is reached: Top Stop, Toggle, and Pulse.
When a Batch counter is set to TOP STOP, SmartPAC 2 top-stops the press and displays a
message (see page 7-2), as it does for Strokes and Good Parts counters. This setting is
useful when stopping the press to change bins or chutes before resuming production.
When a Batch counter is set to TOGGLE, SmartPAC 2 switches the state of a ProCamPAC
output from Open to Closed or from Closed to Open. This option is useful for activating a
parts diverter.
When a Batch counter is set to PULSE, SmartPAC 2 actuates a ProCamPAC output for a
specified length of time. The output On time must be specified when making a Pulse
setting. You can connect this output to any device that needs to be turned on once every
fixed number of strokes (i.e., the Batch counter setting).
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Each batch counter is assigned to a specific ProCamPAC channel: Batch 1 to Channel 6,
Batch 2 to Channel 7, and Batch 3 to Channel 8. If you set a Batch counter to either
TOGGLE or PULSE, the ProCamPAC channel controlled by that counter is displayed on
the Counters screen (see Figure 5-11).
The ram angle at which Strokes, Good Parts, Total Hits, and Batch counters is incremented
can also be programmed.
Setting Preset Values
Counter presets specify the count at which SmartPAC 2 initiates one of three programmed
actions (i.e., Top-stop, Toggle, or Pulse). To enter counter presets, do the following:
1. On the Tool Program Menu, select COUNTERS to display the Counters screen.
ENTER YOUR PASSWORD
USE THE KEYPAD TO ENTER NUMBERS.
USE THE UP/DOWN CURSOR KEYS TO
INCREASE/DECREASE. PRESS ENTER
WHEN DONE. PRESS RESET TO CANCEL.
60599
If this display appears, you need to enter the general password to program preset values.
Security access is set in Initialization mode (see SECURITY ACCESS, page 4-22).
Figure 5-12. “Enter Your Password” Screen
2. Select the setting displayed in the PRESET VALUE column of the counter you want to
program. The Numeric Entry window (see Figure 5-3, page 5-3) displays.
3. Key in a preset value, following the directions in the window, and press ENTER. The
value you entered displays in the PRESET VALUE field for the counter you selected in
step 2.
NOTICE
You can disable a counter by setting its preset value to zero.
4. Repeat steps 2 and 3 for each counter preset you want to program.
Changing Count Values
Under some circumstances, you may need to adjust the count upward or downward, or you
may want to start the count at some value other than zero. To change count settings, do the
following:
Program Mode
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NOTICE
ARE YOU “LOCKED OUT”?
If you cannot change count values, security access for the CHANGE COUNTS function may be
set to NO CHANGES ALLOWED. See SECURITY ACCESS, page 4-22.
1. On the Counters screen, select the setting displayed in the COUNT column of the counter
you want to adjust. The Numeric Entry window (see Figure 5-3, page 5-3) displays.
NOTICE
You can return a count to zero by simply moving the highlight bar to the appropriate
COUNT field and pressing the CLEAR key.
2. Key in a new value, following the directions in the window, and press ENTER. The
window shown in Figure 5-13 displays, asking you to confirm that you want to change the
COUNT value.
Figure 5-13. Change Count Confirmation Window
3. Press the Up () cursor key to proceed with the Change Count process. The value you
entered in step 2 displays in the COUNT field for the counter you selected in step 1.
4. Repeat steps 1 through 3 for each count you want to change.
Clearing the Total Hits Counter
Since the Total Hits counter does not reset to zero (0) when its preset is reached, you must
reset the counter manually. To do so, perform the following steps:
1. On the Counters screen, select the setting displayed in the COUNT column for TOTAL
HITS.
2. Press the CLEAR key. The Change Count Confirmation window (see Figure 5-13)
displays, asking you to confirm that you want to change the COUNT value.
3. Press the Up () cursor key to proceed with the Change Count process and clear the Total
Hits count. The value in the COUNT column for TOTAL HITS is reset to zero (0).
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Setting Batch Counter Output and Increment Modes
If you set a Batch counter preset value on the Counters screen, you must also specify the
output and increment modes for that counter if they differ from the factory settings. By
default, output mode is set to TOP STOP, increment mode to STROKE. To change these
settings, perform the following steps:
1. On the Counters screen, press F2 (Set Counter Modes). The Counter Mode Selections
screen, shown in Figure 5-14, displays.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-14. Counter Mode Selections Screen
2. Move the highlight bar to the setting in the OUTPUT MODE column for the Batch
counter you want to program, then press ENTER to scroll through the three options (i.e.,
TOP STOP, TOGGLE, and PULSE) until the setting you want is displayed.
NOTICE
When you select TOGGLE or PULSE, the ProCamPAC channel associated with output
from that batch counter displays on the Counters screen (see Figure 5-11, page 5-10).
3. If you selected PULSE as the output mode in step 2, move the highlight bar to the PULSE
TIME (MSEC) column, and press ENTER. The Numeric Entry window (see Figure 5-3,
page 5-3) displays.
4. Key in a value for the cam channel On time in milliseconds (maximum value, 9,999 mS,
or about 10 seconds), following the instructions in the window, then press ENTER. The
value you keyed in displays in the PULSE TIME (MSEC) column for the specified Batch
counter.
5. Move the highlight bar to the INCREMENT MODE column, then press ENTER to toggle
between the STROKE and GOOD PARTS options until the setting you want is displayed.
6. Repeat steps 2 through 5 for other Batch counters, as necessary.
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7. Press RESET to return to the Counters screen.
Setting Counter Increment Angle
The ram angle at which counters are incremented is set at the factory to a default value of
270°. This value is satisfactory for counting parts, but if you have programmed Batch counter
outputs to control automation, increment angles for those counters should be set to the angle at
which you want the automation to activate. The Counter Mode Selections screen allows you
to set a common increment angle for Strokes, Good Parts, and Batch 1 counters and separate
increment angles for Batch 2 and Batch 3 counters. To change default increment angles, do
the following:
1. On the Counter Mode Selections screen, move the highlight bar to the increment angle
value for the counter you want to adjust (e.g., Batch 2), then press ENTER. The Numeric
Entry window (see Figure 5-3, page 5-3) displays.
2. Key in a new increment angle value, following the directions in the window, then press
ENTER. The value you entered is displayed on the Counter Mode Selections screen.
3. Repeat steps 1 and 2 for other counters, as necessary.
Setting Parts per Stroke or Strokes per Part
SmartPAC 2 allows you to control how the Strokes and Good Parts counters increment in
relation to each other. You can specify the number of parts made during each stroke, in which
case the Good Parts counter will increment in multiple units (e.g., 2, 3, etc.) for each
increment of the Strokes counter. This setting is useful in multiple-up die applications.
Conversely, you can specify the number of strokes required to make each part, causing the
Good Parts counter to increment only once for multiple increments (e.g., 2, 3, etc.) of the
Strokes counter. This setting is useful in die applications with a gagged cutoff.
To set the number of parts made per stroke or number of strokes required to make a part, do
the following:
1. On the Counter Mode Selections screen, press F2 (Advanced Modes). The Advanced
Counter Mode Selections screen, shown in Figure 5-15, page 5-15, displays.
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Figure 5-15. Advanced Counter Mode Selections Screen
2. Select the value displayed for the item you want to program (i.e., PARTS MADE PER
EACH STROKE or STROKES TO MAKE EACH PART). The Numeric Entry window
(see Figure 5-3, page 5-3) displays.
3. Key in the value you want, following the directions in the window, and press ENTER.
The value you keyed in displays in the field you selected in step 2.
4. Press RESET to return to the Counter Mode Selections screen.
Setting Batch Pre-Load Counts
If you are setting up a tool for gagging operations, you can specify a pre-load count for each
Batch counter on the Advanced Counter Mode Selections screen. This pre-load value
displays in the COUNT field for each Batch counter you specify, decreasing by that value the
number of strokes (or good parts) required to reach the preset value. You can reset these preload values in Run mode when the Batch preset is reached (see COUNTERS, page 6-8) as
long as you set the CHANGE COUNTS parameter on the Security Access Menu in
Initialization to PROGRAM AND RUN MODES (see SECURITY ACCESS, page 4-22).
To set batch pre-load counts, do the following:
1. Select the pre-load count value for the batch you want (e.g., Batch 1, Batch 2, etc.). The
Numeric Entry window (see Figure 5-3, page 5-3) displays.
2. Key in a pre-load count value, following the directions in the window, and press ENTER.
The value you keyed in displays on the Advanced Counter Mode Selections screen.
3. Make sure that the AUTO BATCH PRE-LOAD field is set to OFF.
4. Press RESET to return to the Counter Mode Selections screen.
Program Mode
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DIE PROTECTION (Optional)
(PROGRAM – GO TO THE TOOL MANAGER – select tool – F4-EDIT TOOL – DIE PROTECTION)
CAUTION
Some Servo presses are capable of hitting the same part more than once at Bottom Dead Center
(BDC) before returning to the top of the stroke. You will have to note the angle ranges at which
repeated strokes occur. Any cams programmed within these ranges will actuate once for each hit.
Die protection ready signals programmed within these ranges will expect sensor actuation once for
each hit. If this is not feasible, please contact Wintriss Tech. Support to learn about new advanced
features.
Failure to comply with these instructions could result in property damage.
NOTICE
For help with the Die Protection Sensor Menu and screens accessible from it, press the HELP key
when the applicable screen is displayed.
This item, which appears on the Tool Program Menu only when DiProPAC 8 or DiProPAC 16
is installed, enables you to program up to 8 or 16 die protection sensors. (When DiProPAC 32
is an installed option, this menu item is subdivided into DIPROPAC 1-16 and DIPROPAC
17-32 entries–see Programming DiProPAC 32 Sensors, page 5-32.) Settings are made via the
Die Protection Sensor Menu, which is shown in Figure 5-16.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-16. Die Protection Sensor Menu
(DiProPAC 16-sensor option shown. Your display may look different.)
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Understanding Sensor Terminology
In order to make proper sensor settings on the SmartPAC 2 display, you need to be familiar
with basic sensor terminology. Terms that appear on sensor displays are explained in the
following sections.
Normally Open, Normally Closed
A normally open (N/O) sensor actuates (signals SmartPAC 2) when the sensor circuit to
SmartPAC 2 switches from open to closed-to-ground. N/O sensors are either “yellow” or
“green” (see page 5-18).
In a normally closed (N/C) sensor, the sensor circuit to SmartPAC 2 is closed to ground in its
normal state. The sensor actuates when the circuit opens. Normally closed sensors are “red”
(see page 5-18).
Most contact sensors can be used as either normally open or normally closed, depending on
how they are connected. Some electronic sensors can be switched to work either as normally
open or normally closed. Most sensors are used as normally open because no current is
flowing in the normal state.
Ready Signal
For many sensors, like those that monitor part ejection, blow-off, or feed advance, the event
being monitored must occur during a specific portion of the stroke. If the event doesn’t occur
during this period, the die may be damaged. The portion of the stroke during which a sensor
must actuate is called the Ready signal. You set a Ready signal only for green sensors, which
monitor events that must occur on every stroke.
The term “Ready signal” derives from older die protection systems on which a mechanical
cam switch on the press sent a signal to the die protection unit during the range of angles
within which the sensor was required to actuate.
The Ready signal is set by keying in the beginning (called “ready on”) and ending (called
“ready off”) angles of the range of angles during which the sensor must actuate. If the sensor
does not actuate (i.e., closure to ground does not occur) during this window, SmartPAC 2
sends a stop command to the press. The type of stop (i.e., top stop, emergency stop, or smart
stop) is programmable. See Setting Sensor Stop Type, page 5-26.
Impedance
Impedance is a measure of the resistance to the flow of electric current. Some die protection
controls have inputs for electromechanical sensors that provide different impedances. As a
rule of thumb, use a high-impedance input if the part is dirty or covered with a non-conductive
lubricant. Use a low-impedance input if the part is covered with a water-based or conductive
lubricant.
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DiProPAC boards shipped since August, 2007 are compatible with all impedance levels.
However, DiPro Sensor Interface (DSI) 2 cannot be used with low-impedance sensors. If you
have a low-impedance application (e.g., a wire probe application in which a part/strip covered
with a water-based, conductive lubricant completes the circuit), the sensor must be wired
directly to the DiProPAC board.
Sensor Types
Sensors used with die protection systems are classified as red, yellow, or green. For
SmartPAC 2 with DiProPAC, there are four types of green sensors–green, green quick check,
green constant, and green special–all of which require an event to occur on every stroke or at
least once during a set number of strokes.
When you make settings for a tool, you select the sensor type for each sensor connected to
SmartPAC 2. You can program any combination of reds, yellows, or greens. Instructions for
programming sensor types is provided starting on page 5-25.
Yellow Sensors
Yellow sensors, which are normally open to ground, are ideally suited to monitor events like
stock buckling, end of stock, or die overload. When a yellow sensor closes, SmartPAC 2
sends a Stop command to the press. Because yellow sensors work independently of the ram
angle and do not actuate on every stroke, you do not set a Ready signal for them.
Red Sensors
Red sensors, which are normally closed to ground, are used to monitor the same events as
yellow sensors: die overloads, end of stock, and buckling. A Stop command is sent to the
press when the red sensor opens. No Ready signal is set for red sensors.
Green Sensors
Green sensors, which are normally open, are used to monitor events that must occur during a
certain portion of each stroke or intermittently every designated number of strokes. Examples
are part ejection, stock feed, and part transfer. SmartPAC 2 stops the press when the green
sensor closes to ground.
Any sensor set to green, green quick check, or green constant must actuate during the Ready
signal.
Depending on the type of green sensor, the Ready signal is set either a little longer or a little
shorter than the actuation time.
The four types of green sensors are described below.
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Green Sensors
A sensor input set to “green” must turn on, at least momentarily, within the Ready signal and
be off, at least momentarily, at some point outside the Ready signal (see Figure 5-17).
KEY
not allowed
not allowed
TDC
TDC
TDC
BDC
BDC
BDC
BDC
Sensor ON only
inside ready signal.
Sensor is ON
inside ready signal
and stays on for a
time after the end of
ready signal, but
turns OFF before
next ready signal.
Sensor never goes
OFF.
Sensor never goes
ON.
Stop signal sent at
beginning of ready
signal.
Stop signal sent at
end of ready signal.
OK
OK
TDC
(press stops)
(press stops)
= Ready
Signal
= Sensor
ON
Green Sensor
Figure 5-17. Ready Signal Programming for a “Green” Sensor
Green Quick Check Sensors
A sensor input set to “green quick check” must turn on, at least momentarily, within the
Ready signal and may not turn off outside the Ready signal (see Figure 5-18). In other words,
the sensor must turn on and turn off within the Ready signal.
KEY
OK
not allowed
not allowed
(press stops)
(press stops)
TDC
TDC
TDC
TDC
TDC
BDC
BDC
BDC
BDC
BDC
= Ready
Signal
= Sensor
ON
Green
Quick Check
Sensor
Sensor goes ON Sensor never goes
only inside ready ON.
signal.
Stop signal sent at
end of ready signal.
Sensor is ON outside ready signal.
Stop signal sent when sensor is ON outside ready
signal.
Figure 5-18. Ready Signal Programming for a “Green Quick Check” Sensor
Program Mode
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Green Constant Sensors
When you set a sensor input to “green constant,” the sensor must turn on before the Ready
signal begins and turn off after the Ready signal ends, remaining actuated continuously during
the entire Ready signal (see Figure 5-19).
KEY
not allowed
not allowed
not allowed
TDC
TDC
TDC
TDC
BDC
BDC
BDC
BDC
Sensor staysON
during entire ready
signal and goes OFF
at least momentarily
outside the ready
signal.
Sensor goes OFF
before ready signal
ends.
Sensor never goes
OFF outside ready
signal.
Sensor never goes
ON.
Stop signal sent
immediately.
Stop signal sent at
beginning of ready
signal.
Stop Signal sent at
end of ready signal.
OK
(press stops)
(press stops)
(press stops)
= Ready
Signal
= Sensor
ON
Green
Constant
Sensor
Figure 5-19. Ready Signal Programming for a “Green Constant” Sensor
Green Special Sensors
CAUTION
GREEN SPECIAL SENSOR MAY NOT PREVENT DAMAGE
Use the green special sensor with caution. An undesirable number of slugs can stack up in an
ejection hole while still satisfying a green special sensor’s requirements. See the example below.
Failure to comply with these instructions could result in property damage.
Green special sensors are designed to monitor slug ejection, signalling when slugs have
stacked up excessively in a slug ejection hole. Slugs are not necessarily ejected on every
stroke. Several strokes may be required before they finally break free and fall out of the
bottom of the die. If the slugs jam and too many stack up in the hole, the die can be damaged.
Slug stacking is virtually impossible to monitor with a standard green sensor. A red or yellow
sensor is equally ineffective because the sensor changes state whenever a slug is ejected.
Instead of actuating once per stroke like a typical green sensor, the green special sensor must
actuate at least once during a preset number of strokes. Rather than setting a Ready signal,
you set the maximum number of strokes that the press can make without the sensor actuating.
For example, if your die clears all the slugs from a particular ejection hole approximately once
every four strokes, you would set a Green Special sensor input for a six-stroke window. If no
slugs are ejected after six strokes, SmartPAC 2 sends a Stop command to the press.
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Example: How a Green Special Sensor May Not Detect a Problem
Referring to the case cited above, assume that the press makes five strokes without ejecting a
slug. On the sixth stroke, one slug ejects and actuates the sensor. The green special sensor is
satisfied and the press continues to run. However, there are still five slugs in the ejection hole.
If the press makes five more strokes without ejecting a slug, ten slugs are now stuck in the hole.
If this process were to continue, it is conceivable that an infinite number of slugs could stack up
in the hole without the press stopping. Luckily, the laws of physics make this scenario unlikely.
When slugs jam, it is usually because the bottom one is stuck. If the bottom slug ejects, it is
very likely that the rest will soon follow.
Programming Sensor Settings
On the Die Protection Sensor Menu, you select a sensor to program, then enter settings for the
sensor on a series of screens that display sequentially. The settings you enter determine which
screens display, and programming for each sensor is likely to use a slightly different series of
screens. The following sections show you how to make these sensor program settings:
• Set the Auto Enable by Tool (see page 5-21) or Auto Enable by Sensor (see page 5-24)
stroke counter
• Assign a name to each sensor (see page 5-23)
• Set the sensor type (i.e., red, yellow, green, etc.) (see page 5-25)
• Set stop type (i.e., Emergency Stop, Top Stop, and Smart Stop) (see page 5-26)
• Set the critical angle for a sensor programmed as Smart Stop (see page 5-27)
• Set the Ready signal for a green sensor (see page 5-28)
• Set the stroke count for a green special sensor (see page 5-30)
You are also shown how to change sensor settings (see page 5-31), view the sensor summary
(see page 5-31), and delete sensors (see page 5-32).
Setting the “Auto Enable by Tool” Counter Value
If you have set Sensor Enable Mode in Initialization to AUTO BY TOOL (see page 4-12),
you must set the Auto Enable by Tool counter when you first access the Die Protection Sensor
Menu. The Auto Enable by Tool counter specifies the number of strokes the press must make
before all sensors in the tool are re-enabled following a DISABLE SENSORS command (see
SENSOR ENABLE/DISABLE & STATUS (Optional), page 5-52 and DISABLE (ENABLE)
SENSORS, page 6-7).
To set the Auto Enable by Tool counter, do the following:
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1. Select DIE PROTECTION on the Tool Program Menu. The Die Protection Sensor Menu
displays (see Figure 5-21) with the AUTO ENABLE COUNTER field shown to the left of
the list of sensors.
ENTER YOUR PASSWORD
USE THE KEYPAD TO ENTER NUMBERS.
USE THE UP/DOWN CURSOR KEYS TO
INCREASE/DECREASE. PRESS ENTER
WHEN DONE. PRESS RESET TO CANCEL.
60599
If this display appears, you need to enter the general password to program die protection
settings. Security access is set in Initialization mode (see SECURITY ACCESS,
page 4-22).
Figure 5-20. “Enter Your Password” Screen
F1
Number of strokes
after which DiProPAC
auto enables all sensors
in the tool
F2
F3
F4
F5
F6
F7
F8
Figure 5-21. Die Protection Sensor Menu with Auto Enable by Tool Counter
2. Select the AUTO ENABLE COUNTER field. The Numeric Entry window (see
Figure 5-3, page 5-3) displays.
3. Key in the value you want (maximum is 99), following the directions in the window, and
press ENTER. The value you keyed in displays in the AUTO ENABLE COUNTER field.
4. Select a sensor to program by moving the highlight bar to that sensor and pressing
ENTER.
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Naming the Sensor
When you select a sensor to program on the Die Protection Sensor Menu, the Sensor Names
screen, shown in Figure 5-22, displays.
Figure 5-22. Sensor Names Screen
On this screen you can select one of the names displayed, or you can select one of the
“custom” names set in Initialization (see CUSTOM SENSOR NAMES (Optional), page 4-11).
To name a sensor, do the following:
1. Select a sensor (e.g., Sensor 1) on the Die Protection Sensor Menu. The Sensor Names
screen displays.
2. Select from the list of names the name that best describes the function of the selected
sensor.
To view names that appear below the MORE NAMES line, press the Down () cursor
key. A new name appears each time you press the Down () cursor. When you have
cycled through the complete list, the highlight bar returns to UNNAMED, the first item.
3. If none of the names in the list seems suitable but you still want to name the sensor, select
“CUSTOM” NAME. The Custom Sensor Names screen, shown in Figure 5-23,
page 5-24, displays.
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Figure 5-23. Custom Sensor Names Screen
4. Select a “custom” name from the list. (The number of the custom name–e.g., CUSTOM
1–does not have to match the number of the sensor being programmed–e.g., SENSOR 1.)
If Sensor Enable Mode is set to AUTO BY SENSOR (see page 4-12), you are taken to the
Auto Enable by Sensor Counter screen (see next section). Otherwise, the Sensor Type
screen displays (see Setting Sensor Type, page 5-25).
Setting the “Auto Enable by Sensor” Counter Value
If Sensor Enable Mode is set to AUTO BY SENSOR in Initialization (see page 4-12), a screen
like the one shown in Figure 5-24 displays after you enter a sensor name.
Number of strokes
after which DiProPAC
auto enables this sensor
in the tool
Figure 5-24. Auto Enable by Sensor Counter Screen
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This screen allows you to set the Auto Enable by Sensor counter, which specifies the number
of press strokes necessary to re-enable the sensor following a DISABLE SENSORS command
(see SENSOR ENABLE/DISABLE & STATUS (Optional), page 5-52 and DISABLE (ENABLE)
SENSORS, page 6-7).
To set the Auto Enable by Sensor counter, do the following:
1. On the Auto Enable by Sensor Counter screen, select the value in the AUTO ENABLE
COUNTER field. The Numeric Entry window (see Figure 5-3, page 5-3) displays.
2. Key in the value you want (maximum is 99), following the directions in the window, and
press ENTER. The value you keyed in displays in the AUTO ENABLE COUNTER field.
3. Press ENTER to display the Sensor Type screen (see next section).
Setting Sensor Type
After you select a sensor name and, if AUTO ENABLE BY SENSOR is the Initialization
setting, specify the Auto Enable stroke count, the Sensor Type screen, shown in Figure 5-25,
displays with the name you selected for the sensor shown at the right of the Status Box
beneath the sensor number.
Figure 5-25. Sensor Type Screen
You can select one of six types of sensor (see Sensor Types, page 5-18 for details), or you can
select NOT USED, in which case that sensor is not programmed for the tool.
To set the sensor type, do the following:
1. Select the sensor type you want. For all selections except UNUSED, the Sensor Stop Type
screen (see next section) displays with the sensor type you selected displayed at the right
of the Status Box beneath the sensor name.
If you selected UNUSED, you are returned to the Die Protection Sensor Menu. The name
of the sensor you started to program is reset to SENSOR 1, SENSOR 2, etc.
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Setting Sensor Stop Type
When you select a sensor type, the Sensor Stop Type screen, shown in Figure 5-26, displays.
The Sensor Stop Type screen allows you to specify how the press is to be stopped when the
die protection sensor detects a fault.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-26. Sensor Stop Type Screen
You can select one of three Stop Type settings for the sensor: emergency stop, top stop, or
smart stop. The three Stop Type options are described below.
• Emergency Stop (E-Stop). SmartPAC 2 stops the press as soon as a sensor fault is
detected. You should use this setting for any die-threatening event that occurs before the
critical angle, the point in the ram downstroke after which a stop signal to the press cannot
prevent the die from closing. A typical Emergency Stop application is a sensor that
monitors part ejection on the upstroke. Setting this sensor to an Emergency Stop ensures
that the ram will stop on the next stroke before the die closes.
• Top Stop. SmartPAC 2 stops the press at the top of its stroke after a sensor fault is
detected. You should use this setting for events that do not threaten the die or that occur
between the critical angle and bottom dead center (BDC). A typical Top Stop application is
a sensor that monitors a feed like a roll feed that takes place well into the downstroke.
Setting this sensor to a Top Stop ensures that the press does not stick on the bottom as a
result of a stop signal being sent just as the ram is about to contact the material.
• Smart Stop. SmartPAC 2 performs either a Top Stop or Emergency Stop depending on the
angle at which the sensor fault is detected. SmartPAC 2 top-stops the press if the fault is
detected after the critical angle but before bottom dead center (BDC). If the fault is
detected after BDC but before the critical angle, SmartPAC 2 performs an emergency stop.
A typical Smart Stop application is a sensor that monitors short feeds, which can occur
either before or after the critical angle. When you select SMART STOP as the stop type,
you must specify the critical angle.
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To set the stop type for a sensor, do the following:
1. On the Sensor Stop Type screen, select the stop type you want (i.e., EMERGENCY STOP,
TOP STOP, or SMART STOP).
If you selected SMART STOP and the critical angle has not yet been set, you are taken to
the Critical Angle Programming screen (see next section).
If you selected EMERGENCY STOP or TOP STOP and the sensor you are programming
is a Green, Green Quick Check, or Green Constant sensor, you are taken to the Ready
Signal Programming screen (see Setting the Ready Signal for a Green Sensor, page 5-28).
If you selected EMERGENCY STOP or TOP STOP and the sensor you are programming
is a Green Special sensor, you are taken to the Green Special Sensor Stroke Count screen
(see Setting the Counter Value for a Green Special Sensor, page 5-30).
If you selected EMERGENCY STOP or TOP STOP and the sensor you are programming
is a red or yellow sensor, you are finished, and the Sensor Settings screen displays, on
which all your programmed sensor settings are shown (see Viewing and Changing Sensor
Settings, page 5-31).
Setting the Critical Angle for a Sensor Set to SMART STOP
When you program a sensor for a Smart Stop, you must also set the critical angle SmartPAC 2
uses to determine whether an Emergency Stop or Top Stop command is sent to the press. The
critical angle you program for the first sensor set to Smart Stop is used as the critical angle for
all sensors set to Smart Stop for that tool. If you change the Critical Angle setting for one
Smart Stop sensor, the new critical angle is applied to all Smart Stop sensors for that tool.
To set the critical angle for the first sensor set to SMART STOP for a tool, do the following:
1. On the Sensor Stop Type screen, select SMART STOP. The Critical Angle Programming
screen, shown in Figure 5-27, displays.
Figure 5-27. Critical Angle Programming Screen
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2. Decrement the CRITICAL ANGLE default value of 185°, using the Down () cursor
key, until the value you want is displayed. SmartPAC 2 accepts Critical Angle values
between 0° and 184°.
NOTICE
The Critical Angle default of 185° cannot be used as your Smart Stop critical angle setting.
If you attempt to enter 185° as the critical angle, a window will open, asking you to enter a
different value.
3. Press ENTER when you are done.
If the sensor you are programming is a Green, Green Quick Check, or Green Constant
sensor, the Ready Signal Programming screen displays (see next section).
If the sensor you are programming is a red or yellow sensor, you are finished, and you are
taken to the Sensor Settings screen (see Viewing and Changing Sensor Settings,
page 5-31).
After you have programmed one or more Smart Stop sensors, you can change the critical
angle by performing these steps:
1. On the Die Protection Sensor Menu, select a sensor programmed as Smart Stop. The
Sensor Settings screen (see Figure 5-30, page 5-31) displays.
2. Select SMART STOP. The Sensor Stop Type screen displays with SMART STOP
highlighted.
3. Press F5 (Set Critical Angle) to display the Critical Angle Programming screen.
4. Change the Critical Angle setting, using the Up () and Down () cursor keys.
NOTICE
The critical angle can only be set for values between 0° and 184°. If you attempt to enter
185° as the critical angle, a window will open, asking you to enter a different value.
Setting the Ready Signal for a Green Sensor
After you select the stop type for a Green, Green Quick Check, or Green Constant sensor, the
Ready Signal Programming screen, shown in Figure 5-28, page 5-29, displays.
On this screen, you set the Ready signal for Green, Green Quick Check, and Green Constant
sensor types. The Ready signal is the timing window during which the sensor must actuate to
prevent SmartPAC 2 from sending a stop signal to the press. In the example shown in
Figure 5-28, the Ready On signal is set to 180°, the Ready Off signal to 265°.
For Green and Green Quick Check sensors, you set the Ready signal so that it is a little longer
than the sensor’s actuation time. You set the Ready signal for Green Constant sensors so that
it is a little shorter than the sensor’s actuation time. See Understanding Sensor Terminology,
page 5-17 for more information.
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Ready signal
On and Off angles
Highlighted arc
shows duration
of Ready signal
Figure 5-28. Ready Signal Programming Screen
NOTICE
The Ready signal you set in Program mode can be fine-tuned in Run mode after you have run the
press. See Adjusting the Ready Signal for Green Sensors, page 6-11 for details.
To set the Ready signal, do the following:
NOTICE
If you do not know how to use the cursor keys to set sensor Ready signal timing, see page 3-6.
1. On the Ready Signal Programming screen, set the Ready On angle on the ram angle clock,
using the Left () and Right () cursor keys.
As you press the Left () cursor key, the On cursor moves counterclockwise around the
display, and the On angle value decreases. When you press the Right () cursor key, the
On cursor moves clockwise around the display, and the On angle value increases.
The precise On angle value is displayed in the window inside the clock display.
2. Set the Ready Off angle on the ram angle clock, using the Up () and Down () cursor
keys.
As you press the Up () cursor key, the Off cursor moves clockwise around the display,
and the Off angle increases. As you press the Down () cursor key, the Off cursor moves
counterclockwise around the display, and the Off angle decreases.
The precise Off angle value is displayed in the window inside the clock display.
3. When you have finished setting the Ready On and Ready Off angles, press RESET. The
Sensor Settings screen (see Figure 5-30, page 5-31) displays with all your sensor settings
shown.
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4. If you want to change any settings, refer to Viewing and Changing Sensor Settings,
page 5-31).
Otherwise, press RESET to return to the Die Protection Sensor Menu. The highlight bar
automatically scrolls down to the next sensor displayed on the menu.
Setting the Counter Value for a Green Special Sensor
When you select GREEN SPECIAL as the sensor type on the Sensor Type screen, the Green
Special Sensor Stroke Count screen, shown in Figure 5-29, displays. On this screen, you set
the number of strokes that the press can make before the Green Special sensor must actuate.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-29. Green Special Sensor Stroke Count Screen
NOTICE
For more information about Green Special sensors, refer to Understanding Sensor Terminology,
page 5-17.
To set the Green Special sensor stroke count, do the following:
1. On the Green Special Sensor Stroke Count screen, increment or decrement the stroke
counter (maximum value is 99), using the Up () or Down () cursor key, until the value
you want is displayed.
2. Press RESET. The Sensor Settings screen (see Figure 5-30, page 5-31) displays with all
your sensor settings shown.
3. If you want to change any settings, refer to Viewing and Changing Sensor Settings (next
section).
Otherwise, press RESET again to return to the Die Protection Sensor Menu. The highlight
bar automatically scrolls down to the next sensor displayed on the menu.
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Viewing and Changing Sensor Settings
When you finish making settings for a sensor, you are taken to a screen like the one shown in
Figure 5-30, which displays all your sensor settings.
Figure 5-30. Sensor Settings Screen
This screen also displays whenever you select a programmed sensor on the Die Protection
Sensor Menu.
To change sensor settings, do the following:
1. On the Sensor Settings screen, select the setting you want to change. The screen on which
that setting is programmed displays. For example, if you select the SENSOR NAME
setting, the Sensor Names screen (Figure 5-22, page 5-23) displays.
2. Change the setting on the displayed screen.
3. Press RESET when you are finished to return to the Sensor Settings screen.
4. Repeat steps 1 to 3 for each setting you want to change.
5. Press RESET when you have finished changing settings on the Sensor Settings screen.
You are returned to the Die Protection Sensor Menu.
Viewing the Sensor Summary
You can view a summary of the settings that have been made for all programmed sensors
shown on the Die Protection Sensor Menu, including the critical angle that has been set for the
tool. To view the summary, do the following:
1. On the Die Protection Sensor Menu, press F6 (View Sensor Summary). The Sensor
Summary screen, shown in Figure 5-31, page 5-32, displays. This screen shows the
sensor name, sensor type, stop type, and the Ready signal On and Off angles for Green,
Green Quick Check, and Green Constant sensors or the stroke count for Green Special
sensors.
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Figure 5-31. Sensor Summary Screen
Deleting a Sensor
To delete a Die Protection sensor, do the following:
1. On the Die Protection Sensor Menu, select the sensor you want to delete. The Sensor
Settings screen displays.
2. Select the Sensor Type. The Sensor Type screen appears.
3. Select NOT USED. You are returned to the Die Protection Sensor Menu with the name of
the sensor you selected in step 1 removed and a caption specifying the sensor number
(e.g., SENSOR 1, SENSOR 2, etc.) displayed.
Programming DiProPAC 32 Sensors
When DiProPAC 32 is an installed option, two menu choices appear on the Tool Program
Menu in place of the DIE PROTECTION item: DIPROPAC 1-16 and DIPROPAC 17-32 (see
Figure 5-32, page 5-33). You program the first sixteen DiProPAC 32 sensors, using the
DIPROPAC 1-16 menu item. You select the DIPROPAC 17-32 item to program sensors
17-32.
The first sixteen DiProPAC 32 sensors are programmed in exactly the same way you program
DiProPAC 8 and DiProPAC 16 sensors. If you are programming sensors 17-32 as red or
yellow sensors, procedures are also the same as for DiProPAC 8 and DiProPAC 16.
When you program sensors 17-32 as green sensors, you must handle them differently. When
programmed as green, green quick check, and green constant sensors, sensors 17-32 must use
the same Ready signal as an already programmed green, green quick check, or green constant
sensor among sensors 1-16. When programmed as green special sensors, sensors 17-32 must
use the same stroke count as an already programmed green special sensor among sensors
1-16.
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-32. Tool Program Menu with DIPROPAC 1-16 and DIPROPAC 17-32 Items
When planning the sensors to be assigned to each DiProPAC 32 input, make sure to reserve
sensor positions 1-16 for green sensors only. Also, if you are using multiple green sensors for
the same function (e.g., transfer, stripper, slug detection, etc.), program only one of the sensor
positions 1-16 for this application, leaving sensor positions 17-32 for programming the
remaining sensors in the group.
Programming Sensors 17-32 as Green, Green Quick Check, or Green Constant
To program a sensor in the group of sensors 17-32 as a green, green quick check, or green
constant sensor, do the following, referring to the appropriate sections of Programming
Sensor Settings (see page 5-21) if necessary:
1. On the Tool Program Menu (see Figure 5-32) select the DIPROPAC 17-32 item. The Die
Protection Sensor 17-32 Menu (see Figure 5-33) displays.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-33. Die Protection Sensor 17-32 Menu
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2. Select the sensor number that you want to program. The Sensor Names screen (see
Figure 5-34) displays.
Figure 5-34. Sensor Names Screen with Stripper Function Highlighted
3. Select a function for the sensor. (“Stripper” is used as an example in Figure 5-34.) The
Sensor Type screen (see Figure 5-35) displays.
Figure 5-35. Sensor Type Screen with “GREEN” Highlighted
4. Select the sensor type (i.e., GREEN, GREEN QUICK CHECK, or GREEN CONSTANT).
The Sensor Stop Type screen (see Figure 5-36, page 5-35) displays.
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-36. Sensor Stop Type Screen
5. Select the stop type you want. The Sensor Summary screen displays (see Figure 5-37)
with the Ready signal On and Off angles shown for each green sensor programmed in the
group of sensors 1-16. Sensors are displayed in ascending On angle order.
Figure 5-37. Sensor Summary Screen Showing Ready Signals for Green Sensors
6. Select the Ready signal you want. The Sensor Settings screen displays (see Figure 5-38,
page 5-36), showing the sensor name, sensor type, stop type, and Ready signal On and Off
angles you have selected. The screen also shows the number of the sensor in the group of
sensors 1-16 whose Ready signal is being used as the Ready signal for the sensor you are
programming.
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Figure 5-38. Sensor Settings Screen
7. Press RESET to return to the Die Protection Sensor 17-32 Menu.
Programming a Sensor as Green Special
To program one of the sensors in the group of sensors 17-32 as a green special sensor, perform
the following steps, referring to the appropriate sections of Programming Sensor Settings (see
page 5-21) if necessary:
1. Perform steps 1 and 2 of the Programming Sensors 17-32 as Green, Green Quick Check,
or Green Constant procedure, page 5-33. The Sensor Names screen (see Figure 5-39)
displays.
Figure 5-39. Sensor Names Screen with Slug Detection Function Highlighted
2. Select a function for the sensor. (“Slug Detection” is used as an example in Figure 5-39.)
The Sensor Type screen (see Figure 5-40, page 5-37) displays.
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Figure 5-40. Sensor Type Screen with “GREEN SPECIAL” Highlighted
3. Select GREEN SPECIAL from the Sensor Type items.
4. When the Sensor Stop Type screen displays, select a stop type. The Sensor Summary
screen (see Figure 5-41) displays with the stroke count shown for each green special
sensor programmed in the group of sensors 1-16.
Figure 5-41. Sensor Summary Screen Showing Stroke Counts for Green Special Sensors
5. Select the green special stroke count you want. The Sensor Settings screen (see
Figure 5-42, page 5-38) displays, showing the name of the sensor, sensor type, stop type,
and stroke count you have selected. The screen also shows the number of the sensor in the
group of sensors 1-16 whose stroke count is being used as the stroke count for the sensor
you are programming.
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Figure 5-42. Sensor Settings Screen
6. Press RESET to return to the Die Protection Sensor 17-32 Menu.
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CAM SWITCH
(PROGRAM – GO TO THE TOOL MANAGER – select tool – F4-EDIT TOOL – CAM SWITCH)
!
DANGER
PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE
Use SmartPAC 2 Servo’s programmable cam switch to control auxiliary functions only. The
SmartPAC 2 programmable cam capability should never be used to provide timing signals for any
safety use including muting of light curtains.
Failure to comply with these instructions will result in death or serious injury.
NOTICE
MAXIMUM NUMBER OF TIMED CHANNELS PER TOOL
Each tool can have up to four Timed Output cam channels.
CAUTION
Some Servo presses are capable of hitting the same part more than once at Bottom Dead Center
(BDC) before returning to the top of the stroke. You will have to note the angle ranges at which
repeated strokes occur. Any cams programmed within these ranges will actuate once for each hit.
Die protection ready signals programmed within these ranges will expect sensor actuation once for
each hit. If this is not feasible, please contact Wintriss Tech. Support to learn about new advanced
features.
Failure to comply with these instructions could result in property damage.
NOTICE
For help with the Cam Channel Menu and screens accessible from it, press the HELP key when
the applicable screen is displayed.
This item enables you to program up to 8 (for standard 8-channel ProCamPAC) or 15 (for
optional 15-channel ProCamPAC) cam channels. Cam channel settings are made via the Cam
Channel Menu, which is shown in Figure 5-43, page 5-40.
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-43. Cam Channel Menu
(ProCamPAC Linear 8-channel option shown. Your display may look different.)
Names you have assigned to cam channels in Initialization are displayed on the Cam Channel
Menu in place of the default channel numbers (see SELECT CAM NAMES, page 4-7).
Channel numbers that are missing from the menu have been programmed as “global” cams in
Initialization (see SET GLOBAL CAMS, page 4-9). To view global cam channels, press F5
(View Global Cam Summary) (see page 5-47).
Selecting a Cam Channel
To make cam settings, you must first select a cam channel. To do so, perform the following
steps:
1. Select CAM SWITCH on the Tool Program Menu. The Cam Channel Menu displays.
ENTER YOUR PASSWORD
USE THE KEYPAD TO ENTER NUMBERS.
USE THE UP/DOWN CURSOR KEYS TO
INCREASE/DECREASE. PRESS ENTER
WHEN DONE. PRESS RESET TO CANCEL.
60599
If this display appears, you need to enter the general password to program cam settings.
Security access is set in Initialization mode (see SECURITY ACCESS, page 4-22).
Figure 5-44. “Enter Your Password” Screen
2. Select a cam channel to program. The Cam Channel Program Type Menu, shown in
Figure 5-45, page 5-41, displays.
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Figure 5-45. Cam Channel Program Type Menu
Instructions for programming cam channels using each of the program types shown on the
Cam Channel Program Type Menu except Auto Advance are provided in the following
sections. Auto Advance is not available as a cam timing option for SmartPAC 2 Servo.
Making an ON/OFF Setting
The PROGRAM ON/OFF ANGLES item on the Cam Channel Program Type Menu enables
you to program the ram angle and position at which a selected cam channel turns on and off.
You can program up to four on/off sequences per stroke. To make a single on/off setting for a
selected cam channel, perform the following steps (to make multiple on/off settings, see
Setting Multiple ON/OFF Cycles, page 5-42):
1. Select PROGRAM ON/OFF ANGLES on the Cam Channel Program Type Menu. The
Cam Channel On/Off Program screen, shown in Figure 5-46, displays.
Cam On and Off
ram position
F1
F2
F3
Cam On and Off
angles
Highlighted arc
shows “dwell”
of cam On signal
F4
F5
F6
F7
F8
Figure 5-46. Cam Channel On/Off Program Screen
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2. Set the On angle on the ram angle clock, using the Left () and Right () cursor keys.
As you press the Left () cursor key, the On cursor moves counterclockwise around the
display, and the On angle value decreases. When you press the Right () cursor key, the
On cursor moves clockwise around the display, and the On angle value increases.
The precise On angle value is displayed in the window inside the clock display. The ram
position (in inches) at which the cam turns on is shown in the ON POS = field at the right
of the screen.
3. Set the Off angle on the ram angle clock, using the Up () and Down () cursor keys.
As you press the Up () cursor key, the Off cursor moves clockwise around the display,
and the Off angle increases. As you press the Down () cursor key, the Off cursor moves
counterclockwise around the display, and the Off angle decreases.
The precise Off angle value is displayed in the window inside the clock display. The ram
position (in inches) at which the cam turns off is shown in the OFF POS = field at the right
of the screen.
4. Press RESET when you are finished to return to the Cam Channel Program Type Menu.
Setting Multiple ON/OFF Cycles
SmartPAC 2 Servo enables you to set more than one On/Off event (or cycle) for selected cam
channels. You can program up to four On/Off events for a single channel and up to six
additional On/Offs for all channels. The six-cycle maximum applies to both 8-channel and
15-channel ProCamPAC. Additional On/Offs you set for global cam channels (see SET
GLOBAL CAMS, page 4-9) count toward the six-cycle maximum.
Table 5-2 gives examples of how you might use the extra ON/OFFs on an 8-channel
ProCamPAC.
Table 5-2. Additional On/Off Settings, 8-channel ProCamPAC: Examples
Ch Ch Ch Ch Ch Ch Ch Ch
1
2
3
4
5
6
7
8
Total
ON/
OFFs
Total
Extra
ON/
OFFs
1
1
1
1
1
1
1
1
8
0
1
2
2
1
1
1
2
1
11
3
1
2
2
2
2
2
2
1
14
6
4
4
1
1
1
1
1
1
14
6
To set more than one on/off cycle for a cam channel, do the following:
1. Make the first On/Off setting as instructed in Making an ON/OFF Setting, page 5-41.
Figure 5-47, page 5-43 shows the Cam Channel On/Off Program screen set for an On
angle of 30° and an Off angle of 50°. The ram On and Off positions are 6.998 in. and
6.341 in. Note the caption at the upper left of the screen indicating that Arc 1 is selected.
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-47. Cam Channel On/Off Program Screen: One On/Off Arc
2. Press F6 (Add a New Arc) on the Cam Channel On/Off Program screen to program a
second On/Off cycle. The arc you set in step 1 (i.e., Arc 1) turns dark gray. A new arc
appears as a green line at the zero (0) position, and the caption at the left of the screen
changes to SELECTED ARC–2.
NOTICE
A new arc always starts at 0°. If one of the arcs you want to program is located near 0°,
program it last. If you find that you have too many arcs at 0°, delete channel settings (see
page 5-46) and start over again.
3. Program the second arc. Figure 5-48 shows the Cam Channel On/Off Program screen
with Arc 2 programmed for an On Angle of 70° and an Off angle of 90°. The
corresponding ram On and Off positions are 5.660 in. and 5.003 in.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-48. Cam Channel On/Off Program Screen: Two On/Off Arcs
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4. Repeat steps 2 and 3 to add additional arcs. Figure 5-49 shows the Cam Channel On/Off
Program screen with a third arc programmed for an On angle of 110° and an Off angle of
130°. Ram On position is 4.323 in., ram Off position 3.666 in.
F1
Selected (active)
arc shown here
and colored green
on ram angle
clock diagram
F2
F3
F4
F5
F6
Inactive arcs
are colored
grey
F7
F8
Figure 5-49. Cam Channel On/Off Program Screen: Three On/Off Arcs
5. If you want to adjust On/Off settings for a previously programmed arc, press F7 (Select
Arc) one or more times until the highlighting for that arc turns green, then use the cursor
keys to change the On and/or Off angles.
NOTICE
To delete an On/Off arc for a multi-arc cam channel, you must delete all settings for the
channel (see page 5-46) and program the On/Off outputs again.
6. Press RESET when you have finished to return to the Cam Channel Program Type Menu.
Making a Timed Output Setting
NOTICE
MAXIMUM NUMBER OF TIMED CHANNELS PER TOOL
Each tool can have up to four Timed Output cam channels.
The PROGRAM TIMED OUTPUT item on the Cam Channel Program Type Menu enables
you to program the ram angle and position at which a selected cam channel turns On and the
time, or dwell, in milliseconds that the channel stays On.
A Timed Output setting is independent of press speed–with On/Off cam outputs, the On time
decreases with press speed–and is recommended for functions such as controlling air and
lubrication. This type of cam output also ensures that the channel will turn off after the
programmed time. With On/Off cam settings, the channel stays on if the press stops within
the On/Off window, potentially wasting air or lube.
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To set a Timed Output for a cam, do the following:
1. Select PROGRAM TIMED OUTPUT on the Cam Channel Program Type Menu. The
Cam Channel Timed Output Program screen, shown in Figure 5-50, displays.
Cam On
ram position
Cam On
angle
Cam On
duration
Figure 5-50. Cam Channel Timed Output Program Screen
2. Set the On angle on the ram angle clock, using the Left () and Right () cursor keys.
As you press the Left () cursor key, the On cursor moves counterclockwise around the
display, and the On angle value decreases. When you press the Right () cursor key, the
On cursor moves clockwise around the display, and the On angle value increases.
The precise On angle value is displayed next to the Angle caption in the window inside the
clock display. The corresponding ram position (in inches) is shown in the ON POS = field
at the right of the screen. In Figure 5-50 the On angle is set to 270°; the ram On position is
5.003 in.
3. Set the On time in milliseconds (maximum is 500 mS, or 0.5 seconds), using the Up ()
cursor key to increment the Time value displayed in the window and the Down () cursor
key to decrement the Time value. The Time value changes in increments of 10 mS. In
Figure 5-50, the On time is set to 50 mS.
4. Press RESET when you are finished to return to the Cam Channel Program Type Menu.
NOTICE
FOR APPLICATIONS REQUIRING MORE THAN 500 MILLISECONDS
If you have an application where an On time of more than 500 milliseconds is required, do
the following. Program one of the batch counters to a preset of “1,” set the Counter
Increment Angle to the desired On angle and the Output Mode to PULSE. Then program
the Pulse Time to the cam On time you want (e.g., 600 mS). See Setting Batch Counter
Output and Increment Modes, page 5-13.
Program Mode
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Setting DSV ON Channel Timing
NOTICE
The DSV ON output type setting is available only if you have wired the input check circuit inputs
#205 and #206 on TB102 on the SmartPAC 2 Servo board (see Wiring a Press-in-Motion Signal
(Optional), page 2-32). To activate this circuit, you must apply 12 to 250 V to these inputs when the
press is in motion.
The PROGRAM DSV ON item on the Cam Channel Program Type Menu enables you to set
the amount of time (in seconds) after the press stops that a DSV On cam channel remains on.
A DSV On cam channel turns on when the Dual Safety Valve is energized and the press starts
and turns off when the DSV is de-energized and the press stops. You set the DSV delay time
on the Cam Channel DSV On Program Screen, which is shown in Figure 5-51.
Figure 5-51. Cam Channel DSV On Program Screen
DSV On cam channel programming is useful for controlling conveyors and other accessories
that must operate for a short time after the press stops.
To set the DSV delay time, do the following:
1. Select PROGRAM DSV ON on the Cam Channel Program Type Menu. The Cam
Channel DSV On Program screen displays.
2. Increment or decrement the OFF DELAY TIME value (maximum is 254 seconds), using
the Up () or Down () cursor key.
3. Press RESET when you are done to return to the Cam Channel Program Type Menu.
Deleting Channel Settings
The DELETE CHANNEL SETTINGS item on the Cam Channel Program Type Menu
enables you to delete programmed settings for a selected cam channel. When you delete cam
channel settings, all programmed angles and times return to 0 (zero).
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To delete settings for a selected cam channel, do the following:
1. Select DELETE CHANNEL SETTINGS on the Cam Channel Program Type Menu. The
following window displays, asking you to confirm that you want to delete cam settings.
Figure 5-52. Cam Channel Deletion Confirmation Window
2. Press CLEAR to delete the channel. You are returned to the Cam Channel Menu.
Viewing the Cam Summary
Once cam channels have been programmed, you can view their settings on a summary screen
accessible from the Cam Channel Menu. To view this screen, do the following:
1. Press F6 (View Cam Summary) on the Cam Channel Menu. The Cam Summary screen,
shown in Figure 5-53, displays with the name, program type, and programmed settings
shown for each programmed cam channel. Global cams are not displayed on this screen
(see Viewing Global Cams, page 5-47).
Figure 5-53. Cam Summary Screen
Viewing Global Cams
Global cams, which are programmed in Initialization mode (see SET GLOBAL CAMS,
page 4-9), are cam channels that can be used with any tool set up on your SmartPAC 2 Servo.
Global cams can be programmed for any channel except channels 6, 7 and 8 and, once set,
cannot be programmed for individual tools. You cannot change global cam settings in
Program mode, but you can view them as you are programming other cams.
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To view global cams, do the following:
1. Press F5 (View Global Cam Summary) on the Cam Channel Menu. The Global Cam
Summary screen (see Figure 5-54) displays with the name, program type, and
programmed settings shown for each channel set as a global cam.
Figure 5-54. Global Cam Summary Screen
TOOL INFORMATION
(PROGRAM – GO TO THE TOOL MANAGER – select tool – F4-EDIT TOOL – TOOL INFORMATION)
NOTICE
• The Tool Information screen provides a convenient place to record information about the tool. It
does not control any aspect of press operation.
• This feature is not available if you have the optional PLC interface installed.
This item on the Tool Program Menu enables you to record information about the tool you are
programming that may be helpful to operators and setup personnel. You enter information on
the Tool Information screen, which is shown in Figure 5-55, page 5-49.
The Tool Information screen allows you to enter up to six parameters and up to two lines of
memo text. The names, units of measurement, and number of decimal places for the
parameters are set in Initialization mode (see TOOL INFORMATION, page 4-17).
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-55. Tool Information Screen
To enter tool information, do the following:
1. Select TOOL INFORMATION on the Tool Program Menu. The Tool Information screen
displays.
ENTER YOUR PASSWORD
USE THE KEYPAD TO ENTER NUMBERS.
USE THE UP/DOWN CURSOR KEYS TO
INCREASE/DECREASE. PRESS ENTER
WHEN DONE. PRESS RESET TO CANCEL.
60599
If this display appears, you need to enter the general password to program tool information
settings. Security access is set in Initialization mode (see SECURITY ACCESS,
page 4-22).
Figure 5-56. “Enter Your Password” Screen
2. Select a desired parameter. The Numeric Entry window (see Figure 5-3, page 5-3)
displays.
3. Key in the value you want, following the directions in the Numeric Entry window. For
Yes/No items, key in “0” for NO, “1” for YES. Press ENTER when you are finished. You
are returned to the Tool Information screen with your entry displayed in the field you
selected in step 2.
4. Repeat steps 2 and 3 to enter other parameters, as necessary.
5. To enter text into the memo box, press F5 for the first line, F6 for the second line. When
the Alphabetic Entry window (see Figure 5-10, page 5-9) displays, key in your entry,
following the directions in the window, and press F6. The window closes, and your entry
appears on the first or second line of the memo box.
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6. When you have finished entering tool information, press RESET to return to the Tool
Program Menu.
RAM POSITION
NOTICE
SET INITIALIZATION PARAMETERS BEFORE PROGRAMMING UPPER/LOWER LIMITS
Before you create settings for upper and lower limits in Program mode, be sure to set the Upper
Limit and Offset Value on the Linear Sensor Setup screen in Initialization mode (see page 4-14).
This item on the Tool Program Menu enables you to set upper and lower limits for your
magnetostrictive linear transducer. These settings are made on the Ram Position screen,
which is shown in Figure 5-57.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-57. Ram Position Screen
SmartPAC 2 Servo sets the Upper Limit you specify on this screen equal to 0° and the Lower
Limit to 180°. The vertical distance between Upper and Lower limits is divided into 180
equal parts to represent the angle range of downstroke (0° to 180°) and upstroke (180° to
360°/0°). If the ram passes the Lower Limit on the downstroke, SmartPAC 2 Servo holds the
angle at 180°. On the upstroke, the angle begins to increase only when the ram passes the
Lower Limit. Similarly, if the ram passes the Upper Limit on the upstroke, SmartPAC 2
Servo holds the angle at 0° until the ram moves past the Upper Limit on its downstroke.
It is extremely important to set limits for each tool precisely. If the ram returns to the Upper
Limit without reaching the Lower Limit or returns to its Lower Limit without reaching its
Upper Limit, SmartPAC 2 Servo generates a fault (see page 7-7), prohibiting the press from
further stroking until RESET is pressed. Although this message may display for other reasons
(e.g., a light curtain obstruction), it commonly occurs when the Lower Limit is set too low or
the Upper Limit too high.
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In a pendulum motion, the ram position at the top during clockwise movement is often not the
same as the top position during counter-clockwise movement. In such a situation, it is very
important to set the Upper Limit just below the lower of these two positions.
The STAGE MODE and CURVE TYPE fields should be changed only by advanced users and
only after contacting Wintriss Tech. Support.
To set upper and lower limits for the linear sensor, perform the following steps:
NOTICE
It is easier to program upper and lower limits for your transducer in Run mode. You simply Inch the
ram to the desired position and press F5 to set the Upper Limit or F6 to set the Lower Limit. See
RAM POSITION, page 6-22.
1. Select RAM POSITION on the Tool Program Menu. The Ram Position screen displays.
ENTER YOUR PASSWORD
USE THE KEYPAD TO ENTER NUMBERS.
USE THE UP/DOWN CURSOR KEYS TO
INCREASE/DECREASE. PRESS ENTER
WHEN DONE. PRESS RESET TO CANCEL.
60599
If this display appears, you need to enter the general password to program ram position
settings. Security access is set in Initialization mode (see SECURITY ACCESS,
page 4-22).
Figure 5-58. “Enter Your Password” Screen
2. Press F4 (Clear Limits) to clear the current Upper and Lower limits.
NOTICE
The settings you make for Upper Limit and Lower Limit can be any values within the
sensor’s range up to the maximum Upper Limit set in Initialization. For example, if your
sensor is 6 in. in length but you want a stroke of 2 in., you can set your Upper Limit to 4 in.
and Lower Limit to 2 in.
3. Set the Upper Limit value in one of the following ways:
• Switch to Run mode (see page 6-2 for instructions), Inch the ram to the Upper Limit for
the loaded tool, return to this screen, and press F5 (Set Upper Limit). The reading
reported by the linear sensor displays in the UPPER LIMIT field.
• Select UPPER LIMIT, and when the Numeric Entry window displays, key in the value
you want, using the numeric keypad or the Up () and Down () cursor keys, and
press ENTER. The value you specified displays in the UPPER LIMIT field.
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4. Set the Lower Limit value in the same manner:
• Switch to Run mode, Inch the ram to the Lower Limit for the loaded tool, return to this
screen, and press F6 (Set Lower Limit). The reading reported by the linear sensor
displays in the LOWER LIMIT field.
• Select LOWER LIMIT, key in the value you want in the Numeric Entry window, and
press ENTER. The value you specified displays in the LOWER LIMIT field.
5. Leave the STAGE TYPE field set to “SINGLE STAGE.” Advanced users who wish to
change the setting to “MULTI STAGE” should contact Wintriss Tech. Support.
6. Leave the CURVE TYPE field set to “SINE.” Advanced users who wish to change the
setting to one of the other options (i.e., “PROPORT,” “LOW CNT,” “MED CNT,” or
“HIGH CNT”) should contact Wintriss Tech. Support.
7. When you are finished, press RESET to return to the Tool Program Menu.
SENSOR ENABLE/DISABLE & STATUS (Optional)
[PROGRAM - SENSOR ENABLE/DISABLE & STATUS]
NOTICE
For help with this menu item, press the HELP key.
This item, which appears on the Main Program Menu only when DiProPAC is installed,
enables you to view the status of your die protection sensors, enable or disable all the sensors
shown on the screen, and turn a selected sensor On or Off. You perform these tasks on the
Sensor On/Off Status screen, which is shown in Figure 5-59.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 5-59. Sensor On/Off Status
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Viewing Sensor Status
To view the status of your sensors, do the following:
1. Select SENSOR ENABLE/DISABLE & STATUS on the Main Program Menu. The
Sensor On/Off Status screen displays with status settings for sensors 1 through 8
displayed. Sensors may have one of three status settings: OFF, ON or N/U (Not Used).
2. To view sensors 9 through 16 (if a 16-sensor DiProPAC is installed), press F4 (Next 8
Sensors). The F4 label changes to “Previous 8 Sensors.” To return to the display for
sensors 1 through 8, press F4 again.
3. Press RESET to return to the Main Program Menu.
NOTICE
When a tool is loaded, or when SmartPAC 2 is powered up, all sensors are turned on and
enabled.
Enabling or Disabling All Sensors
When you access the Sensor On/Off Status screen, a message is displayed on the second line
of the screen beneath the screen title indicating whether sensors are enabled or disabled. If the
message is SENSORS ENABLED, the F5 function key is labelled “Disable All Sensors.” If
the message is SENSORS DISABLED, F5 is labelled “Enable All Sensors.”
When the message is SENSORS ENABLED, SmartPAC 2 is communicating with all the
sensors that are programmed and turned on. When the message is SENSORS DISABLED,
SmartPAC 2 is not communicating with the sensors.
To enable or disable all sensors, do the following:
1. On the Sensor On/Off Status screen, press F5.
If the SENSORS DISABLED message is displayed, F5 is labelled “Enable All Sensors,”
and pressing F5 enables all the sensors.
If the SENSORS ENABLED message is displayed, F5 is labelled “Disable All Sensors,”
and pressing F5 disables all the sensors.
2. Press RESET to return to the Main Program Menu.
NOTICE
You can also enable or disable all sensors in Run mode. See DISABLE (ENABLE)
SENSORS, page 6-7.
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Turning a Sensor Off or On
To turn a selected sensor Off or On, do the following:
1. On the Sensor On/Off Status screen, highlight the sensor you want.
2. Press ENTER to toggle between the OFF and ON settings until the setting you want is
displayed.
3. Press RESET to return to the Main Program Menu.
NOTICE
• Sensors that show an N/U status have not been programmed. You cannot change their
status.
• If you turn a sensor Off on the Sensor On/Off Status screen, the sensor will turn on
when you reload the tool.
In Run mode, you can see which sensors are turned Off by viewing sensor status (see
page 6-14.) If you select a sensor in Run mode that is turned Off, SmartPAC notifies you with
the message shown in Figure 5-60.
Figure 5-60. “Sensor Turned Off” Message
5-54
Program Mode
Chapter 6. Run Mode
NOTICE
RAM POSITION SETTINGS MUST BE PROGRAMMED FOR ALL TOOLS
Make sure that Ram Position settings have been programmed (see page 5-50) for each tool you
load. If you do not set ram upper and lower limits, SmartPAC 2 Servo will use the default setting of
0.000 in., and the ram angle clock will display 0° irrespective of the vertical position of the ram.
This chapter shows you how to use the displays in SmartPAC 2 Run mode, which is the mode
you select to run the press. You learn how to adjust programmed settings for individual tools
(see Chapter 5), enable and disable sensors, and monitor tool settings and press operation.
Run mode displays are accessible via the Main Run Menu, which is shown in Figure 6-1.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-1. Main Run Menu
(Includes some options. Your display may look different.)
In Run mode, you can view and adjust settings only for the tool that is currently loaded. You
cannot create new tool numbers or modify settings for an unloaded tool as you can in Program
mode.
Some functions that you can perform in Run mode, such as loading a tool and adjusting sensor
and cam timing, are also provided in Program mode. Duplicating these functions allows
operators to perform essential tasks in Run mode without giving them access to Program
mode. Operators can be locked out of Program mode by turning the Program/Run key to
RUN and, then, removing the key.
To prevent unauthorized personnel from changing settings or loading tool numbers, you can
lock out choices on the Run menu or require a password for access. See SECURITY ACCESS,
page 4-22 for instructions.
Run Mode
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The following sections show you how to load a tool, adjust counter, die protection, cam, and
ram position settings for the tool, and view tool information and the error log. The chapter
also covers displaying multiple faults, sending e-mail messages, programming Hot keys, and
toggling between the two sets of Hot keys.
If you need help using the SmartPAC 2 keyboard to input information on Run mode displays,
refer to Chapter 3.
Entering and Exiting Run Mode
NOTICE
SELECT = HIGHLIGHT + ENTER
When this manual instructs you to select an item, you should highlight the item and press ENTER.
NOTICE
Load a tool number before entering Run mode (see next section).
Follow the instructions shown in Table 6-1 to enter and exit Run mode. See Figure 3-26,
page 3-21 for help in navigating in Run mode.
Table 6-1. Instructions for Entering and Exiting Run Mode
To Enter Run Mode
To Exit Run Mode
From Program mode:
To switch to Program mode:
Turn the Program/Run key to RUN.*
Turn the Program/Run key to PROG.*
* If you turn the key and nothing happens, press RESET repeatedly until SmartPAC 2 changes modes. Make sure SmartPAC
2 is in the Main (or top) menu for the mode it is in before you turn the Program/Run key. If SmartPAC 2 is not in a toplevel menu, press RESET repeatedly until the Main menu appears.
NOTICE
For help with a Run mode screen, press the HELP key when that screen is displayed.
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Loading a Tool
A tool must be loaded before SmartPAC 2 will allow the press to run. If you attempt to switch
from Initialization or Program mode to Run mode with no tool loaded, the error message
shown in Figure 6-2 displays.
Figure 6-2. No Tool Loaded Warning Window
To respond to this error, do the following:
1. Turn the Program/Run key to PROG.
2. On the Main Program Menu, press RESET to clear the message.
3. Load a tool (see Loading a Tool, page 5-5).
4. Turn the Program/Run key to RUN. SmartPAC 2 switches to Run mode.
Programming Hot Keys
Hot keys are function keys that you can program to take you directly from the Main Run
Menu to screens you use frequently. Once a Hot key is programmed, pressing that function
key displays the desired screen.
Example
You frequently need to adjust the timing for the cam channel that controls part blowoff. For
convenience, you set up a Hot key to take you directly from the Main Run Menu to the
adjustment screen for that cam channel.
All the function keys, F1 through F8, can be used as Hot keys, unless you have the bilingual
option, which uses F1 to change languages. Each function key can be programmed with two
Hot key assignments, providing a total of up to sixteen Hot keys. Hot keys can be identified
by the red frame around the label describing the key’s function (see Figure 6-3, page 6-4).
If you program one or more function keys with dual Hot key assignments, you move between
the two sets of assignments by selecting the TOGGLE HOT KEYS item on the Main Run
Menu (see TOGGLE HOT KEYS, page 6-28). When the first set of Hot keys is displayed, the
menu item caption is “TOGGLE HOT KEYS 1.” Selecting this item displays the second set
of Hot keys and changes the item caption to “TOGGLE HOT KEYS 2.”
NOTICE
If you add or remove a SmartPAC 2 option (e.g., DiProPAC, AutoSetPAC, etc.), the Hot keys you
have programmed previously may not navigate correctly. If one or more Hot keys no longer take
you to desired screens, delete and re-program those Hot keys.
Run Mode
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TOOL NUMBER
DEMO TOOL 2
DEMO PRESS
6160
PART CNTR
USE THE CURSOR KEYS
TO MAKE SELECTIONS.
PRESS ENTER TO
ACCESS SELECTION.
180
0
PRESS ANGLE 180
ENABLE SENSORS
COUNTERS
DIE PROTECTION
CAM SWITCH
TOOL INFORMATION
RAM POSITION
ERROR/EVENT LOG
LOAD NEW TOOL
MESSAGING
TOGGLE HOT KEYS 1
CAMBIE
AL ESPANOL
F1
VIEW SENSOR
SUMMARY
F2
VIEW GLOBAL
CAM SUMMARY
F3
ADJ SENSOR
PART EJECTION
F4
ADJUST CAM
SPRAY LUBE
F5
TONNAGE
PLAN VIEW
F6
VIEW RAM
POSITION
F7
SHOW
CAM TIMING
F8
Use F1 - F8 as Hot keys
If you have the Bilingual Option,
F1 is reserved for changing
language and cannot be used
as a Hot key.
Descriptive labels
for Hot keys
Figure 6-3. Main Run Menu, Showing Hot Keys Programmed
To program a Hot key, do the following:
1. From the Main Run Menu, access the screen you want.
NOTICE
For best results, start from the Main Run Menu and go as directly as possible to the
desired screen.
2. On the numeric keypad, press “2” and “0” simultaneously for a few seconds until the
window shown in Figure 6-4 displays. Labels for the currently selected set of
programmed Hot keys display to the left of the applicable function keys.
Figure 6-4. Hot Keys Instruction Window
3. To display the other set of Hot keys, press the Up () or Down () cursor.
4. To program a Hot key, press the desired function key. The instruction window closes and
SmartPAC 2 returns to the previous screen in the screen hierarchy.
If you select a function key that has already been programmed, that key will be linked to
the new screen.
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To delete a Hot key, do the following:
1. With the Hot Keys Instruction window (see Figure 6-4) displayed, press CLEAR, then the
function key associated with the Hot key you wish to delete.
Settings Locked, or Password Required
When a Run mode setting is locked, the screen shown in Figure 6-5 displays if the
PASSWORD REQUIRED access type has been set for that item on the Security Access Menu
in Initialization (see SECURITY ACCESS, page 4-22).
ENTER YOUR PASSWORD
USE THE KEYPAD TO ENTER NUMBERS.
USE THE UP/DOWN CURSOR KEYS TO
INCREASE/DECREASE. PRESS ENTER
WHEN DONE. PRESS RESET TO CANCEL.
60599
If this display appears, you need to enter the general password to access the desired item.
Security access is set in Initialization mode (see SECURITY ACCESS, page 4-22).
Figure 6-5. “Enter Your Password” Screen
When you enter the password, you are given access to the item.
When a Run mode item is set to PROGRAM MODE ONLY, NO CHANGES ALLOWED,
ALLOW RECALC ONLY, or NO RECALC/ADJUST, you are prevented from gaining
access to that item. No message displays to indicate that the setting is locked, but when you
press ENTER to access the item or press the cursor keys to make an adjustment, nothing
happens. When the LOAD NEW TOOL item is locked out, that entry does not appear on the
Main Run Menu.
Displaying Multiple Faults
Whenever more than one fault occurs in response to a press condition, the message for the
first fault displays in a window on the Main Run Menu and the label “Display All Errors”
appears to the left of function key F8. To view the multiple errors, press F8. A large red
message window opens, as shown in Figure 6-6, page 6-6, with each fault listed in sequence
beneath the caption “ALL PENDING ERRORS.” To close the window, press RESET.
Run Mode
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-6. Display All Errors Message Window
Opening the Ram Angle Window
You can open a window displaying the ram angle at a magnification comparable to that on the
ram angle clock on the Main Run Menu for use on Run mode screens where a prominent ram
angle display is useful such as angle adjustment screens for cams and die protection sensors.
Simply press the decimal point (.) key when you are on the Main Run Menu. The ram angle
window opens in the upper right corner of the screen, as shown in Figure 6-7. To close the
window, press the decimal point key again.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-7. Ram Angle Window Displayed on Main Run Menu
The ram angle window can only be opened on the Main Run Menu. Once the window is
displayed, it carries over to other selected Run mode screens.
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DISABLE (ENABLE) SENSORS
(RUN – DISABLE [ENABLE] SENSORS)
NOTICE
DiProPAC has an optional “sensors disabled” output that turns on when the sensors are disabled.
See page 2-32 for details.
This item allows you to manually enable your sensors when they are disabled or disable your
sensors when they are enabled. When sensors are enabled, the message SENSORS
ENABLED is displayed at the left of the Status Box on the Main Run Menu, as shown in
Figure 6-8, and this item is captioned DISABLE SENSORS.
Sensor status message
toggles between Enabled
and Disabled depending on
Run menu selection
Figure 6-8. Main Run Menu with SENSORS ENABLED and SENSOR DISABLED Displays
When sensors are disabled, the message SENSORS DISABLED flashes in red at the left of
the Status Box, and the item is captioned ENABLE SENSORS.
To disable or enable sensors, do the following:
1. Press ENTER with the highlight bar on the DISABLE SENSORS or ENABLE SENSORS
item on the Main Run Menu.
If you are enabling sensors, the message at the left of the Status Box changes from
SENSORS DISABLED to SENSORS ENABLED.
If you are disabling sensors, the window shown in Figure 6-9 displays.
Figure 6-9. Disable Sensors Confirmation Message
Run Mode
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2. Press the 5 key to confirm that you want to disable the sensors. The message at the left of
the Status Box changes from SENSORS ENABLED to SENSORS DISABLED, which
flashes in red.
You can manually enable or disable sensors no matter which setting (i.e., Manual, Auto by
Tool, or Auto by Sensor) is selected for Sensor Enable Mode in Initialization (see Selecting
Sensor Enable Mode, page 4-13). If either of the Auto Enable options is selected, you should
refer to Setting the “Auto Enable by Tool” Counter Value, page 5-21 or Setting the “Auto
Enable by Sensor” Counter Value, page 5-24 to make the appropriate setting for the tool.
In order to protect the tool, sensors should always be enabled except during setup and
troubleshooting when they can be temporarily disabled. You can wire (see page 2-32) and
enable (see page 4-14) a setup mode circuit that allows you to run the press in Inch during
setup with green sensors disabled. When Setup Mode is active, the message SENSORS IN
SETUP MODE is displayed in the Status Box in place of the SENSORS ENABLED message.
NOTICE
If you temporarily disable sensors, be sure to re-enable them before you resume making parts.
COUNTERS
(RUN – COUNTERS)
NOTICE
For help with the Counters screen and screens accessible from it, press the HELP key when the
applicable screen is displayed.
This item allows you to make adjustments to counter settings made in Program mode.
Adjustments are entered on the Counters screen (see Figure 6-10, page 6-9), which displays
when you select the COUNTERS item on the Main Run Menu.
NOTICE
ARE YOU LOCKED OUT?
Access to items on the Counters screen may be limited to Program mode or may require a
password. The security access settings in Initialization mode determine when changes can be
made. See Table 4-6, page 4-23.
On this screen, you can change or reset the programmed strokes, good parts, batch and total
hits counters and presets if you have the appropriate security access (see Table 4-6,
page 4-23). For instructions on entering counter and preset values, see COUNTERS,
page 5-9.
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-10. Counters Screen
If you have set the CHANGE COUNTS parameter on the Security Access Menu in
Initialization to PROGRAM AND RUN MODES (see page 4-23), you can reset batch counts
to the values you have programmed for batch pre-loads (see Setting Batch Pre-Load Counts,
page 5-15). When the CHANGE COUNTS feature is enabled for Run mode, the label
RELOAD BATCH COUNTERS displays to the left of the F2 function key (see Figure 6-11),
and F2 becomes active. To reset batch counts to their pre-load values, simply press F2.
Pre-load values display in the Count field for the batches you have programmed with those
values.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-11. Counters Screen with “Reload Batch Counters” Function
When messages display indicating that counter presets have been reached, press RESET to
clear the message (see Counter Preset Reached Messages, page 7-2).
Run Mode
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NOTICE
When the Total Hits counter reaches its preset value, a flashing message, “Total Hits Preset,”
appears in the Status Box at the top of the screen. To clear this message, set the Total Hits preset
to zero (0), then reset this value to the desired quantity. See COUNTERS, page 5-9.
DIE PROTECTION (Optional)
(RUN – DIE PROTECTION)
CAUTION
Some Servo presses are capable of hitting the same part more than once at Bottom Dead Center
(BDC) before returning to the top of the stroke. You will have to note the angle ranges at which
repeated strokes occur. Any cams programmed within these ranges will actuate once for each hit.
Die protection ready signals programmed within these ranges will expect sensor actuation once for
each hit. If this is not feasible, please contact Wintriss Tech. Support to learn about new advanced
features.
Failure to comply with these instructions could result in property damage.
NOTICE
For help with the Die Protection Menu and the screens accessible from it, press the HELP key
when the applicable screen is displayed.
This item, which appears on the Main Run Menu only when DiProPAC 8 or DiProPAC 16 is
installed, allows you to adjust the Ready signal for green sensors and the stroke preset for
green special sensors. Adjustments are made via the Die Protection Menu (see Figure 6-12),
which displays when you select DIE PROTECTION on the Main Run Menu. You can also
view a summary of information for all your sensors and a graphical display of sensor status
from this menu.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-12. Die Protection Menu (Run Mode)
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NOTICE
ARE YOU LOCKED OUT?
Access to items on the Die Protection Menu may be limited to Program mode or may require a
password. The security access settings in Initialization mode determine when changes can be
made. See Table 4-6, page 4-23.
The DIE PROTECTION item is split into DIPROPAC 1-16 and DIPROPAC 17-32 entries
when DiProPAC 32 is an installed option (see Adjusting DiProPAC 32 Sensors, page 6-15).
To change programmed settings on the Die Protection Menu, you first select a sensor from the
list of sensors displayed. Sensors set to UNUSED in Program mode are not shown.
NOTICE
FOR MORE INFORMATION
For a detailed description of the different types of sensors available in SmartPAC 2 with die
protection, refer to Understanding Sensor Terminology, page 5-17. Refer to Programming Sensor
Settings, page 5-21 for detailed instructions on modifying sensors.
Adjusting the Ready Signal for Green Sensors
When you select a green, green quick check, or green constant sensor on the Die Protection
Menu, the Ready Signal Programming screen, shown in Figure 6-13, displays.
The functionality of this screen differs slightly from that of the Ready Signal Programming
screen in Program mode. When you run the press, the angles at which the selected sensor
turns on and off on each stroke are shown in the window labelled SENSOR at the right of the
screen, and the number of degrees that the sensor is on is represented graphically by a green
arc on the ram angle clock. These displays allow you to fine-tune the Ready signal settings
made in Program mode.
Actual sensor
ON and OFF
angles
Adjust
Ready signal
on the fly
F1
F2
F3
F4
F5
F6
Sensor actuation
shown in green
F7
F8
Figure 6-13. Ready Signal Programming Screen
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Another difference is that the On and Off cursors move around the ram angle clock more
slowly when you press the cursor keys, enabling you to set Ready On and Ready Off angles
more precisely.
The On/Off actuation angles displayed in the Sensor window are not updated on every stroke.
For green and green quick check sensors, SmartPAC 2 displays the earliest On and latest Off
angles for the current sequence of press strokes (until the F5 (Update the Sensor Arc) function
key is pressed), updating the display only when the sensor turns on before the previous earliest
On signal or turns off after the previous latest Off signal.
For green constant sensors, SmartPAC 2 displays the latest On and earliest Off angles,
updating the display only when the sensor turns on after the previous latest On angle and turns
off before the previous earliest Off angle.
EXAMPLE
If the On angle for a green quick check sensor fluctuates between 190° and 195° from stroke to
stroke, SmartPAC 2 continuously displays 190° as the sensor’s On value. However, if the On
angle changes to 189°, SmartPAC 2 displays the On angle as 189° on the next stroke.
To clear the actuation angles displayed for a sensor, press the F5 (Update the Sensor Arc)
function key. If the press is stopped, the Sensor window displays zeros. If the press is
running, SmartPAC 2 displays the actuation angles for the next stroke.
NOTICE
Pressing F5 will not properly update sensor actuations when you are using a mechanical sensor,
which vibrates constantly during the stroke. It is better to use an electronic sensor, which is not
prone to constant contact bounce.
Pressing F4 (Change Reference Angle) changes the reference angle used to determine
earliest/latest On and Off signals from 0°, the default, to 180°. Executing this function may be
necessary to correct On readings for green and green quick check sensors that actuate before
and stay actuated after TDC. When 0° is the reference angle, there can be no earliest On angle
for a sensor that turns on before and off after 0° since angles just before TDC (e.g., 330°) are
numerically greater than those just after TDC (e.g., 30°). You should press F4 whenever the
On/Off settings in the Sensor window do not match the start and end points of the green
actuation arc on the clock diagram.
To adjust the Ready signal for green sensors, do the following:
NOTICE
IF YOU DO NOT KNOW READY SIGNAL TIMING FOR GREEN SENSORS
If you are unsure of when the sensor turns on and off, program estimated settings in Program
mode, load the tool, and turn off the sensor, using the SENSOR ENABLE/DISABLE & STATUS
item on the Main Program Menu (see page 5-54). Turning the sensor off prevents nuisance stops
when you switch to Run mode.
Then, without reloading the tool, turn the Program/Run switch to RUN and perform the procedure
shown below. When you are finished adjusting settings in Run mode, go back to Program mode
and turn the sensor back on.
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1. On the Die Protection Menu, select the desired sensor. The Ready Signal Programming
screen displays.
NOTICE
If you have turned off the sensor in Program mode (see NOTICE above), a message
displays indicating that the sensor is turned off. Press ENTER to clear the message.
2. Run the press.
3. Observe the On and Off angles displayed in the Sensor window and the green actuation
arc shown on the ram angle clock.
NOTICE
To update the sensor’s On/Off readings, press F5 (Update the Sensor Arc).
To change the reference angle from 0° to 180°, press F4. The reference angle is used to
determine earliest and latest On/Off readings.
NOTICE
When you press F5, dashes ( — — ) will display in the ON and OFF fields in the Sensor
window just before the information updates.
4. Adjust the sensor’s Ready On and Ready Off angles based on the actual On and Off angle
readings, using the Left () and Right () cursor keys to move the On cursor and the
Up () and Down () cursor keys to move the Off cursor. See Setting the Ready Signal
for a Green Sensor, page 5-28 if you need help manipulating the On and Off cursors.
5. Press RESET to return to the Die Protection Menu.
Adjusting the Stroke Preset for Green Special Sensors
To adjust the green special sensor preset value for press strokes, do the following:
1. On the Die Protection Menu, select the desired sensor. The Green Special Sensor Stroke
Count screen displays. This screen is identical to the Green Special Sensor Stroke Count
screen in Program mode (see Figure 5-29, page 5-30) except that it displays additional
information in the Status box.
2. Increment or decrement the displayed stroke count value, using the Up () or Down ()
cursor key, until the value you want is shown.
3. Press RESET when you are finished to return to the Die Protection Menu.
Run Mode
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Viewing the Sensor Summary
(RUN – DIE PROTECTION – F6-VIEW SENSOR SUMMARY)
You can view a summary of your die protection sensors by pressing F6 (View Sensor
Summary). The screen that displays is identical to the Sensor Summary screen accessible in
Program mode (see Viewing the Sensor Summary, page 5-31) except that it displays additional
information in the Status box.
Viewing Sensor Status
(RUN – DIE PROTECTION – F7-SHOW SENSOR STATUS)
You can view the status of your sensors by pressing F7 (Show Sensor Status). When you do
so, the Sensor Status screen, shown in Figure 6-14, page 6-15, displays.
The Sensor Status screen shows the status of every sensor for a loaded tool. Sensor inputs are
identified by the numbers 1 through 8 (for 8-sensor DiProPAC) or 1 through 16 (for 16-sensor
DiProPAC). The type of sensor connected to each input is indicated by the following
abbreviations, which appear beneath the blocks representing the sensors.
• G = Green
• GQC = Green Quick Check
• GCON = Green Constant
• GS = Green Special (Number of required strokes is shown to the right of “GS”)
• RED = Red
• YEL = Yellow
• N/U = Not Used
If the sensor block is dark, the sensor is actuated. If it is white, the sensor is not actuated.
The Sensor Status screen is designed so that you can quickly check the status of all your
sensors and correct programming or wiring mistakes. When a sensor signals a fault, you can
use the display to see the status of all your sensors at the stroke angle at which the press
stopped.
When you select the screen with the press running, the actuation blocks for green sensors will
flash as they actuate once every stroke. (Due to the slow update rate of this screen, some
sensor actuations may be missed.) An actuation block for a green special sensor will flash
every preset number of strokes.
A red sensor actuation block is always actuated except when there is a sensor fault since it is
normally grounded. Actuation blocks for yellow sensors are only actuated during a fault
condition.
When the press is stopped, the actuation block shows the state of the sensor at that point in the
stroke. The actuation block for an unused sensor may display if a sensor has been connected
to that input by mistake. The Sensor Status screen shows any change in the state of an input
whether the input is being used or not.
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Black actuation block
indicates sensor is
grounded
TOOL NUMBER
FLANGE
White actuation block
indicates sensor is
ungrounded
PRESS #14
6160
PART CNTR 51635
TWO HAND CONT
PRESS SPEED 67
CAMBIE
AL ESPANOL
SENSOR STATUS
1
G
2
G
9
10
GS 5 YEL
3
RED
4
G
11
12
GCONS N/U
5
GCONS
13
N/U
6
G
7
GQC
14
N/U
15
N/U
8
G
16
N/U
PRESS THE RESET KEY WHEN DONE.
Number indicates
maximum number
of strokes allowed
for Green Special
Color indicates
type of sensor
(green, red, yellow)
RETURN TO
MAIN MENU
X indicates
sensor is
turned off
Gray indicates not-used
(unprogrammed) sensors
Figure 6-14. Sensor Status Screen
Adjusting DiProPAC 32 Sensors
You access DiProPAC 32 sensors on the SmartPAC 2 Servo Main Run Menu via the
DIPROPAC 1-16 and DIPROPAC 17-32 items, as shown in Figure 6-15.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-15. Main Run Menu with DIPROPAC 1-16 and DIPROPAC 17-32 Items Shown
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When you select the DIPROPAC 1-16 item, the Die Protection Sensor menu for sensors 1-16
displays. On this menu, you can adjust settings for green and green special sensors as
described in Adjusting the Ready Signal for Green Sensors, page 6-11 and Adjusting the
Stroke Preset for Green Special Sensors, page 6-13.
When you select DIPROPAC 17-32, the Die Protection Sensor menu for sensors 17-32
displays (see Figure 6-16, which shows the sensors that are used as examples in Chapter 5).
F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-16. Die Protection Sensor Menu for Sensors 17-32
When programmed as green sensors, sensors 17-32 cannot be adjusted in Run mode since
they share their Ready signals or stroke counts with one of the first sixteen sensors. You can,
however, adjust the Ready signal or stroke count for the sensor on which settings are based.
Adjustments are automatically duplicated in all linked sensors 17-32.
The Die Protection Sensor menu for sensors 17-32 allows you to view the Sensory Summary
and Sensor Status screens (see page 6-14) for those sixteen sensors.
When you select a sensor programmed as green, green quick check, or green constant on the
Die Protection Menu for Sensors 17-32, the Run mode Ready Signal Programming screen
displays with a message, located underneath the status box, indicating that you cannot change
Ready signal timing for this sensor (see Figure 6-17, page 6-17). If you want to change
timing, you must change the timing for the sensor in the group of sensors 1-16 whose Ready
signal is being used for the sensor you are programming.
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-17. Ready Signal Programming Screen, Run Mode
When you select a sensor programmed as green special on the Die Protection Sensor Menu for
Sensors 17-32, the Green Special Sensor Stroke Count screen displays with a message,
located beneath the stroke preset, indicating that you cannot change the green special stroke
count for this sensor (see Figure 6-18). If you want to adjust the stroke count, you must make
this change for the green special sensor in the group of sensors 1-16 whose stroke count is
being used for the sensor you are programming.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-18. Green Special Sensor Stroke Count Screen, Run Mode
Run Mode
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CAM SWITCH
(RUN – CAM SWITCH)
!
DANGER
PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE
Use SmartPAC 2 Servo’s programmable cam switch to control auxiliary functions only. The
SmartPAC 2 programmable cam capability should never be used to provide timing signals for any
safety use including muting of light curtains.
Failure to comply with these instructions will result in death or serious injury.
CAUTION
Some Servo presses are capable of hitting the same part more than once at Bottom Dead Center
(BDC) before returning to the top of the stroke. You will have to note the angle ranges at which
repeated strokes occur. Any cams programmed within these ranges will actuate once for each hit.
Die protection ready signals programmed within these ranges will expect sensor actuation once for
each hit. If this is not feasible, please contact Wintriss Tech. Support to learn about new advanced
features.
Failure to comply with these instructions could result in property damage.
NOTICE
For help with the Cam Switch Menu and the screens accessible from it, press the HELP key when
the applicable screen is displayed.
This item enables you to adjust timing for each programmed cam channel. Adjustments are
made via the Cam Switch Menu (see Figure 6-19), which displays when you select CAM
SWITCH.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-19. Cam Switch Menu
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The Cam Switch Menu displays a list of the cam channels that have been set up in Program
mode. Up to 8 channels may be displayed for standard ProCamPAC, as many as 15 channels
if you have installed the ProCamPAC 15 option. If you have assigned names to your cam
channels in Initialization mode, those names will be displayed. Channels programmed as
Global cams are not shown (see SET GLOBAL CAMS, page 4-9).
To adjust cam timings for the loaded tool, do the following:
1. On the Cam Switch Menu, select the channel you want to adjust. The Cam Channel
Program screen appropriate to the program type of the selected cam channel displays.
NOTICE
ARE YOU LOCKED OUT?
Access to items on this screen may be limited to Program mode or may require a
password. The security access settings in Initialization mode determine when changes
can be made. See Table 4-6, page 4-23.
2. Adjust cam timings for the selected channel, following the instructions in the following
sections in Chapter 5:
• Making an ON/OFF Setting, page 5-41
• Setting Multiple ON/OFF Cycles, page 5-42
• Making a Timed Output Setting, page 5-44
• Setting DSV ON Channel Timing, page 5-46
3. When you are finished, press RESET to return to the Cam Switch Menu.
Viewing Cam Timing
(RUN – CAM SWITCH – F7-SHOW CAM TIMING)
You can view a real-time graphic display of the timing settings for your cams by pressing the
F7 (Show Cam Timing) function key. The screen that displays when you press F7 is shown in
Figure 6-20, page 6-20.
Cam channels are displayed by number on the Y-axis. Only eight channels can be displayed
at a time, so if a 15-channel ProCamPAC is installed, you must press ENTER to display
channels 9 through 15. The X-axis displays the ram angle (from 0° to 360°) at which channels
turn on and off.
Channel On/Off timing is shown as a blue horizontal bar, the end points of which, when read
against the ram angle “ruler” on the X-axis, specify on and off settings for that channel.
Channels with Timed outputs are shown in pink characters beginning with the letter “T,” the
position of which, when viewed against the ram angle “ruler,” indicates the On angle,
followed by a number (e.g., 50), which indicates the channel’s On time in milliseconds.
The Cam Timing screen is updated once every second.
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Channel 5:
ON/OFF output
(dark blue)
Channel 6:
Timed output
(pink)
Figure 6-20. Cam Timing Screen
Viewing the Global Cam Summary
(RUN – CAM SWITCH – F5-VIEW GLOBAL CAM SUMMARY)
You can view a summary of the Global cams by pressing F5 (View Global Cam Summary).
The screen that displays is identical to the Global Cam Summary screen accessible in Program
mode (see Viewing Global Cams, page 5-47) except that it displays additional information in
the Status box.
Viewing the Cam Summary
(RUN – CAM SWITCH – F6-VIEW CAM SUMMARY)
You can view a summary of the other cams by pressing F6 (View Cam Summary). The
screen that displays is identical to the Cam Summary screen accessible in Program mode (see
Viewing the Cam Summary, page 5-47) except that it displays additional information in the
Status box.
TOOL INFORMATION
(RUN – TOOL INFORMATION)
NOTICE
IF INFO CENTER IS INSTALLED
If you have ordered Info Center as an installed option, the TOOL INFORMATION item will not
appear on the Main Run Menu. Instead, INFO CENTER will be displayed. Documentation of the
Info Center option is available at
www.smartpac2.com/SmartView/InfoCenterSetupHelp.htm
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NOTICE
• The Tool Information screen provides a convenient place to record information about the tool. It
does not control any aspect of press operation.
• This feature is not available if you have the optional PLC interface installed.
NOTICE
For help with the Tool Information screen, press the HELP key when the screen is displayed.
This item enables you to change information about the loaded tool that was entered in
Program mode (see TOOL INFORMATION, page 5-48). Adjustments are made on the Tool
Number Information screen, which is shown in Figure 6-21.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-21. Tool Number Information Screen
To change tool information, do the following:
1. Select TOOL INFORMATION on the Main Run Menu. The Tool Number Information
screen displays.
NOTICE
ARE YOU LOCKED OUT?
Access to items on this screen may be limited to Program mode or may require a
password. The security access settings in Initialization mode determine when changes
can be made. See Table 4-6, page 4-23.
2. Select a parameter you want to change. The Numeric Entry window (see Figure 5-3,
page 5-3) displays.
Run Mode
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3. Key in a new value, following the directions in the Numeric Entry window. For Yes/No
items, key in “0” for No, “1” for Yes. Press ENTER when you are finished. You are
returned to the Tool Number Information screen with your change displayed in the field
you selected in step 2.
4. Repeat steps 2 and 3 to change other parameters, as necessary.
5. To edit text in the memo box, press F4 for the first line, F5 for the second line. When the
Alphabetic Entry window (Figure 5-10, page 5-9) displays, key in your edits, following
the directions in the window, and press F6. The window closes, and your changes appear
on the memo box line you selected.
6. When you have finished changing tool information, press RESET to return to the Main
Run Menu.
RAM POSITION
(RUN–RAM POSITION)
NOTICE
SET INITIALIZATION PARAMETERS BEFORE SETTING UPPER/LOWER LIMITS
Before you create or adjust settings for upper and lower limits in Run mode, be sure to set the
maximum Upper Limit and Offset Value on the Linear Sensor screen in Initialization mode (see
page 4-14).
This item allows you to adjust programmed settings (see RAM POSITION, page 5-50) for
upper and lower ram position limits and also to program ram position settings. You perform
these actions on the Ram Position screen, which is shown in Figure 6-22.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-22. Ram Position Screen
To adjust or create upper and lower limits, perform the following steps:
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1. Select RAM POSITION on the Main Run Menu. The Ram Position screen displays.
NOTICE
ARE YOU LOCKED OUT?
Access to items on this screen may be limited to Program mode or may require a
password. The security access settings in Initialization mode determine when changes
can be made. See Table 4-6, page 4-23.
2. Adjust/set the Upper Limit value in one of the following ways:
• Inch the press to the desired position, and press F5 (Set Upper Limit). The reading
reported by the linear sensor displays in the UPPER LIMIT field.
• Select UPPER LIMIT, key in the value you want in the Numeric Entry window, or use
the Up () or Down () cursor key to increment or decrement the Upper Limit setting,
and press ENTER. The value you specified displays in the UPPER LIMIT field.
3. Adjust/set the Lower Limit value in the same manner:
• Inch the press to the desired position, and press F6 (Set Lower Limit). The reading
reported by the linear sensor displays in the LOWER LIMIT field.
• Select LOWER LIMIT, key in the value you want in the Numeric Entry window, or use
the Up () or Down () cursor key to increment or decrement the Lower Limit setting,
and press ENTER. The value you specified displays in the LOWER LIMIT field.
4. Press RESET when you are done to return to the Main Run Menu.
ERROR/EVENT LOG
(RUN – ERROR LOG)
NOTICE
For HELP with the Error/Event Log, press the HELP key when the screen is displayed.
This item enables you to view a list, called the Error/Event Log (see Figure 6-23, page 6-24),
that displays in reverse chronological order the 100 most recent errors or events that have
occurred at the press or within SmartPAC 2 Servo.
The Error/Event Log is useful as a troubleshooting aid. Each time the press is stopped due to
a fault, the log records the error message, which gives the reason for the stop, and the stroke
count and ram angle at which the stop occurred. When a new tool is loaded, the log displays
the tool number. If SmartPAC 2 is connected to a computer network and e-mail is enabled,
the log also shows messages sent by SmartPAC 2. When SmartPAC 2 is networked, you can
send the Error/Event Log to Wintriss Tech. Support (see MESSAGING, page 6-26). Error
messages displayed on the Error/Event Log are documented in Chapter 7.
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-23. Error/Event Log
To view the Error/Event Log, do the following:
1. Select ERROR/EVENT LOG on the Main Run Menu to display the Error/Event Log.
2. Use the cursor keys to scroll through the errors and events. When an error is selected, the
full text of the error message is displayed in the blue window at the bottom of the screen.
LOAD NEW TOOL
(RUN – LOAD NEW TOOL)
!
DANGER
ANCILLARY EQUIPMENT MAY OPERATE WHEN TOOL IS LOADED
Ensure that all personnel stand clear when you load a tool.
Failure to comply with these instructions will result in death or serious injury.
NOTICE
“LOAD NEW TOOL” does not appear on the Main Run Menu if LOAD TOOL # has been set to
PROGRAM MODE ONLY on the Security Access Menu in Initialization mode. See SECURITY
ACCESS, page 4-22.
NOTICE
For help with the Tool Manager screen, which displays which you select the LOAD NEW TOOL
item, press the HELP key when the screen appears.
This item enables you to load a new tool when the press is stopped. (You cannot load a new
tool when the press is running. If you attempt to do so, SmartPAC displays an error message,
indicating that the press must be stopped before a tool can be loaded.) When you select
LOAD NEW TOOL, the Tool Manager screen, shown in Figure 6-24, page 6-25, displays.
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-24. Tool Manager Screen
Follow these steps to load a new tool:
1. Select LOAD NEW TOOL from the Main Run Menu. The Tool Manager screen displays.
NOTICE
ARE YOU LOCKED OUT?
Loading a new tool number may be limited to Program mode or may require a password.
The security access settings in Initialization mode determine when a tool can be loaded.
See Table 4-6, page 4-23.
2. Highlight the tool you want and press F5 (Load Tool). The warning window shown in
Figure 6-25 displays.
Figure 6-25. Load Tool Warning Window
3. Press ENTER. A message displays, indicating that the tool you selected is being loaded,
then you are returned to the Main Run Menu with the tool you loaded shown in the Status
Box.
NOTICE
If an error message displays, go to Chapter 7 and follow the instructions for correcting the
problem. If the error is not covered in Chapter 7, or you cannot fix the problem, call
Wintriss Tech. Support.
Run Mode
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MESSAGING
(RUN – MESSAGING)
NOTICE
For help with the MESSAGING item, press the HELP key when the Messaging screen is
displayed.
This item, which appears on the Main Run Menu only when e-mail has been enabled in
Initialization (see E-MAIL FUNCTION, page 4-31), allows you to send e-mail messages to
recipients accessible via your SmartPAC 2 Servo computer network. Before you can use the
e-mail messaging function, you must set up the e-mail recipients and messages using the
SmartView remote viewing utility (see Appendix D).
To send an e-mail message, using the Messaging function, do the following:
1. Select MESSAGING on the Main Run Menu. A screen displays similar to the one shown
in Figure 6-26, which lists the recipients you have set up using SmartView.
F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-26. Messaging Screen: List of Recipients
2. Highlight the message recipient, using the cursor keys, then press F3 (Select Recipient).
The recipient’s name displays in the “To:” field at the top of the screen.
3. To add other recipients, repeat step 2.
4. Press F4 (Select Message) to display a list of messages, as shown in Figure 6-27,
page 6-27.
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F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-27. Messaging Screen: List of Messages
5. Highlight the message you want, using the cursor keys, then press F4 (Select Message)
again to select the message. The message name displays in the “Message:” field at the top
of the screen.
6. Press F5 (Send Message and Exit) to send the message. You are returned to the Main Run
Menu.
Sending E-mail to Wintriss Technical Support
If you select “Wintriss Technical Support” as your recipient, and “Error Log Files” as your
message, you can send an e-mail to Wintriss Tech. Support that includes error logs, a list of
installed options, and other useful information. An example is shown in Figure 6-28.
Figure 6-28. Sample E-mail to Wintriss Tech. Support
Run Mode
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SmartPAC 2 Servo User Manual
TOGGLE HOT KEYS
(RUN – TOGGLE HOT KEYS)
This item enables you to switch between the two sets of Hot keys available in SmartPAC 2. If
you select this item when TOGGLE HOT KEYS 1 is the caption, the second set of Hot Keys
displays; when you select TOGGLE HOT KEYS 2, the first set of Hot Keys appears (see
Figure 6-29). For more information about programming and using Hot keys, see
Programming Hot Keys, page 6-3.
F1
F1
F2
F2
F3
F3
F4
F4
F5
F5
F6
F6
F7
F7
F8
F8
Figure 6-29. Toggle Hot Keys 1 and 2 Menu Items
6-28
Run Mode
Chapter 7. Fault Messages
NOTICE
IMPORTANT INFORMATION TO PROVIDE WHEN CALLING WINTRISS TECH. SUPPORT
When you contact Wintriss Controls for technical assistance, be ready to provide the following
information to expedite a resolution to the problem: product name (e.g. SmartPAC 2 Servo);
installed options (e.g. DiProPAC, AutoSetPAC, etc.); and firmware version number (e.g., Vs. 2.00).
You can determine the last two items by accessing the Installed Options screen in Initialization
mode (see page 4-5).
NOTICE
RAM POSITION SETTINGS MUST BE PROGRAMMED FOR ALL TOOLS
Make sure that Ram Position settings have been programmed (see page 5-50) for each tool you
load. If you do not set ram upper and lower limits, SmartPAC 2 Servo will use the default setting of
0.000 in., and the ram angle clock will display 0° irrespective of the vertical position of the ram.
This chapter documents the fault messages that display on the SmartPAC 2 LCD or in the
Error/Event Log, providing a brief explanation of each message and a remedy for correcting
the problem.
Responding to Fault Messages
When an error occurs, a red message window like the one shown in Figure 7-1 displays,
indicating the type of error and providing a brief explanation.
Figure 7-1. Error Code Window
If the press stops because one of the counter presets has been reached, a yellow message
window like the one shown in Figure 7-2 displays.
Figure 7-2. Counter Preset Message Window
When an error message displays, correct the malfunction or other problem, consulting the
Problem and Remedy descriptions for the appropriate error message in the sections that
follow. When the problem has been corrected, press the RESET key (or Remote Reset
Fault Messages
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SmartPAC 2 Servo User Manual
Button, if installed) to clear the message. If the problem has been solved, you will be able to
run the press. Otherwise, you will get the fault message again.
If the problem persists, contact Wintriss Tech. Support. Do not attempt to run the press before
correcting the problem.
In the following sections, messages are grouped in five categories:
• Messages that display when a counter preset is reached
• Messages that display for equipment problems
• Messages that display for programming problems
• Messages that display when a sensor signals a fault
• Miscellaneous fault messages
Counter Preset Reached Messages
“Good parts counter preset reached”
Explanation:
Remedy:
The value set for the parts counter has been reached. The press should
stop at top dead center.
Press RESET to clear the message. If your part run is complete, you need
to change tooling, material, etc. before you re-start the press.
NOTICE
When this message appears, the good parts count is automatically reset to 0.
“Strokes counter preset reached”
Explanation:
Remedy:
The value set for the strokes counter has been reached. The press should
stop at top dead center.
Press RESET to clear the message. If your part run is complete, you need
to change tooling, material, etc. before you re-start the press.
NOTICE
When this message appears, the strokes count is automatically reset to 0.
“Batch # counter preset reached”
Explanation:
Remedy:
7-2
The value set for one of the three batch counters when the output type is
set to TOP STOP has been reached. The press should stop at top dead
center. See Setting Batch Counter Output and Increment Modes,
page 5-13.
Press RESET to clear the message.
Fault Messages
SmartPAC 2 Servo User Manual
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NOTICE
When this message appears, the corresponding batch count is automatically reset to 0.
Messages for Equipment Problems
The following messages indicate problems with the way the press is running and internal
problems with SmartPAC 2.
“Position sensor incorrect”
Explanation:
Remedy:
The POSITION SENSOR setting has been enabled in Initialization (see
page 4-3). SmartPAC 2 Servo does not use a position sensor. The
POSITION SENSOR item should be set to DISABLED.
Change the POSITION SENSOR setting to DISABLED.
E-Stop errors
Explanation:
If the word “ESTOP” appears in a message, one or both of the emergency
stop relay circuits are not working satisfactorily and may be defective.
Remedy:
Check both stop relay circuits. To reset SmartPAC 2, turn the unit off,
then on again. (You cannot use the RESET key to reset this error.) If the
error recurs, contact Wintriss Tech. Support.
“Inboard ram test failure”
Explanation:
Remedy:
Something is wrong with the SmartPAC 2 main processor board. The
board may need to be serviced or replaced.
Try turning the power off, then on again. (You cannot use the RESET key
to reset this error.) If the message continues to appear, contact Wintriss
Tech. Support for assistance or replacement of the board.
Messages for Programming Problems
These messages indicate that there is a problem with the tool, the tool is not properly loaded,
or there is an internal problem with SmartPAC 2.
“No tool number has been loaded”
Explanation:
You are attempting to access Run mode without a tool being loaded. A
tool must be loaded before you can enter Run mode.
Remedy:
Turn the Program/Run key to PROG to access Program mode, then load
the appropriate tool, and turn the Program/Run key back to RUN.
Fault Messages
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“Tool number table checksum error”
Explanation:
The programming for the loaded tool has become corrupted.
This error can occur when SmartPAC 2 has been turned off while you are
in the middle of programming a setup, or when you have not properly
exited (i.e., by pressing RESET) from a Program or Run menu.
The error can also occur when you upgrade SmartPAC 2. Sometimes the
information in the older firmware does not synchronize properly with the
information in the new firmware. Settings can also be damaged due to an
internal SmartPAC 2 malfunction.
SmartPAC 2 creates a “checksum” for every tool to check that the tool
settings stored in memory are the same as the settings that are loaded with
the tool. The checksum value calculated when tool settings are stored in
memory must be the same as the value calculated when the settings are
loaded.
Remedy:
Access Program mode, and double-check the tool settings. If settings are
correct, reload the tool.
If the error was caused because the system was turned off while in
Program or Run modes, perform these steps:
1. Press the RESET key to clear the fault message.
2. Access Program mode, and select GO TO THE TOOL MANAGER.
3. On the Tool Manager screen, highlight the tool, and press F4 (Edit
Tool).
4. On the Tool Program Menu, select CAM SWITCH.
5. Press RESET. SmartPAC 2 will create a new checksum for the tool.
6. Select the tool again, access the Tool Program Menu, and select CAM
SWITCH. Verify that all settings are correct.
7. Reload the tool. You should no longer get this fault message.
If the problem is due to a system malfunction, the tool settings will have to
be created again from scratch. If this happens more than once, contact
Wintriss Tech. Support for assistance.
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Fault Messages
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Messages for Sensor Faults
“Green sensor missed”
Explanation:
Remedy:
A green or green quick check sensor did not turn on during the Ready
signal nor within 50 milliseconds after the end of the Ready signal. No
stroke angle is displayed for this error since the sensor never turned on.
Check for the malfunction that the sensor was supposed to detect (part
ejection problem, misfeed, transfer problem, etc.). If a malfunction is not
the cause, check to be sure that the Ready signal is set properly for this
sensor. Check that a sensor is actually plugged into this input on the DSI
2. If no sensor is connected to a sensor input, that input must be set to
UNUSED. Check connections between sensors and the controller.
“Green sensor actuated late”
Explanation:
A green or green quick check sensor turned on within 50 milliseconds
after the end of the Ready signal.
If a green or green quick check sensor does not come on during its Ready
signal, SmartPAC 2 continues to look for the sensor signal. If it sees the
sensor come on within 50 milliseconds after the Ready signal ends, this
message displays. The angle at which the sensor turned on is shown in the
message.
Remedy:
Check for the malfunction the sensor was supposed to detect (like a part
ejection problem or misfeed, etc.). Check that the Ready signal is set
properly, and adjust if necessary.
“Green sensor failure”
Explanation:
A green or green constant sensor has stayed on from the end of one Ready
signal to the beginning of the Ready signal for the next stroke. No stroke
angle is shown with this fault.
Remedy:
Check for a shorted sensor. Make sure the Ready signal has been set
correctly. Check to see if a press or equipment malfunction is causing the
sensor to stay on–for instance, a part wedged against a sensor or a pinched
wire.
Fault Messages
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“Green constant fault”
Explanation:
Remedy:
A green constant sensor turned off during its Ready signal. Green
constant sensors must stay on throughout the Ready signal. The angle at
which the sensor turned off is displayed.
Check for the malfunction that the sensor was supposed to detect.
If no malfunction has occurred, check to make sure that the Ready signal
is set properly. Remember, for green constant sensors, the Ready signal
must be a little shorter than the sensor’s actuation angle. Check that a
sensor is actually plugged into this input. Check connections between the
DSI 2 and the controller.
“Green quick check sensor actuated outside ready”
Explanation:
A green quick check sensor actuated or stayed on outside the Ready
signal. The stroke angle at which the sensor was first detected on outside
the Ready signal is shown.
Remedy:
Check for the malfunction the sensor was supposed to detect (part ejection
problem, misfeed, etc.). Check for a part wedged against the sensor, a
shorted sensor, a pinched wire, or other cause that would keep the sensor
on or cause it to go on outside its Ready signal. Make sure the Ready
signal is set correctly.
“Green special fault”
Explanation:
A green special sensor did not actuate (i.e., there was no contact closure to
ground) within the maximum number of strokes set in Program mode.
Remedy:
Check for the press or equipment malfunction that the sensor was
supposed to detect. Check for any cause that would keep the sensor from
going on. Make sure the maximum stroke count is set correctly, especially
that it is not set too low. See Setting the Counter Value for a Green
Special Sensor, page 5-30.
Fault message for yellow sensors “This N/O sensor is grounded”
Explanation:
A yellow sensor turned on (i.e., there was a contact closure to ground).
When this message is displayed, the angle at which the condition was
detected is shown.
Remedy:
Check for the press or equipment malfunction that the sensor was
supposed to detect. If no malfunction has occurred, check for a shorted
sensor or pinched wire.
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Fault Messages
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Fault message for red sensors “This N/C sensor is open”
Explanation:
A red sensor has actuated (i.e., is open to ground). When this message is
displayed, the angle at which the condition was detected is shown.
Remedy:
Check for the press or equipment malfunction that the sensor was
supposed to detect. If no malfunction has occurred, check for a problem
with the sensor. Check for loose or detached wiring at the DSI 2 or
controller. Check for a severed wire from the sensor to the DSI 2 or
controller.
Miscellaneous Fault Messages
“The press cycle was interrupted before upper or lower limits were reached”
Explanation:
The ram is returning to its Upper Limit without having reached its Lower
Limit or returning to its Lower Limit without having reached its Upper
Limit.
Remedy:
Check to see whether the upstroke or downstroke was prevented by a light
curtain interruption, the ram hitting something, etc. Verify that the Lower
Limit set for Ram Position (see page 6-22) is a little higher than BDC, and
adjust, if necessary. Also verify that the ram Upper Limit is set a little
lower than TDC, and adjust, if necessary.
NOTICE
When the ram position at the top during clockwise movement is not the same as the top
position during counter-clockwise movement, as is often the case in a pendulum motion,
make sure to set the Upper Limit just below the lower of these two “top” positions.
“One of the sensor auto enable counters is greater than 99”
Explanation:
Remedy:
Fault Messages
Normally, this fault will never occur since SmartPAC 2 does not let you
enter a value greater than 99. However, this message could display if
there is an internal problem with SmartPAC 2.
First press RESET. If the message reappears, contact Wintriss Tech.
Support.
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“Loss of Communication at Address X”
Explanation:
SmartPAC 2 is unable to communicate with the optional module identified
by “X” in the message (see Table 7-1).
Remedy:
Check the wiring of the specified module. If you continue to get this error
message, call Wintriss Tech. Support.
Table 7-1. Communication Errors: SmartPAC 2 Option Identified by Address Number
Message
Option Identified by Address
Loss of Communication at Address 1
AutoSetPAC, Channels 1-4
Loss of Communication at Address 2
AutoSetPAC, Channels 5-8
“File Not Found”
Explanation:
You cannot access the Dialog Menu when the DIALOG SCREEN MODE
setting on the Set Communications Menu in SmartPAC 2 Initialization is
“32 CUSTOM.” This message displays only when you have the LETS
firmware option.
Remedy:
Press RESET, then change the DIALOG SCREEN MODE setting to “16/
16” (see page G-7).
Troubleshooting Using the Error/Event Log
The Error/Event Log, which you can view in Run mode, is a useful troubleshooting aid. You
can use the Error/Event log to help you diagnose the cause of a problem, or you can send the
log to Wintriss Tech. Support to help them narrow down probable causes. See ERROR/
EVENT LOG, page 6-23 and Sending E-mail to Wintriss Technical Support, page 6-27 for
more information.
7-8
Fault Messages
Appendix A. Installing the Balluff Linear
Transducer
Make sure to install a magnetostrictive linear transducer (see page 1-4 for a description of
transducer operation) that is at least as long as or longer than the sum of the maximum stroke
length of your press and the maximum shut-height adjustment.
CAUTION
It is important that the transducer cable be facing up. If the cable is facing down, the transducer will
not work properly.
Failure to comply with these instructions could result in property damage.
Mounting the Transducer
NOTICE
Not all Servo presses are the same. Each installation will be different. The following installation
procedure is an example.
Once you have thought out your design and gathered the parts, mount the magnetostrictive
linear transducer by performing the following steps, referring to Figure 2-1, page 2-4 for
suggested mounting location and Figure A-1, page A-2 for mounting dimensions:
1. Make sure the press is at its Upper Limit (see RAM POSITION, page 5-50).
2. Fabricate a bracket that will fit the length of the transducer and its mounting feet. See
Table A-1 for the number of mounting feet for each transducer model.
Make sure the bracket mounting holes are elongated or oval-shaped so the transducer can
be moved up and down during fine-tuning of the transducer’s mounting position.
Table A-1. Balluff Linear Transducer: Number of Mounting Feet
Transducer Length
Number of Mounting Feet
6 - 12 in.
2
18 - 24 in.
3
30 - 36 in.
4
42 - 48 in.
5
3. Make a second bracket to hold the magnet connecting rod.
4. Mount the bracket for the transducer on the press.
Installing the Balluff Linear Transducer
A-1
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SmartPAC 2 Servo User Manual
2.4”
(62 mm)
1.1”
(28 mm)
2.9”
(73 mm)
2.4”
2.6”
(60 mm) (66.4 mm)
M5x10
.6”
(15 mm)
1.6”
(40 mm)
physical length
Max. electrical stroke
1.9”
(50 mm)
.04”
(1 mm)
2.7”
(68 mm)
Shown Sideways
2.9”
(73 mm)
.6”
(15 mm)
Shown
installed
Figure A-1. Balluff Linear Transducer Dimensions
5. Mount the transducer on the bracket, leaving the screws loose to allow adjustment of
transducer position.
NOTICE
The mounting feet come with insulators. They must be installed properly for electrical
isolation.
6. Mount the bracket for the magnet connecting rod on the ram.
7. Connect the magnet to the rod. Make sure the magnet is positioned within the
transducer’s electrical range–a line on the face of the transducer indicates the beginning of
its electrical range–and that the arrow on the magnet is facing the electrical connection
when the press moves up and down (see Figure A-1). If the magnet is not positioned
within the transducer’s electrical range, it will not work properly.
8. Once the magnet is secure, tighten down the transducer.
A-2
Installing the Balluff Linear Transducer
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Wiring the Transducer
To wire the transducer to the SmartPAC 2 Servo board, perform the following steps:
1. Plug the connector on the transducer cable into the transducer if it is not already
connected, twisting the locknut so the connection is tight. The connector plugs into the
transducer only one way.
2. Run the transducer cable through 1/2-in. conduit from the transducer to one of the
knockouts on the bottom left of the SmartPAC 2 enclosure.
3. Measure and cut the transducer wires so they comfortably reach TB402 on the
ProCamPAC board. See Figure 2-7, page 2-12 for the location of the ProCamPAC board
on the SmartPAC 2 Servo board and Figure 2-8, page 2-13 for the location of TB402 on
the ProCamPAC board.
4. Unplug the connector from TB402, and attach transducer wires as shown in Figure A-2,
below, Table A-2, page A-4, and Figure 6 (8-channel ProCamPAC) or 7 (15-channel
ProCamPAC) at the back of the manual. Refer to Connecting Wires to Terminal Block
Connectors, page 2-5 if you need additional help.
NOTICE
The connector can plug into the ProCamPAC board in only one direction. Before wiring the
connector, mark its left and right ends when it is plugged in to make sure you wire the
correct pin numbers.
54
32
1
Numbers match numbered
slots on socket
.
Blu
Brn
Pink
Yel
Grn
Gry
76
Connect the shield to
the enclosure next to
the conduit entry point.
Wht tion
c
onne
C
ld
o
N
Shie
Figure A-2. Balluff Linear Transducer Pinout
Installing the Balluff Linear Transducer
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Table A-2. Balluff Linear Transducer Wiring
Pin # on TB402
ProCamPAC Linear Board
Wire Color *
Shield
(terminate to ground stud
nearest entry to enclosure)
1 (+DATA)
Grey
2 (-DATA)
Green
3 (+CLK)
Yellow
4 (-CLK)
Pink
5 (+24VDC)
Brown
6 (GND)
Blue
* White is not used.
5. Double-check connections, then plug the connector back into TB402. It plugs in only one
way.
A-4
Installing the Balluff Linear Transducer
Appendix B. SmartPAC Preventive
Maintenance (PM) Monitor (Optional)
This appendix explains how to initialize, set up, and use the features of the SmartPAC
Preventive Maintenance (PM) Monitor. This appendix serves as an add-on to the chapters in
this manual. References will be made to certain sections. Complete all the steps in each of
those sections unless otherwise noted.
NOTICE
UPGRADING FIRMWARE
If you have a SmartPAC 2 system with AutoSetPAC, you must upgrade the firmware to accept PM
Monitor functionality. Check the version of your AutoSetPAC firmware at “Installed Options” in
Initialization mode. If the firmware version number is lower than 1.26 for a 2-channel AutoSetPAC
or lower than 1.22 for a 4-channel unit, contact Wintriss Tech. Support immediately to obtain the
correct AutoSetPAC firmware.
About SmartPAC PM Monitor
The SmartPAC PM Monitor is an option which allows the maintenance department to manage
its time more effectively. The PM Monitor tracks up to 64 items on the press based on
specific usage, rather than merely signaling when a period of time has passed. Consequently,
the entire stamping process is monitored automatically, and maintenance is alerted only when
equipment requires attention.
Comparison with Traditional Preventive Maintenance
Equipment used on or around the press needs to be checked at regular intervals, such as daily,
weekly, or every specified number of strokes. Traditional preventive maintenance programs
are based upon elapsed time and would be adequate if your presses were used in the same way
all the time. However, with just-in-time manufacturing, shorter job runs, and more tool
changes, presses and auxiliary equipment must frequently change the way that they operate.
Each change results in varying degrees of wear and tear on the machinery. As a result,
traditional PM programs are not the most effective way to handle these kinds of variations.
Here is an example. A traditional PM program may alert maintenance to inspect a press‚s
braking system every three months. During that time, the press is idle or running a continuous
coil-fed job, and the brake experiences minimal wear. As a result, any time spent checking
the brake would be wasted. On the other hand, if the press were running a hand-fed job in
Single-stroke mode, the many starts and stops of the machine would cause greater-thannormal brake wear, and three months would be too long to wait between inspections.
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How the PM Monitor Works
In the previous example, the SmartPAC 2 PM monitor would keep track of machine stops and
could be set to signal a PM alert for the braking system after 50,000 machine stops, for
example. If the press is idle or running coil fed jobs, the time between alerts will be long. If
the press is used for hand-fed jobs, the time between alerts will be shorter.
Up to 64 items can be set up in the PM Monitor‚s schedule. Tracking units such as machine
starts or stops, strokes, motor-on hours, cam channel actuations, die changes, tonnage
overloads, etc. (depending on how SmartPAC is configured), can be assigned to each item in
the schedule. The PM Monitor can also track hours, days, weeks and months for items that
need to be maintained according to a specific time schedule. A tracking frequency is
assigned to each item to tell the PM Monitor when to signal an alert. At that time, an alert
message appears in SmartPAC’s status bar in Run mode.
The entire PM schedule can be viewed in Run mode. The schedule shows each item, its units,
frequency, and current value. Any items in alert status are highlighted. Items with alert
status will be highlighted until the alert is cleared and the item is reset. The PM monitor
continues to track alerted items until they are reset. Please note that SmartPAC does not stop
the press when an item is in alert status. SmartPAC’s PM schedule is password-protected to
keep unauthorized personnel from clearing an alert.
Examples of How to Use the PM Monitor
Some examples to help you properly set up your PM monitor are provided in Table B-1 and
Table B-2, page B-3, which show “PM items” and “PM tracking units.” If you do not find a
suitable PM item name, you can program a “custom” name to match your application.
Examples below provide such “custom” suggestions. To obtain further assistance in using the
PM Monitor, contact Wintriss Tech. Support.
The tracking unit “Ch. cycles” (for cam channels 1 through 8 or 16), can be used to track the
usage of various ancillary devices controlled by SmartPAC. Some PM items might include:
feeder, pilot release solenoid, and ejection cylinders.
The tracking unit “Die changes” can be used to track the usage of components that are
directly related to changing tools at SmartPAC. Some PM item examples might include:
hydraulic clamping mechanism and the ram adjust motor.
WPC press control faults F50 through F58 can be used to monitor items connected to the
user-definable inputs set when SmartPAC is integrated with the Wintriss Clutch/Brake
Control (WPC). Here are some examples: lube pressure, lube level, Nitrogen pressure
(related to Nitrogen die spring systems).
B-2
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Table B-1. Preventive Maintenance Items
air rotary seals
back shaft bearing (1 through 4)
brake
bull gear
clutch valve
conveyor (1 through 6)
counterbalance system
drive belts
DSV
feeder
flywheel bearing
gibs
lube filter
lube motor
lube system
main bearing (1 through 4)
main motor
oil level
pilot solenoid
pinion key
pitman bearing (1 through 4)
“Custom” name
Table B-2. PM Tracking Units
run hours1
days
weeks
months
die changes
ch. cycles (1 through 16)2
WPC press control faults, F50-F583
press overloads4
1 For SmartPAC (without WPC), “run hours” refers to the length of time that SmartPAC is “on”. For SmartPAC with
WPC, it means how long the motor is “on”. (The version of SmartPAC that you currently have is without WPC. Contact Wintriss Controls if you require WPC.)
2 Ch. cycles 1 through 16 can be used only if you have a 16-channel ProCamPAC. Only ch. cycles 1 through 8 can be
used for an 8-channel configuration.
3 These are only available if you have SmartPAC with WPC and if you have wired and assigned press functions to the
user-definable inputs. (The version of SmartPAC that you currently have is without WPC. Contact Wintriss Controls
if you require WPC.)
4 “Press overload” is only available with the AutoSetPAC option.
Installing the PM Monitor
For New Systems from the Factory
If you purchased a SmartPAC 2 system with the PM Monitor pre-installed at the factory, you
can proceed directly to Using the PM Monitor in Initialization Mode, page B-4.
For Existing Systems
If you ordered the PM Monitor options separately (in other words, if you already had a
SmartPAC 2, and you were just adding the PM option), you must first physically upgrade
your SmartPAC 2 system for compatibility. To upgrade your SmartPAC 2 firmware, refer to
Appendix C.
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Once firmware has been upgraded, proceed to Using the PM Monitor in Initialization Mode
(below).
NOTICE
PM Monitor must be initialized before you can use it (see page B-6).
Using the PM Monitor in Initialization Mode
How to Get into SmartPAC Initialization and PM Monitor
NOTICE
SELECT = HIGHLIGHT + ENTER
When this manual says SELECT, it means highlight the item and press ENTER.
NOTICE
Before changing modes, make sure your screen shows the first display in the mode you are in. If
that display is not shown, nothing will happen when you turn the Program /Run key. In that case,
keep pressing the RESET key. When the first display in the mode is reached, SmartPAC will
instantly switch to the new mode.
1. To get into Initialization mode, turn the Program/Run key to “PROG,” and then press both
the “1” and “CLEAR” keys simultaneously for one second.
MAIN INITIALIZATION MENU
RESOLVER ZERO
POSITION SENSOR
USE CURSOR KEYS TO PRESS NAME
CHOOSE MENU ITEMS. SELECT CAM NAMES
AUTO ADVANCE
PRESS THE ENTER
CUSTOM SENSOR NAMES
KEY TO SELECT.
SWITCH TO RUN WHEN SENSOR ENABLE MODE
PM MONITOR
DONE.
SECURITY ACCESS
Figure B-1. “PM Monitor” Highlighted on SmartPAC 2 Initialization Menu
2. Select “PM Monitor” from the main Initialization menu (see Figure B-1). A screen will
appear asking for your password.
B-4
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NOTICE
The password prompt will appear EVERY time that you select “PM Monitor” from the
Initialization mode.
ENTER THE PASSWORD
0
USE THE KEYPAD TO ENTER NUMBERS.
USE THE UP/DOWN CURSOR KEYS TO
INCREMENT/DECREMENT. PRESS ENTER
WHEN DONE. PRESS RESET TO CANCEL.
65535
Figure B-2. PM Password Screen
3. At this point, consider the applicable alternatives below, depending on whether you have a
new system (which includes the PM option already installed at the factory), or an existing
SmartPAC (where you have to install and initialize this option yourself). Proceed with the
one that corresponds with your system.
For New Systems from the Factory
If you purchased a SmartPAC system with the PM Monitor pre-installed at the factory, it is
not necessary for you to clear/initialize the PM Monitor. However, you do need to complete
the steps below as directed.
1. Enter the password “1234” at the “PM password” screen. This will take you immediately
to the “PM Entry” screen.
2. As we mentioned above, you do not need to initialize your PM Monitor option, as it has
already been done at the factory. However, it is advisable for you to change your
password from the default “1234” to a different number, for security reasons.
3. To do this, press F6 which is labeled “Init”. It is at this screen (“Initialize PM” - see
Figure B-5) where you can also change your password. Proceed to Assigning a New PM
Password Number, page B-8 to change your password (skip Initializing the PM Monitor,
page B-6 altogether). Once you have done that, you can use the PM Monitor.
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For Existing Systems
If you ordered the PM Monitor options separately, you must initialize this option before you
can actually use it. Complete all the steps in Initializing the PM Monitor, below, to initialize
the PM Monitor.
NOTICE
You should already have installed the firmware upgrade. If not, go back to Installing the PM
Monitor, page B-3 before proceeding further.
Initializing the PM Monitor
1. Select “PM Monitor” from the Main Initialization Menu (see Figure B-1). A screen will
appear asking for your password.
NOTICE
The password prompt will appear EVERY time that you select “PM Monitor” from the
Initialization mode.
2. To determine the password for your system, note the number at the bottom-right corner of
the password screen, and call the factory at the telephone number on the cover of this
manual. (Because you have an upgraded system, the password may not be “1234”.)
Figure B-3. PM Password Screen Showing Password Retrieval Number
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3. Enter the password that you obtained from Wintriss Controls, using the numeric keypad.
This will take you to the PM Entry Screen (see below). Don’t worry if erroneous
information appears on the screen, as it will disappear once you have completed step 5.
YOUR PRESS NAME
PM MONITOR
ITEM
NEW ITEM
ALERT EVERY
USE THE CURSOR KEYS TO MAKE
SELECTION. PRESS ENTER TO
SELECT, RESET WHEN DONE.
INIT
F6
Figure B-4. PM Entry Screen
4. Press function key F6, which is labeled “Init”.
5. From this screen you can initialize the PM Monitor. To initialize, select “Clear PM Info”.
(Notice that you can also change your password on this screen. To change your password,
refer to the next section, Assigning a New PM Password Number.
YOUR PRESS NAME
PM MONITOR
CHANGE PASSWORD
CLEAR PM INFO
select "Clear PM
info" to initialize the
PM monitor
USE THE CURSOR KEYS TO MAKE
SELECTIONS. PRESS ENTER TO ACCESS
THE SELECTION. PRESS THE RESET KEY
WHEN DONE.
Figure B-5. Initialize PM Screen
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6. Notice the “Warning” message and accompanying instructions appearing on the screen
(see below). Press the CLEAR key to initialize. (If you decide not to, then press RESET.)
! ! !! WARNING ! ! !!
THIS WILL CLEAR OUT ALL THE PM
MONITOR INFORMATION . IF YOU
WANT TO DO THIS THEN PRESS
THE CLEAR KEY. IF YOU DO NOT
THEN PRESS THE RESET KEY.
Figure B-6. Initialize Warning Screen
7. Once you press CLEAR, you will briefly see the confirming message “INITIALIZING
PM MONITOR”.
8. Next, press RESET to exit from the “Initialize PM” screen. You will be returned to the
PM Entry screen. Proceed to the next section to assign a new password number.
Assigning a New PM Password Number
Before you can actually set up and use the PM Monitor, you may want to assign a new
password number. (The default password is “1234”.) For security reasons, it is advisable to
change the default password. Follow the steps below to change the password. You can also
change the password under the Security Access item on the Main Initialization Menu (see
Changing Passwords, page 4-25).
1. Go to the “PM Entry” screen (Figure B-4). Press F6 (Init).
2. You will see the “Initialize PM” screen (Figure B-5). Select “Change Password”.
3. As the screen indicates, enter a new password, up to 4 digits (numeric only). Use the
numeric keypad or the up/down cursor keys. Then press ENTER.
4. Make sure that you record this number and keep it in a place where you can find it.
Without it, you cannot change settings in the PM Monitor. You are now ready to use the
PM Monitor. Go to the next section.
Selecting PM Item Names
You are now ready to set up PM parameters in Initialization. You can select a name for each
preventive maintenance item that adequately describes its function. SmartPAC provides
about 35 names. If there is a function for which you cannot find a suitable name, you can
create a new name using the “Custom” feature. (This procedure is explained in step 5 below.)
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1. Select “New item” from this display. (You may be asked for a password before getting to
this screen. If so, enter it.)
YOUR PRESS NAME
PM MONITOR
ITEM
NEW ITEM
ALERT EVERY
USE THE CURSOR KEYS TO MAKE
SELECTION. PRESS ENTER TO
SELECT, RESET WHEN DONE.
INIT
F6
Figure B-7. PM Monitor Screen
2. Next, you will see the following display. You should give the item a name that best
describes its function, so first check the list for a suitable name.
YOUR PRESS NAME
USE THE CURSOR KEYS TO
MAKE SELECTION. PRESS
ENTER TO SELECT, RESET
WHEN DONE.
MORE
PM MONITOR
"CUSTOM NAME"
AIR ROTARY SEALS
BCKSHFT BEARING 1
BCKSHFT BEARING 2
BCKSHFT BEARING 3
BCKSHFT BEARING 4
BRAKE
BULL GEAR
CLUTCH VALVE
CONVEYOR 1
CONVEYOR 2
CONVEYOR 3
CONVEYOR 4
CONVEYOR 5
CONVEYOR 6
Figure B-8. List of Available PM Names Screen
3. To see the complete list of names, press the Down () cursor key until the bottom name
on the list is highlighted, then keep pressing it. A new name will appear each time you
press the key. You can use the Up () cursor key to reverse direction.
4. If you do not find a suitable name but you still want to name the item, you can select
“Custom Name” by highlighting it and pressing ENTER.
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5. When the Alphanumeric Entry window displays (see Figure B-9), key in the custom
name. The name you select can be any combination of alphanumeric characters, symbols,
etc. Pressing the CLEAR key clears the text. To create a custom name, do the following:
a. To select letters or symbols: Use the Up (), Down (), Left (), and/or Right ()
cursor keys to highlight the desired letter; then press ENTER.
b. To select numbers: Use the numeric keypad.
c. When finished, press function key F6 (to the right of the LCD display). To cancel
your selection, press RESET. (For assistance in using the various keys, refer to
Chapter 3 of this manual.)
Figure B-9. Alphanumeric Display Superimposed over PM Names Screen
6. After you have named the item, you are prompted to set the PM monitor tracking units.
You can select a time-based measure, such as run hours, days, weeks, or months; or you
can select measures linked to the process, such as strokes, die changes, or programmable
cam channel cycles. Select the most applicable tracking unit of measure.
YOUR PRESS NAME
PM MONITOR
SLIDE ADJ. MOTOR
RUN HOURS
DAYS
WEEKS
MONTHS
STARTS/STOPS
STROKES
DIE CHANGES
CH1 CYCLES
CH 2 CYCLES
CH 3 CYCLES
CH 4 CYCLES
CH 5 CYCLES
CH 6 CYCLES
CH 7 CYCLES
CH 8 CYCLES
USE THE CURSOR KEYS TO
MAKE SELECTION. PRESS
ENTER TO SELECT, RESET
WHEN DONE.
MORE
select the
tracking unit
for the monitored
item
Figure B-10. Tracking Units Selection Screen
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7. Next, the number display appears superimposed over the previous display (see the next
illustration). Use the number keys or cursor keys to set the tracking frequency for the PM
item.
YOUR PRESS NAME
PM MONITOR
ENTER A MAINTENANCE FREQUENCY FOR
AIR ROTARY SEALS
0
USE THE KEYPAD TO ENTER NUMBERS.
USE THE UP/DOWN CURSOR KEYS TO
INCREMENT/DECREMENT. PRESS ENTER
WHEN DONE. PRESS RESET TO CANCEL.
to set frequency/tracking
units for monitored item,
use number keys (up
to 7-digit number), then
press Enter.
Figure B-11. Superimposed Number Display
8. In the following illustration, we entered the slide adjust motor as our first PM item, set the
tracking unit of measure to be “die changes”, and the frequency at “100”. Notice that the
PM name is listed just below “new item”.:
YOUR PRESS NAME
ITEM
NEW ITEM
SLIDE ADJ. MOTOR
PM MONITOR
ALERT EVERY
100 DIE CHANGES
in this example, we
entered "slide
adj. motor" and
set it to alert at
100 die changes
USE THE CURSOR KEYS TO MAKE
SELECTION. PRESS ENTER TO SELECT
RESET WHEN DONE.
Figure B-12. Programmed PM Item: Example
9. To set more PM items, repeat steps 1 through 8. When you are completely done
initializing the PM items, press RESET to return to the Main Initialization Menu.
10. You can now go to the Run mode to view the PM Monitor status conditions. There is no
PM information to set in SmartPAC’s Program mode. You made all the required settings
in the Initialization mode.
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Using the PM Monitor in Run mode
How to Get into SmartPAC Run Mode
To get into Run mode, turn the Program/Run key to RUN.
NOTICE
Before changing modes, make sure your screen shows the first display in the mode you are in. If
that display is not shown, nothing will happen when you turn the Program /Run key. In that case,
keep pressing the RESET key. When the first display in the mode is reached, you will instantly
switch to the new mode.
A Tool Number Must Be Loaded Before Switching to Run Mode
If no tool number has been loaded, you cannot switch from Initialization mode or Program
mode to Run mode. A tool number must be loaded before SmartPAC will allow the press to
run.
If you try to switch to Run mode without a tool number loaded, you will get this error message
on your screen:
NO TOOL NUMBER HAS BEEN LOADED
If so, turn the Program/Run key to “PROG”. Press RESET to clear the error message. Then
load a tool number. Now turn the Program/Run key to “RUN”. The Run menu, shown below,
is the first display you see in Run mode. From this display you can access the PM Monitor
selection.
TOOL NUMBER 1234567
CHAIR BRACKET
SENSORS ENABLED
SENSOR 1
USE CURSOR KEYS TO
MAKE SELECTIONS.
PRESS ENTER TO ACCESS
SELECTION.
DISABLE SENSORS
COUNTERS
BRAKE MONITOR
DIE PROTECTION
CAM SWITCH
PM MONITOR
LOAD NEW TOOL
PM ALERT
This alert message
appears at the
main Run menu
when a PM alert
condition is present.
Select PM Monitor
from this screen to
attend to the offending
item.
Figure B-13. “PM Monitor” Highlighted on SmartPAC 2 Run Menu
(Your list of options may be different, depending on the features you have installed.)
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Viewing and Modifying PM Alerts
1. Select “PM Monitor” from the first display in Run mode.
2. You will see the list of PM items that you previously assigned in Initialization. The first
item is highlighted in the next example. Use the cursor keys to view the other items on the
schedule. Currently the PM status for all items is “normal” (see display). This means that
none of the items has reached the limits set in Initialization.
YOUR PRESS NAME
STATUS IS NORMAL
PM MONITOR
SLIDE ADJ. MOTOR
ALERT AT
CURRENT
CLUTCH VALVE
ALERT AT
CURRENT
GIBS
ALERT AT
CURRENT
notice that alert status
is "normal"
100 DIE CHANGES
75 DIE CHANGES
2000 STARTS/STOPS
1001 STARTS/STOPS
1000000 STROKES
458239 STROKES
CLEAR
ALERT
F3
CHANGE
VALUE
F4
MORE
USE CURSOR KEYS TO CHANGE SELECTION
PRESS ENTER TO SELECT, RESET WHEN DONE
Figure B-14. Run Mode Screen Showing PM Monitor in “Normal” Status Mode
NOTICE
You may notice that some of the current values do not update on every stroke while the
press is running. SmartPAC is keeping track of these items, but does not refresh the
display until the press actually stops.
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3. The next display shows that one of the items, “Slide Adjust Motor,” is now in “alert”
status mode. It flashes on the screen. Also, the number of items in alert status mode
appears at the top of the screen.
Figure B-15. Run Mode Screen Showing “Slide Adjust Motor” in “Alert” Mode
4. To view other items in the schedule that may or may not be in “alert” status, use the cursor
keys. If more than three PM items were set in Initialization, they will not all appear on the
screen. To view them, simply use the cursor keys to scroll down the list.
5. To clear the alert, first highlight that item, press the appropriate function key (designated
on your screen), and enter the PM password.
NOTICE
When you clear the alert condition for a certain item, you automatically reset its current
value to zero. You cannot recall the previous value.
6. If you want to change the frequency value on a given PM item, first highlight that item,
press the designated function key, and enter the PM password. The number display will
be superimposed over the screen (similar to Figure B-9). Use the number keys or cursor
keys to modify the tracking frequency for that PM item.
7. Once you are done viewing or modifying this screen, press RESET to return to the main
Run menu.
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Appendix C. Updating SmartPAC 2
Firmware
This appendix shows you how to update SmartPAC 2 firmware, using a USB disk, and load
SmartPAC 2 firmware installed on a Compact Flash (CF) card. The appendix is organized in
the following sections:
• Updating Firmware Using a USB Disk (next)
• Installing Firmware from a Replacement Compact Flash (CF) Card, page C-9
Updating Firmware Using a USB Disk
NOTICE
FIRMWARE ORDER MUST INCLUDE SMARTPAC 2 SERIAL NUMBER
When you order new firmware, make sure to include the serial number of your SmartPAC 2 unit.
Wintriss needs the serial number to create the correct firmware for your SmartPAC 2.
The serial number is located on the top-mounting flange of the SmartPAC 2 enclosure and on the
Boot Loader chip (U124) on the SmartPAC 2 board (see Figure 2-11, page 2-17). If you have a
panel mount unit, the serial number can be found on the other side of the plate on which the AC
input terminal block is mounted.
To order new SmartPAC 2 firmware, you must fill out a “SmartPAC 2 Firmware Upgrade”
form, available from your Wintriss representative or Wintriss Tech. Support. Make sure to
specify on the form the serial number on your SmartPAC 2. The firmware upgrade file you
receive from Wintriss includes this serial number in its file name (i.e., SP2nnnnnnnn, where
SP2 stands for SmartPAC 2 and nnnnnnnn is the eight-digit SmartPAC 2 serial number).
You can obtain SmartPAC 2 firmware in several ways. This appendix describes two
methods, in which the firmware is loaded on a USB disk and installed via the USB connector
on your SmartPAC 2 PC board. The two methods are as follows:
• Firmware is loaded on a USB disk and sent to you by United Parcel Service (UPS)
or other shipping method. If you select this option, you pay for shipping and the cost of
the USB disk. You also have to wait for delivery of the order. Follow the instructions
in Installing Updated Firmware from USB Disk to SmartPAC 2 on the next page if you
choose this method.
• Firmware is available via an e-mail with a link to the Wintriss download site. You
download a compressed file containing the firmware, then copy the firmware to your
own USB disk and install it on the SmartPAC 2. To transfer the firmware to the USB
disk, follow the instructions in Downloading Updated Firmware from the Wintriss
Server, page C-7. Then load the firmware into SmartPAC 2, using the Installing
Updated Firmware from USB Disk to SmartPAC 2 procedure on the next page.
Other options are available if your SmartPAC 2 unit is networked. Call Wintriss Tech.
Support for more information.
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NOTICE
If you elect to download SmartPAC 2 firmware from Wintriss, you must have
• A PC with a USB port and one of the following Windows operating systems: Windows 2000,
Windows XP, and Windows 7
• A USB disk with at least 4 MB of available space
Installing Updated Firmware from USB Disk to SmartPAC 2
Follow these steps to load new firmware from a USB disk to your SmartPAC 2.
NOTICE
If you downloaded your firmware from Wintriss, go to page C-7 and follow the instructions in
Downloading Updated Firmware from the Wintriss Server to load the firmware onto a USB disk.
Then return to this page and install the firmware on your SmartPAC 2.
1. If a tool is loaded and you are currently running a job, you must record the current tool
number, tool name or tool ID, and counter values before installing the new firmware. You
do not need to record the preset values, which are saved with the tool settings. You can
use Table C-1 to record counter settings.
Table C-1. Record of Current Counts
Tool Number
Tool Name or Tool ID
Counter
Strokes
Good Parts
Batch 1
Count
Preset Value
You do not have to
record Preset Values.
They are saved with the
tool settings.
Batch 2
Batch 3
Total Hits
2. If you have a SmartPAC 2 Servo or SmartPAC 2 Hydraulic, you must record the current
Linear Sensor settings in Initialization mode. You can use Table C-2, page C3 for this
purpose.
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Table C-2. Record of Linear Sensor Initialization Settings
Parameter
Setting
Sensor Resolution
Offset Value
Zero Value *
Upper Limit
Units
* If your firmware version does not support this item, make sure
to set the field to zero after updating the firmware.
3. Check the serial number of the new firmware to make sure it matches the serial number of
your SmartPAC 2. The firmware serial number begins with the prefix “SP2” (for
SmartPAC 2) followed by a numeric code (i.e., SP2nnnnnnnn). The numeric code is the
serial number of your SmartPAC 2 unit.
NOTICE
• If you received your firmware on a USB disk, the serial number is the name of the folder
stored on the disk. To verify the serial number, insert the disk into your computer’s USB
port, double-click on My Computer, and open the USB disk (usually identified by the
label “Removable Disk” with a drive letter next to it.)
• If you downloaded your firmware from Wintriss, the serial number is the name of the
compressed file you downloaded.
4. Power down your SmartPAC 2.
5. Press and hold down the F1 function key while powering up the SmartPAC 2, releasing F1
when the red Wintriss SmartPAC 2 screen displays. After about a minute the
FIRMWARE LOAD MENU will appear (see Figure C-1).
Figure C-1. Firmware Load Menu with “XFER FROM USB DISK” Highlighted
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WARNING
ELECTRIC SHOCK HAZARD
• Ensure that the power source is off before you replace electronic components in a
control.
• Disconnect power from the machinery it is connected to before replacing electronic
components. This includes disconnecting power to the machine control and motor.
• Ensure that servicing is performed by qualified personnel.
Failure to comply with these instructions could result in death or serious injury.
6. Open the SmartPAC 2 enclosure or console.
CAUTION
DAMAGE TO BOARD FROM STATIC DISCHARGE
Ground yourself before touching circuit boards or chips by touching a large metal object
such as the press. Static electricity can destroy electronic components.
Failure to comply with these instructions could result in property damage.
7. Locate the USB connector, J121, on the SmartPAC 2 board (refer to Figure 2-11,
page 2-17).
NOTICE
The USB disk can fit into the USB connector in only one orientation. DO NOT try to force
the USB disk into the connector when it is in the wrong orientation.
8. Making sure that the USB disk is oriented correctly, carefully insert the USB disk into the
USB connector. Wait about a minute for the SmartPAC 2 to recognize the USB disk.
9. Close the door of the enclosure or console.
10. Using the cursor keys, highlight “XFER FROM USB DISK,” as shown in Figure C-1, and
press ENTER. After a few seconds, the message “USB DISK TRANSFER COMPLETE”
displays briefly, then the Firmware Load Menu appears again, as shown in Figure C-2,
page C-5.
NOTICE
If the USB disk does not contain the correct folder for this SmartPAC 2 serial number, you
will first see a message at the bottom of the screen that says “SP2nnnnnnnn DIRECTORY
NOT FOUND” and then a red window with the message “THERE WAS NO RESPONSE
TO THE USB DISK FILE TRANSFER REQUEST.” If these messages display, re-check
the serial numbers of the SmartPAC 2 and the SmartPAC 2 firmware you are trying to
load. If the two serial numbers match, try loading the firmware again. If this still does not
work, contact Wintriss Tech. Support.
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Figure C-2. Firmware Load Menu with “LOAD NEW FIRMWARE” Highlighted
11. With “LOAD NEW FIRMWARE” selected, as shown in Figure C-2, press ENTER. A
yellow status window appears with the message “YOU ARE ABOUT TO REPROGRAM
THE SMARTPAC 2 RTS UNIT. . .” (see Figure C-3).
Figure C-3. Firmware Load Menu with Yellow Status Window
12. Press ENTER to continue. A display like that shown in Figure C-4, page C-6 appears,
indicating that the firmware is being loaded. It takes about five minutes for the firmware
to load.
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Figure C-4. SmartPAC 2 Display with “Loading Firmware” Message
NOTICE
If power is lost to SmartPAC 2 during installation of the firmware, SmartPAC 2 will default
to the Firmware Load Menu display when the unit is powered back up. Repeat steps 1012 to install the firmware again.
13. When the firmware is completely loaded, the Load Time counter stops incrementing, a
yellow status window appears briefly saying “THE DOWNLOAD SEQUENCE IS
COMPLETE,” and the SmartPAC 2 will restart (reboot) itself. Once the reboot is
complete, another yellow status window appears saying, “YOU HAVE NOW UPDATED
THE SMARTPAC SOFTWARE. SHUT THE POWER OFF AND THEN TURN IT
BACK ON TO RESTART THE SMARTPAC 2.”
14. Power down the SmartPAC 2. Remove the USB disk from the USB connector.
15. Power up the SmartPAC 2. Access the Main Initialization Menu and select “INSTALLED
OPTIONS” to check for new installed options or enhancements, if any.
NOTICE
If you have a MultiPAC module connected to SmartPAC 2, the following message may
appear when you power up the unit: “A MULTIPAC MODULE WAS INSTALLED THE
LAST TIME THE UNIT WAS POWERED-UP AND WAS NOT SEEN THIS TIME.” If you
receive this message, power down SmartPAC 2 again, then power the unit back up. If the
message still appears, contact Wintriss Tech. Support.
16. If you suspended a job in order to load SmartPAC 2 firmware, reload the tool and enter the
counts for your job-in-progress from Table C-1, page C2 as follows:
a. Enter Run mode and select COUNTERS.
b. Enter the count values from Table C-1 for each line in the display.
c. When you are finished, you can continue running the job that was in progress.
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NOTICE
Your Security Access settings may be set to prevent changing the count values in Run
mode. If this is the case, go to the Main Initialization Menu, select “SECURITY ACCESS”,
and set “CHANGE COUNT” to “PROGRAM AND RUN MODES.” After you change the
count values, you can reset the Security Access if desired.
17. If you have a SmartPAC 2 Servo or SmartPAC 2 Hydraulic unit, enter the settings you
recorded in step 2 on the Linear Sensor screen in Initialization mode.
Downloading Updated Firmware from the Wintriss Server
NOTICE
To copy firmware downloaded from Wintriss to a USB disk, you must have:
• A PC with a USB port and one of the following Windows operating systems: Windows 2000,
Windows XP, or Windows 7
• A USB disk with at least 4 MB of available space
To download firmware from the Wintriss server, perform the following steps:
1. Click on the link provided in the e-mail you received from Wintriss in response to your
firmware order. If the link has been disabled by your security settings, copy the link, paste
it into a Browser window, and press ENTER.
2. When a window displays asking if you want to open the file or save the file to your
computer, select the Save option.
3. When the Save As window displays, click on Save with the following settings selected:
Save in:
File name:
Save as type:
Desktop
SP2nnnnnnnn (where nnnnnnnn is your SmartPAC 2 serial number)
Application
4. Click on Save to save the file to your desktop. This may take a few minutes.
5. When the Download Complete window displays, click on Close to end the download. (On
some systems, the window may close automatically.)
6. Locate the downloaded, compressed file on your desktop (the icon displays the WinZip
logo and the file name SP2nnnnnnnn), and double-click on it to launch the WinZip SelfExtractor utility.
7. When the WinZip Self-Extractor window displays, select the folder to which you want the
contents of the unzipped file saved (the default is C:\WintrissUpdates), and click on Unzip.
NOTICE
You can change the drive and/or folder to which you save the file by clicking on the
Browse button and navigating to the desired location. You can create a new folder by
typing the folder name in the Unzip to folder: field.
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8. Click on OK in the window displaying the message that the file has been unzipped
successfully, then click on Close in the WinZip Self-Extractor window.
9. Double-click on the My Computer icon on your desktop, and when the “My Computer”
window opens, navigate to the folder in which you placed the unzipped SmartPAC 2
firmware file. (The contents of the unzipped file are in a folder named SP2nnnnnnnn,
where nnnnnnnn is the serial number of your SmartPAC 2.)
10. Insert a USB disk into your computer’s USB port. Wait a few moments for it to be
recognized.
• If your computer is already set up to use a USB disk, the USB drive (usually named
“Removable Disk” with a drive letter next it) will appear in the “My Computer”
window.
• If you have never used a USB disk on your computer, you will be prompted with a
message saying, “New hardware has been found.” Follow the on-screen instructions to
find and install the proper drivers for your USB disk. For assistance, contact your
information technology staff.
11. With both the SP2nnnnnnnn folder and the USB “Removable Disk” icon visible in “My
Computer” windows, copy the SP2nnnnnnnn folder to the USB disk.
12. Stop the USB disk, using the “Unplug or Eject Hardware” utility on your computer. (The
“Unplug or Eject Hardware” icon is often displayed on the far right side of the Task Bar.)
NOTICE
Be sure to stop the USB disk before removing it from the computer. If you don’t, valuable
data on your computer may be corrupted or lost.
If you are using Windows XP, you do not need to “unplug” or “eject” the USB disk.
13. Remove the USB disk from the USB drive.
To install downloaded firmware from the USB disk to SmartPAC 2, follow the instructions in
Installing Updated Firmware from USB Disk to SmartPAC 2, page C-2.
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Installing Firmware from a Replacement Compact
Flash (CF) Card
NOTICE
MAKE SURE TO SPECIFY YOUR SMARTPAC 2 SERIAL NUMBER
When you order a replacement Compact Flash (CF) card, make sure to include the serial number
of your SmartPAC 2. Wintriss needs the serial number to create the correct firmware for your
SmartPAC 2.
The serial number is located on the top-mounting flange of the SmartPAC 2 enclosure and on the
Boot Loader chip (U124) on the SmartPAC 2 board (see Figure 2-11, page 2-17). If you have a
panel mount unit, the serial number can be found on the other side of the plate on which the AC
input terminal block is mounted.
If you are replacing a Compact Flash (CF) card, perform the following steps to reload the
SmartPAC 2 firmware resident on it:
!
WARNING
ELECTRIC SHOCK HAZARD
• Ensure that the power source is off before you replace electronic components in a control.
• Disconnect power from the machinery it is connected to before replacing electronic
components. This includes disconnecting power to the machine control and motor.
• Ensure that servicing is performed by qualified personnel.
Failure to comply with these instructions could result in death or serious injury.
1. With power to the SmartPAC 2 turned off, insert the replacement Compact Flash card in
the receptacle on the SmartPAC 2 board (see Figure 2-11, page 2-17). If a ProCamPAC
board is installed, you will have to remove it to access the Compact Flash slot.
2. Close the door of the enclosure or console.
3. Press and hold down the F1 function key while powering up the SmartPAC 2, releasing F1
when the red Wintriss SmartPAC 2 screen displays. After about a minute the
FIRMWARE LOAD MENU will appear (see Figure C-5, page C-10).
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Figure C-5. Firmware Load Menu with “RELOAD CURRENT FIRMWARE” Highlighted
4. Using the cursor keys, highlight “RELOAD CURRENT FIRMWARE,” as shown in
Figure C-5, and press ENTER. A yellow status window appears with the message “YOU
ARE ABOUT TO REPROGRAM THE SMARTPAC 2 RTS UNIT . . .” (see Figure C-6).
Figure C-6. Firmware Load Menu with Yellow Status Window
5. Press ENTER to continue. The message “PLEASE WAIT WHILE THE FIRMWARE
MEMORY IS BEING ERASED” displays briefly, followed by a display like the one
shown in Figure C-7, page C-11, indicating that the firmware is being loaded. It takes
about five minutes for the firmware to load.
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Figure C-7. SmartPAC 2 Display with “Loading Firmware” Message
NOTICE
If power is lost to SmartPAC 2 during installation of the firmware, SmartPAC 2 will default
to the Firmware Load Menu display when the unit is powered back up. Repeat steps 4
and 5 to install the firmware again.
6. When the firmware is completely loaded, the Load Time counter stops incrementing, a
yellow status window appears briefly saying “THE DOWNLOAD SEQUENCE IS
COMPLETE,” and the SmartPAC 2 will restart (reboot) itself. Once the reboot is
complete, another yellow status window appears saying, “YOU HAVE NOW UPDATED
THE SMARTPAC SOFTWARE. SHUT THE POWER OFF AND THEN TURN IT
BACK ON TO RESTART THE SMARTPAC 2.”
7. Power down the SmartPAC 2, then power the unit back up.
8. Access the Main Initialization Menu, and select “INSTALLED OPTIONS” to verify that
all the options in your SmartPAC 2 configuration have been installed.
NOTICE
If you have a MultiPAC module connected to SmartPAC 2, the following message may
appear when you power up the unit: “A MULTIPAC MODULE WAS INSTALLED THE
LAST TIME THE UNIT WAS POWERED-UP AND WAS NOT SEEN THIS TIME.” If you
receive this message, power down SmartPAC 2 again, then power the unit back up. If the
message still appears, contact Wintriss Tech. Support.
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Updating SmartPAC 2 Firmware
Appendix D. SmartView Remote Viewing
and E-mail Setup
SmartView is a web-based application that allows you to remotely view the status of your
SmartPAC-2-equipped presses over your network. There is no software to install. You
simply go to the SmartPAC 2 web site, www.smartpac2.com, using Microsoft Internet
Explorer version 5.5 or higher, and enter the network names of the SmartPAC 2s that you
want to view.
You are taken to the SmartView Main Page screen (see Figure D-7, page D-10), which
displays the status–i.e., running, stopped, or offline–of all of your presses as well as selected
details about each press. From the Main Page you can access a Detail display for a selected
press, which provides additional press details. If you have dial-up or VPN (Virtual Private
Network) access to your company’s network, you can view the status of your presses from
anywhere in the world over the World Wide Web.
SmartView also provides a remote messaging feature that allows you to send text messages
from your PC to any SmartPAC 2 on your network.
SmartView’s email facility enables press operators to send diagnostic information, screen
captures or custom text messages to Wintriss Technical Support or to any device capable of
receiving an email-based text message, including computers, cell phones, pagers, and PDAs.
The SmartPAC 2 Error/Event Log can be sent to Wintriss Tech. Support or any other
recipient, aiding in troubleshooting application and programming problems.
Network Requirements
In order to use SmartView or send emails from your SmartPAC 2, your network must meet
the following requirements:
• Hardware
LAN (Local Area Network) (SmartPAC 2 listens on Port 1007 (Default))
SMTP Mail Server (Only if using E-mail feature)
CAT5 cable with RJ45 connector
• Browser
Internet Explorer (5.5 or higher)
Network Setup
You should consult with your company’s IT department before setting up your network. They
will be able to answer key questions such as how your company’s LAN (Local Area Network)
is set up, whether the SmartPAC 2 will have a fixed IP (Internet Protocol) address or use
DHCP (Dynamic Host Configuration Protocol), and how email will be sent. They will also be
able to offer advice regarding network hardware issues such as cabling, hubs and mail servers.
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Plugging in the Network Cable
NOTICE
Do not run Cat5 cable inside conduits containing AC high voltage wires. Ideally, run Cat5 cable in
a separate conduit away from sources of electrical noise.
1. With SmartPAC 2 turned off, open the enclosure and plug your network (CAT5) cable
with the RJ45 connector into the Ethernet connector (J122) on the SmartPAC 2 board
(refer to Figure 2-11, page 2-17 for location).
2. Power up the SmartPAC 2.
The green LED labeled LINK on the RJ45 connector should illuminate, indicating that the
network connection is active. If the LINK LED does not illuminate, unplug the connector
and try plugging it in again. If the LED still fails to illuminate, ask your IT department to
PING (Packet InterNet Groper) it. PING is a DOS utility used to test for network
connectivity. See SmartView Ping Utility, page D-15.
3. When you are satisfied that the network connection is active, close the SmartPAC 2
enclosure.
Programming Network Settings
Enabling E-mail and SmartView and Selecting Press Type
1. On the Main Program Menu, press the 1 and CLEAR keys simultaneously for a few
seconds until the Main Initialization Menu displays (see Figure 4-1, page 4-1).
2. Select SETUP NETWORK to access the Network Setup Utility screen (see Figure 4-24,
page 4-31).
3. Make sure that the E-mail and SmartView functions are both enabled. If they aren’t, press
ENTER to toggle the appropriate entry from DISABLED to ENABLED.
4. Make sure that the Press Type is set correctly.
Setting Up E-mail
NOTICE
You must have an SMTP (Simple Mail Transfer Protocol) mail server for the E-mail feature to
function properly. Contact your IT department for information about SMTP server settings and
account information. It is a good idea to have the information ready ahead of time before trying to
enter program fields.
1. Select SETUP E-MAIL on the Network Setup Utility screen. The screen that displays
(see Figure 4-25, page 4-33) provides fields in which you can enter your SMTP mail
server settings. Follow on-screen instructions to enter or edit entries.
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2. Mail Server: Enter Mail Server address first. Be sure to pay careful attention to case-
sensitive text (e.g., MySMTP.MailServer.Com). Use the F2 function key to toggle letter
case.
3. Mail Port: Leave mail port set to 25.
4. Use Secure Login: Press the ENTER key to toggle between FALSE and TRUE. Some
SMTP accounts require a Username and Password. If so, set Secure Login to TRUE.
NOTICE
Most IT departments do not use secure login. If so, leave this entry set to FALSE.
5. Username: If you selected TRUE in step 4, you must enter a Username. This entry is case
sensitive. Use the F2 function key to toggle letter case. Leave the field blank if you set
Secure Login to FALSE.
6. Password: If you selected TRUE in step 4, you must also enter a Password. This entry is
case sensitive. Use the F2 function key to toggle letter case. Leave the field blank if you
set Secure Login to FALSE.
7. Email Error Recipient: Enter the E-mail address of the person to whom you want
undeliverable messages sent (e.g., the individual responsible for SmartPAC2). Leave the
field blank if you do not need to track or be notified of undeliverable e-mails. If you are
unsure of what to enter, contact your IT department.
8. Email From Name: You will probably want to enter the name of the press in this field
(e.g., Press#@yourcompany.com), although you can enter any name. Depending on how
your company’s SMTP server software is configured and what rules are in place, you may
have to experiment with different name formats. Contact your IT department for help.
9. Wintriss Email Addr: Leave this field unchanged. You can use this E-mail address to
send error logs and screen captures to Wintriss Tech. Support for help in troubleshooting
your SmartPAC 2.
NOTICE
If the Wintriss E-mail Address ever changes, Wintriss will notify you. If this occurs, change
this entry to the new Wintriss Technical Support E-mail Address.
Changing Network Settings
NOTICE
Perform this procedure only if you want to change your SmartPAC 2 from the default DHCP setting
(Dynamic Host Configuration Protocol) to a Static or Fixed IP address or if you want to change
your SmartPAC 2’s default network computer name (i.e., SPAC2-nnnnnnnn, where nnnnnnnn is
the serial number of your SmartPAC 2).
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In order to make changes to network settings, you will need to connect either a USB or PS 2
mouse to the appropriate connector. For a PS 2 mouse, use connector J120 on the SmartPAC
2 board. For a USB mouse, use connector J117.
The USB mouse is probably the more convenient choice for SmartPAC 2 board versions Rev.
5 and lower since plugging it in requires only one operation. If you use a PS 2 type mouse
with Rev. 5 and lower boards, you will need to plug a Y-cable into J120 and then plug the
mouse into the connector on the arm of the Y labeled MOUSE. SmartPAC 2 Rev. 3 boards
require that you reverse the connection and plug the mouse into the Y-cable connector labeled
KEYBOARD. For versions of SmartPAC 2 boards Rev. 6 or higher, the PS 2 mouse plugs
directly into connector J120. Differences in PS 2 mouse connections for different versions of
SmartPAC 2 boards are summarized in Table D-1.
Table D-1. SmartPAC 2 Board: PS 2 and Y-Cable Configuration
Board Rev. #
Identifier
PS 2 Default
Configuration
Y–Cable
Connection
Rev. 2
Green TB102 Connector
Keyboard Default
Do not reverse
Rev. 3
Orange TB102 Connector
Mouse Default
Reverse
Rev. 5
Yellow band on PS2
Connector
Mouse Default
Do not reverse
Rev. 6 & Higher
Mouse = MS J120
Keyboard = KB J125
N.A.
N.A.
Changing from System Default DHCP to Static or Fixed IP Address
1. Power down the SmartPAC 2.
2. Open the enclosure. Access the PS 2 (J120) or USB (J117) connector on the SmartPAC 2
board (see Figure 2-11, page 2-17 for location), and plug in your mouse.
3. Power up the SmartPAC 2. Once the unit has finished booting up, you should see a mouse
pointer on your display and be able to move it around.
4. Turn the PROG/RUN key switch to PROG.
5. Access the Main Initialization Menu, and select SETUP NETWORK.
6. On the Network Setup Utility screen, select CHANGE NETWORK SETTINGS.
7. When the red warning window displays, indicating that you are about to be taken to the
Control Panel and that you need to connect a mouse (which you have done in step 2), press
the 5 key.
8. When the Control Panel displays, double-left-click with your mouse on the Network
Connections folder.
9. Single-right-click on the Local Area Connection icon.
10. Single-left-click on Properties in the drop-down box that displays. A Window should
appear labelled Local Area Connection Properties.
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11. In the Local Area Connection Properties window, select Internet Protocol (TCP/IP) and
single-left-click on the Properties button. The Internet Protocol (TCP/IP) Properties
window displays with two radio buttons already selected: “Obtain an IP address
automatically” and “Obtain DNS server address automatically.” These are the default
settings to make your SmartPAC 2 DHCP-enabled.
12. Single-left-click once to select “Use the following IP address,” and single-left click again
to select “Use the following DNS server address.”
13. Using the on-screen keyboard, enter the appropriate IP addresses. Consult your IT
department if you need help.
14. Single-left-click on the OK button.
15. Close the On-Screen Keyboard, Local Area Connection Properties, and Network
Connections windows. You should see a blank blue screen with a small window labeled
Control Panel Entered with the words Re-Start System and Save Changes. Single-leftclick on the OK button to restart the SmartPAC 2 and save your new network settings.
16. To test these changes, try launching SmartView and viewing the press. Also, go to the
Setup Page in SmartView (see page D-10) and see if the IP address you entered is
displayed.
If you do not have network connectivity, you may need to repeat the preceding steps to
make changes and/or have your settings saved.
Changing Computer Name and Member Settings (System Properties)
1. Repeat steps 1 through 7 above.
2. Double-left-click on the System icon.
3. Single-left-click on the Computer Name tab in the System Properties window.
NOTICE
It is not necessary to enter a Computer description. Leave this window blank.
4. Single-left-click on the Change button.
5. In the Computer Name Changes window, move the mouse pointer over the Del (Delete)
key on the on-screen keyboard–the pointer becomes a hand–and single-left-click with the
mouse. The computer name SPAC2-nnnnnnnn (where nnnnnnnn is the serial number of
your SmartPAC 2) is deleted.
6. Enter the new computer name on the on-screen keyboard, single-left-clicking with the
mouse on the desired characters.
7. If you want to change from the factory default Workgroup to Domain, unselect the
Workgroup radio button, and select the Domain radio button.
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NOTICE
SmartPAC 2 is configured at the factory to be part of a Workgroup. If your IT department
requires that SmartPAC 2 be part of a Domain, you must change this setting. Contact
your IT department for help.
8. Close the on-screen keyboard.
9. Single-left-click on the OK button.
10. When you are prompted to restart the computer, click on the OK button.
11. In the System Properties window, click on OK, then click on Yes to restart the computer
and save changes.
12. After SmartPAC 2 reboots, the Main Initialization Menu should display.
Installing SmartView
SmartView can be installed on any desktop or laptop PC that is networked to your company’s
LAN. If you will use SmartView on multiple computers, you must install the software on
each one. In order to install SmartView, your PC must meet the following requirements:
• Microsoft Internet Explorer (version 5.5 or higher)
• Client must have administrative privileges
• If a firewall is used, SmartPAC 2 must be a trusted site
NOTICE
SmartView performance and speed may be affected by older and slower equipment. For
optimal performance it is recommended that the computer used to run SmartView be
reasonably up-to-date.
Checking Explorer Settings
1. Open Microsoft Internet Explorer.
2. At the top of the Explorer window, click on the Tools drop-down menu and select Internet
Options (see Figure D-1).
Figure D-1. Internet Explorer Window with “Internet Options” Selected
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3. On the Internet Options screen (see Figure D-2), click on the Security tab.
Figure D-2. Internet Options Screen
4. On the Security tab (see Figure D-3), click on the Custom Level button.
Figure D-3. Security Tab with “Custom Level” Button
5. Ensure that the following security browser settings are configured:
•
•
•
•
Download signed ActiveX controls: Prompt
Run ActiveX controls and plug-ins: Enable
Script ActiveX controls marked safe for scripting: Enable
Active scripting: Enable
6. When all settings are verified, click on the OK button on the Security Settings screen, then
click on OK on the Internet Options screen.
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Installing SmartView on Your Computer
1. Enter http://www.smartpac2.com in the Internet Explorer address window, and click on
the Go button to launch SmartView. If you are installing SmartView for the first time, the
SmartView introductory page (see Figure D-4) will display. Otherwise, you will be taken
directly to the SmartView Setup Page (see Figure D-5.
Figure D-4. SmartView Introductory Page
2. Click on the Go to the SmartView Setup Page on the SmartView introductory page, if
necessary, to access the SmartView Setup Page (see Figure D-5).
Figure D-5. SmartView Setup Page
3. Click in the Network Name window, and type “Demo1” as shown in Figure D-5.
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4. Click in the Press Name window, and type “Demo Press 1” as shown in Figure D-5.
5. Click on the Add button. Your entries are displayed in the large window beneath the
Network Name and Press Name windows.
NOTICE
You can also type network and press names directly into the large window.
NOTICE
Additional Demo Press simulations are available. To add these simulations, repeat steps
3 through 5, but instead of using “Demo1,” type “Demo2,” etc. in the Network Name field.
You can enter names with up to two digits (e.g., Demo Press 35) in the Press Name
window. These Demos are for testing and demonstration purposes.
6. Click in the User Name window, and type your name.
7. Click on the Submit Changes button.
8. When the window shown in Figure D-6 displays, asking if you want to download the
Mabry WinSock ActiveX control, click on the Install button.
Figure D-6. Mabry Winsock ActiveX Control Window
NOTICE
The Mabry WinSock ActiveX control enables you to run SmartView on your browser. This
software must be installed on your computer in order for SmartView to function properly.
You may be prompted to install the software prior to this step. If you are not prompted to
install this control, check to make sure your browser security settings are correct (see step
5, page D-7), or contact your IT department for more information.
9. The SmartView Main Page (see Figure D-7, page D-10) should now appear. Click on the
Add to Favorites button
SmartView
to save this web site for future use.
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Figure D-7. SmartView Main Page
SmartView Operation
Setup Page
Follow these steps to fill in the information on the SmartView Setup Page (see Figure D-5,
page D-8):
1. On the SmartView Main Page, click on Setup to display the SmartView Setup Page.
2. Enter in the Network Name window “SPAC2-nnnnnnnn,” where nnnnnnnn is the
SmartPAC 2 8-digit serial number, if you have assigned your SmartPAC 2 a DHCP
address
or
Enter in the Network Name window the SmartPAC 2 IP address if you have assigned your
SmartPAC 2 a fixed or static IP address.
3. Enter in Press Name window a name for your press, using up to 25 characters (e.g., Press
8, Press 9, etc.).
4. Click on the Add button. Your entries are displayed in the large window beneath the
Network Name and Press Name windows.
NOTICE
You can also type network and press names directly into the large window.
5. Enter a user name if you have not already done so.
6. Click on the Submit Changes button. SmartView will check for networked units and
indicate if a connection is made.
7. To add more networked SmartPAC 2s, click on Setup on the Main Page to go back to the
Setup Page, and repeat steps 2 through 6. You do not have to enter your user name each
time. It is a good idea to record your settings on paper.
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8. To make changes, select the line you want in the large window, edit the selection, and
click on the Submit Changes button.
9. To delete an item, select that line in the large window, press the Delete key, and click on
the Submit Changes button.
NOTICE
You can prevent a press from displaying on the Main Page without deleting its entry on the
Setup Page by placing a single quotation mark in front of the entry (e.g., ‘SPAC212345678, Press 7.)
10. If you get a “No Connection” message after clicking on Submit Changes, check to make
sure that you have entered the correct SmartPAC2 serial number or IP address.
NOTICE
If the “No Connection” message persists, you may need to Ping your SmartPAC 2. See
page D-15 for instructions.
Main Page
The SmartView Main Page, shown in Figure D-8, page D-12, lets you view a summary of
information about the presses you have networked.
The Main Page displays the following press information:
• Press running speed (SPM) (if press is running)
• Press angle (if press is stopped or in a fault condition)
• Estimated hours to completion of job
• Number of parts required
• Number of parts made
• Percent of job complete
The color of the press graphic at the right of each press summary indicates the press’s current
state:
• Green – Press is running
• Red – Press is stopped
• Grey – Press is offline (i.e., power is off or there is no network connection)
When a press is offline, the message “Off Line” displays next to the press graphic.
The Refresh button at the top of the page allows you to update the Main Page display with the
latest press status information (e.g., current parts count).
The Detail link at the top of each press summary takes you to the Press Status Information
Page (see next section), on which you can view detail press information.
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Figure D-8. SmartView Main Page with Status of Multiple Presses Shown
Press Status Information Page
The Press Status Information Page (see Figure D-9, page D-13), which displays when you
click on the Detail link in a summary panel on the Main Page, provides an expanded view of
your press.
It displays the following detail information about the selected press:
• Faults (if press is in a fault condition)
• Sensor status
• Current tool number and name
• Job number
• Press capacity
• Number of parts required
• Number of parts made
• Percent of job complete
• Current job running time
• Estimated hours to job completion
• Current press tonnage
• Tonnage as a percent of press capacity
The Update button at the top of the page allows you to view the most current detail
information. You can view the Error/Event Log or Installed Options screen by clicking on the
Error Log or Installed Options link at the top of the page.
To return to the Main Page, click on the Main link. To go to the Wintriss.com web site, click
on the Wintriss.com link.
The Remote Message window at the bottom of the page allows you to send a text message
from your computer to SmartPAC2 (see next section).
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Figure D-9. Press Status Information Page
Remote Messaging
You can send a remote message from your computer to other press operators by typing the
message (95 characters maximum, including spaces) in the Remote Message window on the
Press Status Information Page, and clicking on the Send Button. A Status box displays on
your computer to let you know if the transmission was successful. Your message will display
as a post-it note on the SmartPAC 2 to which you have directed it (see Figure D-10,
page D-14).
Once the message is read, it can be cleared by going to the Error/Event Log (click on the Error
Log link) and pressing the F4 key. The Error/Event log maintains the status of all messages
(i.e., Sent or Cleared) by date and time.
NOTICE
SmartPAC 2 only displays the most recent message. When another message is sent, SmartPAC
2 automatically clears the previous message and displays the new one.
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Figure D-10. SmartPAC 2 Remote Message
E-mail Setup
You can enter new or edit existing recipient email addresses and messages on the E-mail
Setup Page (see Figure D-11, page D-15), which you access from the SmartView Setup Page
by clicking on the Email Setup link.
To add, change, or delete email information, do the following:
1. Click on the Down Arrow () in the Select a Press window, then select the press for
which you want to enter or edit email information.
Existing names/email addresses and messages for that press display in the two large
windows on the screen. A status box displays to inform you that the data has been
received and is ready to change.
2. To add an email name/address entry, click in the Name window, and type the person’s
name, then click in the Email Address window, and type his or her E-mail address. Click
on the Add button. Your entries are displayed in the large window beneath the Name and
E-mail Address windows.
NOTICE
You can also type the name and email address entries, separated by a comma, on a line
in the large window.
3. To add an email message entry, click in the Messages window, type the text of the
message, and click on the Add button. Your entry is displayed in the large window beneath
the Messages window.
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Figure D-11. Email Setup Page
NOTICE
You can also type the email message entry on a line in the large window.
4. Click on the Save button to save your entries.
5. To change an email name, email address, or email message entry, select the appropriate
line in one of the large windows, edit the selection, and click on the Save button.
6. To delete an entry, select the appropriate line in a large window, press the Delete key or
backspace over the item, and click on the Save button.
Your clipboard functions are a convenient way to speed up entry. For example, to copy the
same email list to multiple email-enabled SmartPAC2s, just left-click and drag your mouse
over the entire email recipient list on one SmartPAC2, and paste (Control-V) it into the Email
Setup Page on another SmartPAC2.
SmartView Ping Utility
The Ping utility is an administrator’s tool that is used to check whether a SmartPAC 2 is
connected to the network and communicating properly. This utility is a good resource if you
get a “No Connection” message after clicking on the Submit Changes button on the SmartView
Setup Page (see Setup Page, step 10, page D-11).
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To access the Ping Utility, click on the Ping Utility link on the Setup Page. The first time you
access the Ping utility, you will be prompted to download the Mabry Internet Ping ActiveX
Control and COM Object, as shown in Figure D-12. Click on the Install button in the Security
Warning window to begin the download.
Figure D-12. Mabry Internet Ping Window
To Ping your SmartPAC2 from SmartView, follow these steps:
1. Make sure your SmartPAC 2 is turned on and the network cable is plugged into the
Ethernet connector (J122).
2. On the SmartView Setup Page, click on the Ping Utility link. The Ping Utility window,
shown in Figure D-13, displays.
Figure D-13. Ping Utility Window
3. Click on the Net Name or IP Addr(ess) window, and enter the SmartPAC 2 serial number
(i.e., SPAC2-nnnnnnnn, where nnnnnnnn is the serial number) if configured for DHCP or
the IP address if configured for a Static IP address.
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4. Click on the Ping button. A message indicating the success of the Ping is displayed in the
large window below Net Name or IP Addr(ess) as shown in Figure D-14 and Figure D-15.
Figure D-14 provides an example of a message indicating a successful Ping. Figure D-15
shows messages indicating two unsuccessful Ping attempts.
Figure D-14. Ping Utility Window with Example of a Successful Ping
Figure D-15. Ping Utility Window with Examples of Two Unsuccessful Pings
The “Host not found” message shown in Figure D-15 is typical of what you might see if the
name or IP address entered on the target device is not present on the network. The message
“The current connection has timed out” is typical of what you might find if the SmartPAC 2 is
turned off or the physical network connection is faulty (e.g., the RJ45 connector is not
plugged in or seated correctly or the Cat 5 cable between the SmartPAC 2 and the Hub is cut
or defective).
You can determine the source of the problem more precisely by pinging the PC closest to the
SmartPAC 2 on your LAN. If the Ping is successful, the problem is with the SmartPAC 2
rather than with the network.
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If you continue to get results like those shown in Figure D-15, you may want to contact your
IT department.
5. To clear the message(s) from the Ping Utility Window, click on the Clear List button.
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Appendix E. Replacing SmartPAC 2 PC
Board
The following procedures show you how to unpack and install a replacement SmartPAC 2 PC
board that you have received through the Wintriss Board Exchange (EX) program.
NOTICE
Under the board exchange program, a replacement board can usually be shipped to you overnight
if you contact Wintriss Tech. Support the previous business day. Full details about the program
are available by calling Wintriss Tech. Support.
Unpacking the Replacement Board
Perform the following steps as soon as you receive your replacement SmartPAC 2 PC board:
CAUTION
DAMAGE TO BOARD FROM STATIC DISCHARGE
Ground yourself before touching circuit boards or chips by touching a large metal object such as
the press. Static electricity can destroy electronic components.
Failure to comply with these instructions could result in property damage.
1. Making sure you are grounded, carefully unpack the replacement PC board and remove it
from its anti-static bag.
NOTICE
Be sure to save the shipping box in case you need to return the replacement board.
2. Verify that the board has not been damaged during shipment. If damage has occurred,
contact Wintriss Tech. Support immediately.
3. If your replacement board was shipped with a Boot Loader chip (component U124 in
Figure E-1, page E-3), verify that the serial number located on its label matches the serial
number on the Boot Loader chip on the board being replaced.
NOTICE
The label on the top-mounting flange of the SmartPAC 2 enclosure also shows the serial
number.
4. Put the PC board back in its anti-static bag until you are ready to install it.
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Installing the Replacement Board
To remove the old SmartPAC 2 PC board and install the new replacement board, perform the
following steps:
!
WARNING
ELECTRIC SHOCK HAZARD
• Ensure that the power source is off before you replace electronic components in a
control.
• Disconnect power from the machinery it is connected to before replacing electronic
components. This includes disconnecting power to the machine control and motor.
• Ensure that servicing is performed by qualified personnel.
Failure to comply with these instructions could result in death or serious injury.
1. Shut off power to the SmartPAC 2.
2. Open the SmartPAC 2 enclosure or console.
CAUTION
DAMAGE TO BOARD FROM STATIC DISCHARGE
Ground yourself before touching circuit boards or chips by touching a large metal object
such as the press. Static electricity can destroy electronic components.
Failure to comply with these instructions could result in property damage.
3. Making sure you are grounded, unplug all wired connectors from the SmartPAC 2 PC
board (see Figure E-1, page E-3), including connectors on the ProCamPAC and DiProPAC
boards (if installed).
NOTICE
Connectors are labeled “TBnnn” or “Jnnn” in Figure E-1, where nnn is a three-digit
numeric identifier.
To remove the small display connector J115, grasp the connector firmly between your
index finger and thumb and wiggle it gently back and forth in an upward direction. Do not
pull on the wires attached to the connector.
4. Remove the DiProPAC and ProCamPAC PC boards, if installed, and set them aside in a
safe location.
NOTICE
Do not remove the SOM (Industrial Computer) circuit board (see Figure E-1).
5. With a ¼-in. nut driver, remove all six ¼-in. nuts and six of the eight ¼-in. standoffs (see
Figure E-1). Do not remove the upper right standoff for the ProCamPAC PC board or the
lower left standoff for the DiProPAC PC board.
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Battery Backed Up
RAM Device
U124
S101
TB 105
Slave
60-250
JP 101
Master
Input
Check
Switch
12-60
HWCF 256H
SimpleTech
256MB
J114
Do not remove
this standoff
High
INSERT
TB 102
U105
Do not remove
this standoff
JP 102
Low
Compact Flash
Standoff (6 places)
1/4” Nut
(6 places)
DiPro
Boot Loader
Serial # xxxxxxxx
J113
ProCam
Lever
Ethernet
SOM (Industrial Computer)
USB
Mouse
TB 101
USB
PS 2
Mouse
PS
2
Do Not Remove
This Board
Keyboard (Rev. 6 & above)
TB 106
PS
2
TB 107
TB 104
TB 103
Insert Display Connector
this way
Figure E-1. SmartPAC 2 PC Board
6. Using both hands, carefully lift the PC board out of the enclosure, or from the mounting
plate if your unit is a panel mount.
7. Tag or label the board in a conspicuous place to identify it.
8. Place the old board you have just removed and the new replacement board side by side on
a clean, flat, dry surface.
9. Carefully eject and remove the compact flash card from the old board and insert it into the
replacement board in the same location (see Figure E-1).
NOTICE
To eject the compact flash card, push the lever on the bottom of the compact flash
receptacle all the way to the left.
To reinstall the compact flash card, insert the card into the flash receptacle with the
INSERT arrow on the label pointing toward the receptacle, and carefully push the card into
the receptacle until you hear it click into place.
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10. Remove the Battery Backed Up Ram chip (U105 in Figure E-1) from the original board
and install it in the replacement board. This chip holds all your tool data.
NOTICE
To remove the Battery Backed Up Ram chip:
1. Place a small, flat-blade screwdriver between the Boot Loader Chip (U124 in
Figure E-1) and the bottom of the Battery Backed Up Ram chip. Make sure the
screwdriver is in contact with the chip itself and not with the chip socket.
2. Using the Boot Loader Chip as a fulcrum, gently pry up the Battery Backed Up Ram
chip with the screwdriver until the chip begins to move. Then, grasping the chip firmly at
both ends, pull it upward until it comes free. Be careful not to bend the legs of the chip.
NOTICE
Before replacing the Battery Backed Up Ram chip:
1. Make sure to inspect the legs of the chip. If any are bent, carefully straighten them,
using small needle nose pliers.
2. Line up the chip with the socket, making sure the notch or identification dot on the top of
the chip is aligned with the notch or identification dot on the socket. Then push the chip
in evenly until it is fully seated.
11. If your replacement board was shipped without a Boot Loader chip (U124 in Figure E-1),
you must remove the Boot Loader chip from your old board and insert it into the
replacement board.
NOTICE
Use a flat blade screwdriver or an IC puller to remove the Boot Loader chip. Make sure
that the notch on the chip lines up with the notch on the socket.
12. Make sure that the Input Check switch (S101 in Figure E-1) and the Master/Slave and
High/Low speed jumpers (J101 and J102 in Figure E-1) are in the same position on the
replacement board as they are on the old board.
13. Install the replacement board in the enclosure, or on the mounting plate if your unit is a
panel mount, reusing the nuts and standoffs you removed in step 5 and tightening them
down with the ¼-in. nut driver. Refer to Figure E-1 for correct placement of nuts and
standoffs.
14. Reinstall the ProCamPAC and DiProPAC PC boards, if necessary, in their proper locations
on the SmartPAC 2 board.
15. Plug all the connectors you removed in step 3 back into the SmartPAC 2 board, including
connectors on the ProCamPAC and DiProPAC boards (if installed). Make sure to insert
the display connector (J115 in Figure E-1) into the SmartPAC 2 board with the correct
orientation.
16. Double-check to make that sure all connectors are plugged into the correct slots.
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17. Close the door of the SmartPAC 2 enclosure or console.
18. On the SmartPAC 2 display, press and hold down the F1 function key while powering up
the SmartPAC 2, releasing F1 when the red Wintriss SmartPAC 2 screen displays. After
about a minute the FIRMWARE LOAD MENU (see Figure E-2) will appear.
Figure E-2. Firmware Load Menu with “RELOAD CURRENT FIRMWARE” Highlighted
19. Select “RELOAD CURRENT FIRMWARE” (if this menu choice does not appear, call
Wintriss Tech. Support), and press ENTER.
20. Follow the on-screen instructions for loading new firmware. This process will take
approximately 4 to 5 minutes.
21. When the reload process has been completed, you are ready to resume normal operation.
NOTICE
Before setting up and running a job, it is a good idea to test a few SmartPAC 2 modes and
menus to make sure the unit is operating normally. If you have swapped the Battery
Backed Up Ram chip in step 10, go into the Tool Manager (enter from the Main Program
Menu) and verify that all your tools have been restored. If you experience any problems,
call Wintriss Tech. Support.
22. Place the malfunctioning board in the anti-static bag in which you received the
replacement board.
Place the anti-static bag with the old board in the box in which you received the replacement
board, and ship it back to Wintriss, using the shipping label with the Return Authorization
(RA) number. Contact Wintriss Tech. Support if you have additional questions.
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SmartPAC 2 Servo User Manual
Replacing SmartPAC 2 PC Board
Appendix F. Reporting Downtime and
Scrap to SFC
This appendix shows you how to report press downtime from your SmartPAC 2 control to
Wintriss’s ShopFloorConnect Asset Utilization Software (SFC). The appendix discusses the
six machine states to which SFC logs press time, explains the downtime reporting features of
SmartPAC 2, shows you how to set up SmartPAC 2 to report downtime to SFC, and provides
instructions for reporting downtime.
The appendix also shows you how to use the scrap counter on the SmartPAC 2 Counters
screen in Run mode to report scrap to SFC and how to adjust the Good Parts count that is
reported to SFC.
SmartPAC’s downtime- and scrap-reporting features are available only on SmartPAC 2
versions 4.59 or higher; in addition, the SFC firmware option must be installed.
Machine States to Which SFC Logs Press Time
SFC logs all elapsed time at each press to one of six categories called machine states. The
sum of all the times assigned to these machine states for an individual press is the number of
hours in a production day (e.g., 12 hours, 24 hours, etc.). SFC selects the machine state to
which to log press time on the basis of downtime reporting and other information it receives
from SmartPAC 2. Machine states are differentiated as follows:
• Running Time–Press is running and making parts
• Idle Time–Press is stopped, no SmartPAC error has occurred, and the reason the press is
stopped has not been documented in SmartPAC 2
• Unplanned Downtime–Press is stopped due to a SmartPAC 2 error, or if the press is stopped
for another reason, that reason has been assigned to the Unplanned Downtime state in SFC
• Planned Downtime–Press is stopped, and the reason has been assigned to the Planned
Downtime state in SFC
• Changeover Time–Press is stopped, and the reason has been assigned to the Changeover
state in SFC
• Offline Time–Press is stopped because there is no power to the press or the network is
down
All time during which the press is stopped for any reason other than a power interruption or
network failure is logged by SFC to Idle Time unless a downtime reason is reported from the
SmartPAC 2. Idle Time is treated in ShopFloorConnect as downtime with no documented
reason. Since corrective action cannot be taken until a cause is identified, SmartPAC 2 has
been designed to allow very precise reporting of downtime to SFC and may be programmed to
require the operator to select a specific downtime reason each time the press enters an Idle
state. When operator intervention is required, periods of press inactivity are more likely to be
assigned to a specific downtime reason than to be logged as Idle Time.
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SmartPAC 2 Downtime Reporting Features
Downtime reasons in SmartPAC 2 may be reported to SFC either automatically by the system
or manually by the operator. When the press is stopped because of an error generated by
SmartPAC 2 or an installed SmartPAC 2 module, the specific fault (e.g., “Sensor 1 Part
Ejection Missed”) is reported automatically as a downtime reason to SFC.
When the press is stopped by the operator or by a piece of auxiliary equipment not connected
to the SmartPAC 2, a downtime reason must be reported manually by the operator since
SmartPAC 2 is unable to detect the reason for the interruption (see Forced Idle Dialog Mode,
below). Downtime reasons may also be assigned manually to provide additional detail for
periods documented automatically with specific error conditions (see Forced Error Dialog
Mode, page F-4).
Forced Idle Dialog Mode
If the SmartPAC 2 is set to Forced Idle Dialog mode (see Making Downtime Reporting
Settings, page F-7), a downtime reason must be entered whenever the press is stopped by the
operator or by auxiliary equipment. When the press stops (see Figure F-1, page F-3 for a
schematic time line), a message displays at the SmartPAC 2 stating that the operator must
enter a downtime reason before the press can be restarted. When the operator closes the
message window, the Dialog Menu automatically displays. The Dialog Menu, a selection on
the SmartPAC 2 Main Run Menu, displays a list of downtime reasons from which the operator
must select to report downtime to SFC. Refer to Programming Downtime Reasons, page F-12
for instructions on how to set up the Dialog Menu.
The Forced Dialog message can be programmed to display a specified number of minutes
after the press stops (see Figure F-1). This Idle Dialog Time setting enables the press to be
stopped briefly without requiring entry of a downtime reason.
Backfilling vs. Forward Filling
SFC initially logs the time after the press is stopped by the operator or by auxiliary equipment
to Idle Time. When the operator selects an item on the Dialog Menu, the period of time
previously documented as Idle is assigned that downtime reason. Downtime can be assigned
manually or automatically, depending on how your SmartPAC 2 is programmed (see Making
Downtime Reporting Settings, page F-7).
If SmartPAC 2 is set up for manual downtime reporting, the operator selects how the
downtime is to be assigned in an option window that displays following selection of the
downtime reason (see Figure F-11, page F-18). One option, which is called “backfilling,” is
to assign the downtime reason to all time that has elapsed since the press was stopped (see
Figure F-1). The other option is to “forward fill” the downtime reason, assigning it to the
period from reporting of the downtime reason until the press is restarted (see Figure F-2,
page F-4). When this option is selected, all elapsed time before entry of the downtime reason
is assigned to the previous downtime reason, if one was reported, or to Idle Time.
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If SmartPAC 2 is set up for automatic downtime reporting, the option window does not
display following selection of the downtime reason, and downtime is automatically
backfilled.
Putting the Press “Back on Line”
A period of Idle Time or Planned or Unplanned downtime comes to an end either a
programmed number of strokes after the operator restarts the press (see Reset Strokes
Counters, page F-6) or when he selects “Back on Line” from the Dialog Menu. If the press is
restarted at the same time as “Back on Line” is selected, SFC begins documenting the
machine state as “Running time” (see Figure F-1). When the operator selects “Back on Line”
without restarting the press, the subsequent period until the press is restarted is logged to Idle
Time (see Figure F-2).
Press Status/
Operator Actions
SmartPAC
Settings and
Displays
Initial
SFC
Machine
State
Updated
SFC
Machine
State
Running time
Running time
Idle time
Downtime
reason–
Backfill
Press is running
Press is stopped
by operator or
auxiliary equipment
Time
(in min.)
Forced Dialog
time (5 min.)
Forced Dialog
message displays
Operator presses RESET
Dialog Menu displays
Operator enters
downtime reason
with Backfill option
Operator enters Back on Line,
restarts press
Running time
Figure F-1. Forced Idle Dialog Mode Time Line (Downtime Reason Backfilled)
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Press Status/
Operator Actions
SmartPAC
Settings and
Displays
Initial
SFC
Machine
State
Updated
SFC
Machine
State
Running time
Running time
Idle time
Idle time
Press is running
Press is stopped
by operator or
auxiliary equipment
Time
(in min.)
Forced Dialog
time (5 min.)
Forced Dialog
message displays
Operator presses RESET
Operator enters
downtime reason
with Forward Fill option
Dialog Menu displays
Downtime
reason–
Forward fill
Operator enters Back on Line
Idle time
Operator restarts press
Running time
Figure F-2. Forced Idle Dialog Mode Time Line (Downtime Reason Forward Filled)
Forced Error Dialog Mode
The Dialog Menu can also be programmed to display whenever the press is stopped due to a
SmartPAC 2-generated fault. This feature, called Forced Error Dialog mode (see Making
Downtime Reporting Settings, page F-7), allows the operator to add detail to a period of
downtime that is initially logged to a specific SmartPAC 2 error but may actually have a
different cause.
For example, SmartPAC 2 may be set up to generate an “End of Stock” error whenever the
press runs out of material. This downtime reason is applied to the period of time during which
a new coil is located and brought to the press unless the operator selects a more appropriate
downtime reason, such as “Waiting for Coil,” and, using the backfill option (see Backfilling
vs. Forward Filling, page F-2), applies it to the incompletely documented period. When the
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downtime reason is backfilled (see Figure F-3 for a schematic time line), SmartPAC logs one
second to the initial error (e.g., “Sensor 5–End of Stock”), assuring that the fault is
documented, and the remaining time to the new downtime reason (e.g., “Waiting for Coil”).
Press Status/
Operator Actions
SmartPAC
Settings and
Displays
Initial
SFC
Machine
State
Updated
SFC
Machine
State
Running time
Running time
Press is running
Press is stopped
by SmartPAC
SmartPAC
fault (1 sec.)
Time
(in min.)
Error Dialog
time (5 min.)
Forced Dialog
message displays
Operator presses RESET
Dialog Menu displays
SmartPAC
fault
Downtime
reason–
Backfill
Operator enters
downtime reason
with Backfill option
Operator enters Back on Line,
restarts press
Running time
Figure F-3. Forced Error Dialog Mode Time Line
Downtime reasons can also be “forward filled” in Forced Error Dialog mode.
As in Forced Idle Dialog mode, the Forced Dialog message can be programmed to display a
specified number of minutes after the press stops (see Figure F-3). This Error Dialog Time
setting prevents nuisance faults such as “Counter preset reached” from being reported as
downtime.
Persist Dialog Mode
Periods during which the press is powered down are normally documented as Offline Time
and the period following the next power-up assigned to Idle Time. Periods subsequent to
machine power-ups are documented as Idle Time even when the period immediately
preceding the shutdown has been assigned to an Unplanned Downtime reason. The only
machine states that carry over from the period immediately preceding a shutdown to the
period immediately succeeding a power-up are Changeover Time and Planned Downtime. In
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these cases, the period during which the press is offline and the time immediately following
press power-up are assigned to the machine state in effect when the press was powered down.
SmartPAC 2 can be programmed so that Unplanned Downtime reasons selected from the
Dialog Menu also “persist” through press shutdowns (see Making Downtime Reporting
Settings, page F-7). When this setting is enabled, both the interval during which the press was
powered down and the time following resumption of power to the press are assigned to the
downtime reason in effect when the press was shut down. One second of the period during
which the press was offline is assigned to Offline Time to document this event.
Single-stroke Mode
For hand-fed applications, a special setting can be programmed at the SmartPAC 2 (see
Making Downtime Reporting Settings, page F-7) that allows the state of the press to be
continuously reported as “Running” as long as the operator maintains a pre-determined cycle
time. Normally, Single-stroke operation produces an alternating series of “Running” and
“Idle” events as the press cycles and then stops to allow the operator to remove one part and
load another. Since the state of the press is reported as “Running” only a fraction of the time
even when the operator is maintaining an acceptable production rate, this data stream does not
accurately reflect press productivity, skewing OEE ratings unfairly downward.
When you make this cycle time setting, SmartPAC 2 no longer looks for a change of state to
determine whether the press is running but rather expects to see the press stroke at least once
during the pre-programmed interval. If a stroke is detected, the press is reported as
“Running”; if not, the press is considered to be stopped and reported as “Idle.”
Reset Strokes Counters
Normally, a period of Idle Time, Planned or Unplanned Downtime, or Changeover Time is
ended when the operator selects “Back on Line” from the Dialog Menu and restarts the press
(see Putting the Press “Back on Line,” page F-3). However, since the operator may forget to
select the “Back on Line” item, an alternative way of terminating a period of downtime is
available.
SmartPAC 2 can be programmed to begin logging time following a downtime period to
Running Time after a specified number of press strokes. A Reset Strokes counter (see Making
Downtime Reporting Settings, page F-7) begins incrementing when the press is restarted, and
after the counter reaches its preset, SFC changes the machine state to which it logs press time
from the downtime reason to Running Time. Three different Reset Strokes counters can be
programmed, allowing you to set different restart intervals following periods of Planned
Downtime, Unplanned Downtime, and Changeover time.
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Setting up SmartPAC 2 to Report Downtime
To set up SmartPAC 2 to report downtime to SFC, you make downtime reporting settings on
the Set Communications Menu. You program downtime reasons in one of two ways,
depending on the setting you select in the DIALOG SCREEN MODE field on the Set
Communications Menu (see Table F-1, page F-10).
When the default setting “16 / 16” is selected, you create downtime reasons on the Dialog
Special Choice Name and Dialog Fixed Name Choice menus, which you access via the SET
SPECIAL NAMES and SET CANNED NAMES items on the Set Communications Menu.
When you select the DIALOG SCREEN MODE setting of “32 CUSTOM,” you create
downtime reasons in SFC and download them to the SmartPAC 2. The SET SPECIAL
NAMES and SET CANNED NAMES items do not display when the “32 CUSTOM” option
is selected.
NOTICE
Wintriss recommends that you select the “32 CUSTOM” setting if your shop floor uses only
SmartPAC 2 controls. The “16 / 16” setting should be selected only if you have a mix of
SmartPAC 2s and SmartPAC 1s and want to maintain consistency in your downtime reporting
method.
The “32 CUSTOM” setting provides two advantages. All downtime reasons can be
customized to meet the specific needs of your shop floor setup (up to 32 custom names can be
created in SFC Administrator), and you can include all reasons in the Downtime by Reason
report, which allows you to track occurrences of a specific downtime reason across multiple
machines.
With the “16 / 16” setting you can create only 16 custom reasons (the other 16 are “canned”),
and only the custom reasons can be included in the Downtime by Reason report. The report
cannot be generated for “canned” reasons.
Making Downtime Reporting Settings
To enable and configure the SmartPAC 2 downtime reporting features described in the
previous section, perform the following steps:
1. At the SmartPAC 2, turn the Program/Run key to “PROG,” then press the “1” and
“CLEAR” keys simultaneously for a second or two until the Main Initialization Menu (see
Figure F-4, page F-8) displays.
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Figure F-4. SmartPAC 2 Main Initialization Menu
2. Highlight the “SETUP DATA COMMS” menu item, using the Up () or Down ()
cursor key, and press ENTER. The Set Communications Menu (see Figure F-5) displays:
Figure F-5. Set Communications Menu
NOTICE
Wintriss recommends that you take advantage of the additional features provided by the
“32 Custom” dialog screen mode setting. The “16 / 16” setting should be selected only
when you have both SmartPAC 1s and SmartPAC 2s and, even then, only if complete
consistency is required.
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3. Highlight each menu item you want to set, using the Up () or Down () cursor key,
then do the following:
• To enable or disable a feature, press ENTER until the desired setting is displayed.
• To specify a value for an item (with the exception of IDLE TIMER), press ENTER to
display the Numeric Entry window, key in your entry with the SmartPAC 2 keypad, and
press ENTER again.
• To select an option for DIALOG SCREEN MODE, press ENTER until the desired
setting is displayed. When DIALOG SCREEN MODE is set to “16 / 16,” the SET
SPECIAL NAMES and SET CANNED NAMES items display at the bottom of the
menu. When the setting is “32 CUSTOM,” these items do not appear.
• To select a value for IDLE TIMER, press ENTER until the desired value is displayed.
• To display screens on which you can program Dialog Menu entries (the DIALOG
SCREEN MODE setting must be “16 / 16”), press ENTER with the cursor resting in
the SET SPECIAL NAMES or SET CANNED NAMES field.
To program downtime reasons when DIALOG SCREEN MODE is set to “32
CUSTOM,” you use ShopFloorConnect Administrator.
Table F-1 explains each field on the Set Communications Menu and provides instructions
on how to make settings.
Table F-1. Set Communications Menu Settings
Field
Settings
RSR/SBR CPU NUMBER
When SmartPAC 2 is connected to SFC, this field must be set
to “1.” Other CPU Number values may be used when
SmartPAC 2 is connected to certain legacy software products
that require each SmartPAC 2 to be assigned a unique
identifier.
FORCED IDLE DIALOG
Indicates whether SmartPAC 2 displays the Forced Dialog
message and Dialog Menu after the press has been stopped
by the operator or by auxiliary equipment not connected to
SmartPAC 2. The number of minutes after the press has
stopped before the Forced Dialog message appears is
specified in the IDLE DIALOG TIME field (see next entry). At
the appearance of the Forced Dialog message, the operator
must select a downtime reason on the Dialog Menu in order to
restart the press. This setting allows time that elapses after
the press is stopped by the operator or by equipment not
connected to SmartPAC 2 to be documented with a downtime
reason rather than as Idle Time. There are two settings:
ENABLED Forced Idle Dialog mode enabled
DISABLED Forced Idle Dialog mode disabled
IDLE DIALOG TIME
Specifies the number of minutes (1-60) after the press has
stopped in Forced Idle Dialog mode before the Forced Dialog
message displays. This setting allows you to prevent Forced
Idle Dialog from being triggered by brief stops. Suggested
initial value: 5 minutes.
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Table F-1. Set Communications Menu Settings (Cont.)
Field
Settings
FORCED ERROR DIALOG
Indicates whether SmartPAC 2 displays the Forced Dialog
message and Dialog Menu after the press has been stopped
by a SmartPAC 2 fault. The number of minutes after the press
has stopped before the Forced Dialog message appears is
specified in the ERROR DIALOG TIME field (see next entry).
At the appearance of the Forced Dialog message, the operator
must select a downtime reason on the Dialog Menu in order to
restart the press. This setting allows time that elapses after
the press is stopped due to a SmartPAC 2 fault to be assigned
a different downtime reason. There are two settings:
ENABLED Forced Error Dialog mode enabled
DISABLED Forced Error Dialog mode disabled
ERROR DIALOG TIME
Specifies the number of minutes (1-60) after the press has
stopped in Forced Error Dialog mode before the Forced Dialog
message displays. This setting allows you to prevent reporting
of SmartPAC 2 nuisance faults such as “Counter preset
reached.” Suggested initial value: 5 minutes.
PERSIST DIALOG
Indicates whether an Unplanned Downtime reason from the
Dialog Menu that is assigned before a press shutdown
continues to be applied to the period during which the press is
down and to the time after the press is powered up again.
Normally, the interval during a press shutdown is assigned to
“Offline Time” and the period after the press is powered up to
“Idle Time.” There are two settings:
ENABLED Persist Dialog mode enabled
DISABLED Persist Dialog mode disabled
AUTO BACKFILL
Indicates whether time occurring after the press has been
stopped up to the point when the operator selects a downtime
reason is automatically documented with that reason. When
this item is disabled, the operator is given the option of
backfilling or forward filling downtime following selection of a
downtime reason. When this item is enabled, the downtime
reason selected by the operator is automatically backfilled.
There are two settings:
ENABLED Auto Backfill enabled
DISABLED Auto Backfill disabled
DIALOG SCREEN MODE
Indicates whether downtime reasons are created on the
screens accessible from the SET SPECIAL NAMES and SET
CANNED NAMES menu items (see below) or in
ShopFloorConnect Administrator. There are two settings:
16 / 16
32 CUSTOM
Downtime reasons are created in SmartPAC
Downtime reasons are created in SFC
When the “16 / 16” setting is selected, you can create only 16
custom downtime reasons, and only those reasons can be
included in the Downtime by Reason Report. The “32
CUSTOM” setting enables you to create up to 32 custom
reasons, all of which can appear in the Downtime by Reason
Report. When the “32 CUSTOM” setting is selected, the SET
SPECIAL NAMES and SET CANNED NAMES items do not
display.
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Table F-1. Set Communications Menu Settings (Cont.)
Field
Settings
UNPLANNED RESET
STROKES
Specifies the number of strokes that must occur after the press
is restarted following a period of Unplanned Downtime,
Planned Downtime, or Changeover Time before SFC begins
documenting the machine state as “Running Time.” This
setting prevents additional press time from being attributed to
a downtime reason when the operator forgets to select the
“BACK ON LINE” item from the Dialog Menu. The number of
strokes you specify should be the maximum number of press
cycles that are likely to be needed to return the press to
production. Valid entries: 1-9999. Suggested settings:
PLANNED RESET
STROKES
CHANGEOVER RESET
STROKES
Set the Unplanned Reset Strokes counter to two strokes more
than the maximum number of strokes required to fill an empty
die. This setting should give the operator sufficient time to
complete a response to the downtime cause (such as Coil
Change) that requires the longest time to address.
Set the Planned Reset Strokes counter to the lowest number
of strokes required to return the press to production following a
lunch or other break.
Set the Changeover Reset Strokes counter to the maximum
number of strokes required to complete a die setup.
SINGLE STROKE MODE
This setting, which is used for hand-fed applications when the
press is being run in Single-stroke mode, indicates whether
SFC counts press cycles (or parts made) within the period
specified in the IDLE TIMER field (see next entry) to determine
whether the press is “running.” When this field is set to
“ENABLED,” SFC only documents the press as “Idle” when no
cycles occur (i.e., no parts are made) during an Idle Timer
period. There are two settings:
ENABLED Single-stroke Mode enabled
DISABLED Single-stroke Mode disabled
IDLE TIMER
Specifies the number of seconds during which SmartPAC 2
counts the number of press strokes in Single-stroke mode to
determine a production rate for hand-fed applications. This
value should be twice the cycle time for the slowest hand-fed
job run on a press. For example, if the slowest job produces
an average of 6 parts per minute, the Idle Timer should be set
to 20 seconds (6 parts per minute = 10-second cycle time; 2 x
10 seconds = 20 seconds). Available selections: 5, 10, 15, 20,
30, and 60.
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Table F-1. Set Communications Menu Settings (Cont.)
Field
Settings
SET SPECIAL NAMES
Displays the Dialog Special Choice Name Menu, on which you
can create up to 16 custom downtime reasons for display on
the Dialog Menu and specify the order in which they will
appear (see Creating Special Names on the Dialog Special
Choice Name Menu, page F-14). This item does not display
when the setting for DIALOG SCREEN MODE is “32
CUSTOM.”
SET CANNED NAMES
Displays the Dialog Fixed Name Choice Menu, on which you
can select up to 14 pre-programmed, or “canned,” downtime
reasons for display on the Dialog Menu and specify the order
in which they will appear (see Selecting Canned Names on the
Dialog Fixed Name Choice Menu, page F-13). This item does
not display when the setting for DIALOG SCREEN MODE is
“32 CUSTOM.”
Programming Downtime Reasons
If the DIALOG SCREEN MODE item on the Set Communications Menu has been set to
“16 / 16,” the default, the SET SPECIAL NAMES and SET CANNED NAMES items are
displayed on the menu, allowing you to specify the downtime reasons that appear on the
Dialog Menu and the order in which they are presented. The items you program on these two
menus will be the menu selections available to the operator when the Dialog Menu displays in
Forced Idle Dialog or Forced Error Dialog mode, or when the operator accesses the menu at
other times.
If the DIALOG SCREEN MODE setting is “32 CUSTOM,” the SET SPECIAL NAMES and
SET CANNED NAMES items do not display, and you create downtime reasons in SFC.
“Canned” names are downtime reasons whose text has been pre-programmed into the
SmartPAC 2. “Special” names are downtime reasons whose text you assign. You can select
up to 14 “canned” names and create up to 16 “special” names. The Dialog Menu can include
both “canned” and “special” entries, displaying up to 30 items.
NOTICE
It is recommended that you create a standardized list of downtime reasons for all your presses.
Having the Dialog Menu display the same downtime reasons in the same order on all
SmartPAC 2s will help to minimize reporting errors.
When planning the order in which you want Dialog Menu items to display, you should
attempt to predetermine the downtime causes that are likely to occur most frequently and
place these at the beginning of the downtime reason sequence.
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Selecting Canned Names on the Dialog Fixed Name Choice Menu
When you select the SET CANNED NAMES item on the Set Communications Menu, the
Dialog Fixed Name Choice Menu (see Figure F-6) displays. This menu allows you to select
the “Canned” names that will appear on the Dialog Menu. “Canned” names are downtime
reasons whose text has already been programmed into the SmartPAC 2. You can select up to
14 of these pre-programmed entries for inclusion in the Dialog Menu.
Figure F-6. Dialog Fixed Name Choice Menu
You select a “canned” name by entering a sequence number to the right of the name’s text
entry. The sequence number specifies the position in which that item will appear on the
Dialog Menu. For example, in the screen shown in Figure F-6, the item LUBE PROBLEM
has a sequence number of 6 and, so, will appear sixth on the Dialog Menu. Since “special”
downtime reasons may also appear on the Dialog Menu, be sure to maintain the necessary
intervals in your “canned” name numbering scheme to accommodate these items.
To prevent a “canned” name from appearing on the Dialog Menu, set its sequence number to
0.
It is recommended that you include the following “canned” items in the Dialog Menu:
• TOOL CHANGE–This downtime reason is logged to the Changeover Time machine state,
enabling SFC to track time for tool changes separately from other unplanned downtime and
create special Changeover reports. “Tool Change” is the only Unplanned Downtime reason
that is assigned to time when power to the press is off. Powering down the press is often
necessary during tool changeover.
• BACK ON LINE–This selection enables the operator to end a downtime event. When
BACK ON LINE is selected, the machine state will change from “Unplanned Downtime,”
“Planned Downtime,” or “Changeover Time” to “Running Time” if the press is running or
from one of these “downtime” states to “Idle Time” if the press is stopped.
• OPER. NUMBER–This “canned” name allows the operator to enter an operator number,
enabling SFC to assign a period of press time such as a shift to a particular operator.
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To select the pre-programmed downtime reasons that will appear on the Dialog Menu and the
order in which they will appear, do the following:
1. On the Set Communications Menu, highlight the SET CANNED NAMES item, using the
Up () or Down () cursor key, and press ENTER. The Dialog Fixed Name Choice
Menu (see Figure F-6) displays with the cursor resting in the OPER. NUMBER field.
2. Press ENTER, and when the Numeric Entry window appears, type the numeric position in
which you want that item to appear on the Dialog Menu, or type “0” if you want to prevent
the item from displaying on the Dialog Menu. Press ENTER to save your entry and return
to the Dialog Fixed Name Choice Menu.
3. Move the cursor to the BACK ON LINE field, using the Down () cursor key, and repeat
step 2. Do the same for the remaining menu items.
NOTICE
Remember to leave intervals between sequence numbers to allow room for “special”
downtime reasons. See Creating Special Names on the Dialog Special Choice Name
Menu, page F-14.
If the same sequence number is assigned to both a “canned” and a “special” name, both
entries will display in that position on the Dialog Menu with the “special” name shown first.
4. When you are finished setting the sequence of “canned” names, press RESET to save your
entries and return to the Set Communications Menu.
Creating Special Names on the Dialog Special Choice Name Menu
When you select the SET SPECIAL NAMES item on the Set Communications Menu, the
Dialog Special Choice Name Menu (see Figure F-7, page F-15) displays. This menu allows
you to select the “special” names that will appear on the Dialog Menu. “Special” names are
downtime reasons created by the user. Each name can be up to 12 characters in length, and
you can include up to 16 of them in the Dialog Menu.
You specify the order in which “special” names appear on the Dialog Menu by entering a
sequence number to the right of each text entry. The sequence number specifies the position
in which that item will appear on the Dialog Menu. Since “canned” downtime reasons may
also appear on the Dialog Menu, be sure to maintain the necessary intervals in your “special”
name numbering scheme to accommodate these items.
To prevent a “special” name from appearing on the Dialog Menu, set its sequence number to
0.
To program “special” downtime reasons for inclusion in the Dialog Menu, perform the
following steps:
1. On the Set Communications Menu, highlight the SET SPECIAL NAMES item, using the
Up () or Down () cursor key, and press ENTER. The Dialog Special Choice Name
Menu displays with the cursor resting in the SPEC. 1 field.
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Figure F-7. Dialog Special Choice Name Menu
2. Press ENTER, and when the Alphabetic Entry window displays, type the text (12
characters maximum, including spaces) of the downtime reason that you want to appear
on the Dialog Menu; then, press F6 to save your entry and return to the Dialog Special
Choice Name Menu.
3. Press the Right () cursor key to move the cursor to the column for the SPEC. 1 sequence
number.
4. Press ENTER, and when the Numeric Entry window displays, type the numeric position
in which you want that downtime reason to appear on the Dialog Menu; then, press
ENTER to save your entry and return to the Dialog Special Choice Name Menu.
NOTICE
Remember to leave intervals between sequence numbers to allow room for “canned”
downtime reasons. See Selecting Canned Names on the Dialog Fixed Name Choice
Menu, page F-13.
If the same sequence number is assigned to both a “canned” and a “special” name, both
entries will display in that position on the Dialog Menu with the “special” name shown first.
5. Move the cursor to the SPEC. 2 field, using the Down () cursor key, and repeat steps 2
through 4. Do the same for the remaining menu items.
6. When you have finished programming “special” downtime reasons, press RESET to save
your entries and return to the Set Communications Menu.
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Documenting Downtime on the Dialog Menu
A downtime reason can be selected on the Dialog Menu either in response to the Forced
Dialog message or when the operator wants to change a previous downtime entry or add detail
to reported downtime.
Documenting Downtime in Response to the Forced Dialog Message
With Forced Idle Dialog mode or Forced Error Dialog mode enabled (see Making Downtime
Reporting Settings, page F-7), the operator is prompted to enter a downtime reason on the
Dialog Menu whenever SmartPAC 2 detects that the press has stopped under the appropriate
circumstances. This message is shown in Figure F-8.
F1
F2
F3
F4
F5
F6
F7
F8
Figure F-8. SmartPAC 2 Run Mode Main Menu with Forced Dialog Message Displayed
To respond to this prompt, perform the following steps:
1. Press RESET to clear the message. The Dialog Menu displays. If dialog screen mode is
set to “16/16” (see Setting up SmartPAC 2 to Report Downtime, page F-7), the Dialog
Menu looks like the example shown in Figure F-9, page F-17. If “32 CUSTOM” is the
dialog screen mode setting, the Dialog Menu looks like the example shown in
Figure F-10. Note that the “32 CUSTOM” Dialog Menu has assigned the Operator
Number, Back on Line, and Changeover downtime reasons to function keys F4, F5, and
F6; also, the F7 key has been assigned to the End Job function (see Ending a Job,
page F-20).
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F1
F2
F3
F4
F5
F6
F7
F8
Figure F-9. Dialog Menu (“16/16” Dialog Screen Mode)
F1
F2
F3
F4
F5
F6
F7
F8
Figure F-10. Dialog Menu (“32 CUSTOM” Dialog Screen Mode)
2. Highlight the downtime reason you want (in Figure F-9, MECH PROBLEM is selected as
an example), using the Up () or Down () cursor key, and press ENTER.
or
Press the function key for Operator Number, Back on Line, or Changeover (“32
CUSTOM” dialog screen mode only; see Figure F-10).
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3. If Auto Backfill has been enabled on the Set Communications Menu (see Table F-1,
page F-10), the downtime reason you selected is automatically “backfilled” (i.e., assigned
to the period from the time that the press was stopped up to entry of the next downtime
reason or the BACK ON LINE selection). If a SmartPAC 2 fault has already been
assigned to this period of press inactivity, that fault will be documented as having
consumed 1 second and the remainder of the period filled with the downtime reason you
selected. If the period has been documented as Idle Time, your downtime reason will
replace that entry. The SmartPAC 2 will display a message stating that the downtime
reason has been sent to the host computer.
4. If Auto Backfill has been disabled, the window shown in Figure F-11 displays.
F1
F2
F3
F4
F5
F6
F7
F8
Figure F-11. Dialog Menu with F2/F3 Option Window Displayed
Press the F2 (Change Prev. Reason) function key to “backfill” the selected downtime
reason, in other words, to assign it to the period from the time that the press was stopped
up to entry of the next downtime reason or the BACK ON LINE selection. If a SmartPAC
2 fault has already been assigned to this period of press inactivity, that fault will be
documented as having consumed 1 second and the remainder of the period filled with the
downtime reason you selected. If the period has been documented as Idle Time, your
downtime reason will replace that entry.
or
Press F3 (Keep Prev. Reason) to leave documentation of the period up to the present
unchanged and “forward fill” the selected downtime reason, in other words, assign it to
the period from the present up to entry of the next downtime reason or the BACK ON
LINE selection.
The SmartPAC 2 will display a message stating that the downtime reason has been sent to
the host computer.
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Documenting Downtime in Other Situations
You can report downtime reasons to SFC at any time without being prompted by the Forced
Dialog message.
EXAMPLE: UPDATING A DOWNTIME REASON
The operator stops the press for what he assumes is a feed problem and selects the downtime reason
“FEED PROBLEM” from the Dialog Menu. After further investigation, he finds that the feed is working
properly but the air supply to the feed is intermittent. The operator accesses the Dialog Menu, selects
“AIR PROBLEM” from the list of downtime reasons, and chooses the F2 (Change Prev. Reason)
option. SFC changes the reason for the downtime period from “FEED PROBLEM” to “AIR
PROBLEM.”
To report downtime without being prompted, perform the following steps:
1. On the Main Run Menu (see Figure F-12), select the DIALOG MENU item.
F1
F2
F3
F4
F5
F6
F7
F8
Figure F-12. SmartPAC 2 Run Mode Main Menu with DIALOG MENU Item Selected
2. On the Dialog Menu, highlight the downtime reason you want, using the Up () or
Down () cursor key, and press ENTER.
or
Press the function key for Operator Number, Back on Line, or Changeover (“32
CUSTOM” dialog screen mode only).
3. If Auto Backfill has been enabled on the Set Communications Menu (see Table F-1,
page F-10), the downtime reason you selected is automatically “backfilled” (i.e., assigned
to the period from the time that the press was stopped up to entry of the next downtime
reason or the BACK ON LINE selection). If a SmartPAC 2 fault has already been
assigned to this period of press inactivity, that fault will be documented as having
consumed 1 second and the remainder of the period filled with the downtime reason you
selected. If the period has been documented as Idle Time, your downtime reason will
replace that entry. The SmartPAC 2 will display a message stating that the downtime
reason has been sent to the host computer.
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4. If Auto Backfill has been disabled, the window shown in Figure F-11 displays.
Press the F2 (Change Prev. Reason) function key to “backfill” the selected downtime
reason, in other words, to assign it to the period of Idle Time or downtime up to entry of
the next downtime reason or the BACK ON LINE selection. If a downtime reason other
than a SmartPAC 2 fault has been assigned to this period, the downtime reason you
selected will replace it. If a SmartPAC 2 fault has been assigned to this period, that fault
will be documented as having consumed 1 second and the remainder of the period filled
with the downtime reason you selected. If the period has been documented as Idle Time,
your downtime reason will replace that entry.
or
Press F3 (Keep Prev. Reason) to leave documentation of the period up to the present
unchanged and “forward fill” the selected downtime reason, in other words, assign it to
the period from the present up to entry of the next downtime reason or the BACK ON
LINE selection.
The SmartPAC 2 will display a message stating that the downtime reason has been sent to
the host computer.
Ending a Job
If you are using the “32 CUSTOM” dialog screen mode setting, the Dialog Menu allows you
to “close out” the previous job when no subsequent job is immediately available, thereby
preventing any non-job-related downtime to be charged against it. You close out the previous
job by pressing the F7 (End Job) function key (see Figure F-10, page F-17).
Normally, in ShopFloorConnect one job ends and a new one begins when a new tool number
is loaded, at which point all data stops accruing for the previous tool and begins accruing for
the new tool.
When an End Job function is executed, the SmartPAC 2 will report the tool number to SFC as
Tool Number “0” to indicate that the machine is in a “No Job” condition. All time logged
during the No Job condition can be assigned machine states (Planned Downtime, Unplanned
Downtime, or Changeover) and downtime reasons just as if a tool were actually loaded.
Please note that if the End Job button is used, the current job will end, but the machine can
still be run. Any production run after the job has ended will be attributed to a new job.
NOTICE
DO NOT use the End Job function key unless you are absolutely certain that you want to close out
the previous job. A job cannot be “reopened” once it has ended. If you attempt to reopen a job, any
production that is run after the end of the job will be attributed to a new job using the same tool
number.
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Creating Hot Keys for Dialog Menu Functions
You can create Hot Keys on the Main Run Menu (see page 3-11 for an overview) for menu
selections and function key assignments on the Dialog Menu, enabling you to perform Dialog
Menu tasks from the Run Menu. When Dialogue Screen Mode is set to “32 CUSTOM” (see
Table F-1. page F-10), you can create Hot Keys for both selected menu items and for function
keys F4 through F7, which are pre-programmed. If Dialogue Screen Mode is set to “16/16,”
you can create Hot Keys only for menu items.
To program Hot Keys for selections on the Dialog Menu, perform the following steps:
1. On the Main Run Menu, select the DIALOG MENU item.
NOTICE
The SmartPAC 2 must be in an Idle state when you program Hot Keys. Make sure to
select BACK ON LINE before attempting to make Hot Key assignments.
2. On the Dialog Menu, highlight the BACK ON LINE item and press ENTER to place the
SmartPAC 2 in an Idle state. You are returned to the Main Run Menu.
3. Repeat step 1 to access the Dialog Menu again.
NOTICE
The keystrokes you use to select a downtime reason for a Hot Key are recorded. Make
sure to scroll to the desired selection using the fewest number of keystrokes.
4. Highlight the Dialog Menu selection for which you want to create a Hot Key, using the
Up () or Down () cursor key. Use the fewest number of keystrokes possible in
scrolling to the item.
5. Press the “2” and “0” keys simultaneously for a few seconds until the Hot Keys
Instruction Window displays (see Figure 6-4, page 6-4), then press the function key you
want to make the Hot Key for the selected menu item.
To program Hot Keys for function keys F4 through F7 on the Dialog Menu when Dialog
Screen Mode is set to “32 CUSTOM,” perform the following steps:
1. Repeat steps 1 through 3 of the previous procedure.
2. Select the number on the SmartPAC 2 keypad corresponding to the function key for which
you want to create a Hot Key (e.g., press “5” for function key F5 (Back on Line)).
3. Press the “2” and “0” keys simultaneously for a few seconds until the Hot Keys
Instruction Window displays, then press the function key you want to make the Hot Key
for the selected Dialog Menu function.
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Reporting Scrap and Good Parts to SFC
If you are running SFC-compatible firmware, SmartPAC 2 enables you to document scrap so
that scrap counts can be reported to SFC. The scrap counter, which appears on the Counters
screen in Run mode, maintains a cumulative total of all user scrap entries for the currently
running job, resetting to zero when the job is complete.
The cumulative scrap count reduces by that amount the number of good parts reported to SFC.
The good parts count is maintained in the Good Parts Count field on the Counters screen (see
Figure F-14, page F-23). If you wish to adjust the Good Parts counter upward, you can do so
in up to 1,000-part increments in Run mode and in larger increments in Program mode.
To enable scrap entries and Good Parts counter adjustments to be made in Run mode, you
must set the CHANGE COUNT and CHG GOOD PRTS CNT items on the Security Access
Menu in Initialization mode to “PROGRAM AND RUN MODES,” as shown in Figure F-13.
(To display the Security Access Menu, select SECURITY ACCESS from the Main
Initialization Menu–see Figure F-4, page F-8.)
If you want to allow scrap entries to be made in Run mode but prevent Good Parts counter
adjustments, you must set the CHG GOOD PRTS CNT item on the Security Access Menu to
“NO CHANGES ALLOWED” while leaving the CHANGE COUNT item set to
“PROGRAM AND RUN MODES.”
F1
F2
F3
F4
F5
F6
F7
F8
Figure F-13. Security Access Menu with CHANGE COUNT and CHG GOOD PRTS CNT
Items Set to “PROGRAM AND RUN MODES”
By default, the Good Parts counter does not increment during a fault condition. If you wish
the counter to increment even when there is a fault, set the COUNTER INCREMENT MODE
item on the Position Sensor screen to “INC ALWAYS” (see page 4-5).
Making Scrap Entries
To document scrap for a currently running job, do the following:
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1. With the tool loaded and running, select “COUNTERS” on the Main Run Menu (see
Figure F-12, page F-19) to display the Counters screen (see Figure F-14).
F1
F2
F3
F4
F5
F6
F7
F8
Figure F-14. Counters Screen with “Scrap Value” Function (F3) Shown
2. Press F3 (Scrap Value). The Scrap Value Entry window displays (see Figure F-15).
F1
F2
F3
F4
F5
F6
F7
F8
Figure F-15. Counters Screen with Scrap Value Entry Window Displayed (30 Items Shown)
Key in the amount of scrap you wish to document, following the directions in the window,
and press ENTER. (Figure F-15 shows a scrap entry of “30” as an example.)
When you press ENTER, the Scrap Value Entry window disappears. The value you keyed
in is added to the current scrap value, and the result is displayed beneath the “Scrap Value”
caption to the left of the F3 function key, as shown in Figure F-16, page F-24, where a
scrap value of “30” is used as an example. The Good Parts counter is reduced by the
amount of your scrap entry (e.g., 900-30=870 in Figure F-16).
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F1
F2
F3
F4
F5
F6
F7
F8
Figure F-16. Counters Screen with Scrap Value Updated to 30 Items
NOTICE
INDIVIDUAL SCRAP ENTRIES ARE ADDED TO THE CURRENT SCRAP TOTAL
The Scrap Value counter maintains a cumulative total of the scrap items documented for
each job. The value you enter in the Scrap Value Entry window (see Figure F-15,
page F-23) is automatically added to the total.
For example, if the count in the Scrap Value field is “30,” and you want to include an
additional 10 parts in the count, you would enter “10” in the Scrap Value Entry window
(see Figure F-17). When you are returned to the Counters screen, the Scrap Value
counter would display 40 parts (the 30 parts in the current total plus the 10 parts you
entered; the Good Parts counter would be reduced by 10 parts (see Figure F-18,
page F-25).
F1
F2
F3
F4
F5
F6
F7
F8
Figure F-17. Counters Screen with Scrap Value Entry Window Displayed (10 Items Shown)
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F1
F2
F3
F4
F5
F6
F7
F8
Figure F-18. Counters Screen with Scrap Value Updated to 40 Items
3. Repeat step 2 for the remaining scrap entries associated with the current job until the job is
completed.
Adjusting the Good Parts Counter
NOTICE
You can only increase the value maintained by the Good Parts counter. You cannot decrease the
Good Parts counter except by entering scrap values.
NOTICE
You cannot adjust the Good Parts counter if the CHG GOOD PRTS CNT item on the Security
Access Menu has been set to “NO CHANGES ALLOWED.”
The Run mode Counters screen enables you to increase the Good Parts count to adjust for
count inaccuracies, such as when good parts may be produced but not counted in Setup mode
or during Fault conditions. The count can be increased by up to 1,000 parts at a time.
The Counters screen in Program mode allows you to increase Good Parts by larger amounts
(see Adjusting the Good Parts Counter in Program Mode, next page). This capability is
useful if new firmware is installed in the middle of a job, causing the Good Parts counter to
reset to zero.
Adjusting the Good Parts Counter in Run Mode
To increase the Good Parts count in Run mode, do the following:
1. Select the GOOD PARTS COUNT field on the Counters screen.
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2. When the Good Parts Entry window (like the window shown in Figure F-15) displays, key
in the number of good parts you want to add (1,000 parts maximum), and press ENTER.
A Confirmation window like the one shown in Figure F-19 displays.
Figure F-19. Good Parts Counter Adjustment Confirmation Window
3. Press the Up () cursor key to confirm that you want to change the Good Parts counter
value. You are returned to the Counters screen with your adjustment reflected in the
GOOD PARTS COUNT field.
NOTICE
If you attempt to enter a value greater than 1,000 or one that reduces (rather than increases) the
Good Parts count, an error message will display briefly.
Adjusting the Good Parts Counter in Program Mode
NOTICE
In Program mode, you can increase the Good Parts count in increments greater than 1,000.
To increase the Good Parts count in Program mode, do the following:
1. On the Counters screen in Run mode, press RESET to return to the Main Run Menu.
2. Turn the Program/Run key to “PROG” to display the Main Program Menu.
3. Select “GO TO THE TOOL MANAGER” to display the Tool Manager screen.
4. Press F4 (Edit Tool) with the loaded tool selected to display the Tool Program Menu.
5. Select COUNTERS to display the Counters screen.
6. Perform steps 1 through 3 of the procedure for adjusting the Good Parts counter in Run
mode, above.
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Appendix G. Reporting Downtime and
Scrap to LETS
This appendix shows you how to report press downtime from your SmartPAC 2 control to
Wintriss’s Line Efficiency Tracking Software (LETS). The appendix discusses the six
machine states to which LETS logs press time, explains the downtime reporting features of
SmartPAC 2, shows you how to set up SmartPAC 2 to report downtime to LETS, and
provides instructions for reporting downtime.
The appendix also shows you how to use the scrap counter on the SmartPAC 2 Counters
screen in Run mode to report scrap to LETS and how to adjust the Good Parts count that is
reported to LETS.
SmartPAC’s downtime- and scrap-reporting features are available only on SmartPAC 2
versions 4.59 or higher; in addition, the LETS firmware option must be installed.
Machine States to Which LETS Logs Press Time
LETS logs all elapsed time at each press to one of six categories called machine states. The
sum of all the times assigned to these machine states for an individual press is the number of
hours in a production day (e.g., 12 hours, 24 hours, etc.). LETS selects the machine state to
which to log press time on the basis of downtime reporting and other information it receives
from SmartPAC 2. Machine states are differentiated as follows:
• Running Time–Press is running and making parts
• Idle Time–Press is stopped, no SmartPAC error has occurred, and the reason the press is
stopped has not been documented in SmartPAC 2
• Unplanned Downtime–Press is stopped due to a SmartPAC 2 error, or if the press is stopped
for another reason, that reason has been documented in SmartPAC 2 as a downtime reason
other than Planned Downtime or Tool Change
• Planned Downtime–Press is stopped, and the reason has been documented in SmartPAC 2
as Planned Downtime
NOTICE
The Planned Downtime machine state should only be assigned for lunch and coffee
breaks, meetings, training, etc. Planned Downtime is not used in calculating Overall
Equipment Effectiveness (OEE) and, therefore, does not reduce the OEE value.
• Changeover Time–Press is stopped, and the reason has been documented in SmartPAC 2 as
Tool Change
• Offline Time–Press is stopped because there is no power to the press or the network is
down
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All time during which the press is stopped for any reason other than a power interruption or
network failure is logged by LETS to Idle Time unless a downtime reason is reported from the
SmartPAC 2. Since Overall Equipment Effectiveness (OEE) and other efficiency metrics
assign high ratings to machines with low Idle Time values, SmartPAC 2 has been designed to
allow very precise reporting of downtime to LETS and may be programmed to require the
operator to select a specific downtime reason each time the press enters an Idle state. When
operator intervention is required, periods of press inactivity are more likely to be assigned to a
specific downtime reason than to be logged as Idle Time.
SmartPAC 2 Downtime Reporting Features
Downtime reasons in SmartPAC 2 may be reported to LETS either automatically by the
system or manually by the operator. When the press is stopped because of an error generated
by SmartPAC 2 or an installed SmartPAC 2 module, the specific fault (e.g., “Sensor 1 Part
Ejection Missed”) is reported automatically as a downtime reason to LETS.
When the press is stopped by the operator or by a piece of auxiliary equipment not connected
to the SmartPAC 2, a downtime reason must be reported manually by the operator since
SmartPAC 2 is unable to detect the reason for the interruption (see Forced Idle Dialog Mode,
below). Downtime reasons may also be assigned manually to provide additional detail for
periods documented automatically with specific error conditions (see Forced Error Dialog
Mode, page G-4).
Forced Idle Dialog Mode
If the SmartPAC 2 is set to Forced Idle Dialog mode (see Making Downtime Reporting
Settings, page G-7), a downtime reason must be entered whenever the press is stopped by the
operator or by auxiliary equipment. When the press stops (see Figure G-1, page G-3 for a
schematic time line), a message displays at the SmartPAC 2 stating that the operator must
enter a downtime reason before the press can be restarted. When the operator closes the
message window, the Dialog Menu automatically displays. The Dialog Menu, a selection on
the SmartPAC 2 Main Run Menu, displays a list of downtime reasons from which the operator
must select to report downtime to LETS. Refer to Programming Downtime Reasons,
page G-11 for instructions on how to set up the Dialog Menu.
The Forced Dialog message can be programmed to display a specified number of minutes
after the press stops (see Figure G-1). This Idle Dialog Time setting enables the press to be
stopped briefly without requiring entry of a downtime reason.
Backfilling vs. Forward Filling
LETS initially logs the time after the press is stopped by the operator or by auxiliary
equipment to Idle Time. When the operator selects an item on the Dialog Menu, the period of
time previously documented as Idle is assigned that downtime reason. Downtime can be
assigned manually or automatically, depending on how your SmartPAC 2 is programmed (see
Making Downtime Reporting Settings, page G-7).
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If SmartPAC 2 is set up for manual downtime reporting, the operator selects how the
downtime is to be assigned in an option window that displays following selection of the
downtime reason (see Figure G-10, page G-16). One option, which is called “backfilling,” is
to assign the downtime reason to all time that has elapsed since the press was stopped (see
Figure G-1). The other option is to “forward fill” the downtime reason, assigning it to the
period from reporting of the downtime reason until the press is restarted (see Figure G-2,
page G-4). When this option is selected, all elapsed time before entry of the downtime reason
is assigned to the previous downtime reason, if one was reported, or to Idle Time.
If SmartPAC 2 is set up for automatic downtime reporting, the option window does not
display following selection of the downtime reason and downtime is automatically backfilled.
Putting the Press “Back on Line”
A period of Idle Time or downtime (either “Planned” or “Unplanned”) comes to an end when
the operator selects “Back on Line” from the Dialog Menu. If the press is restarted at the
same time, LETS begins documenting the machine state as “Running time” (see Figure G-1).
When the operator selects “Back on Line” without restarting the press, the subsequent period
until the press is restarted is logged to Idle Time (see Figure G-2).
Press Status/
Operator Actions
SmartPAC
Settings and
Displays
Initial
LETS
Machine
State
Updated
LETS
Machine
State
Running time
Running time
Idle time
Downtime
reason–
Backfill
Press is running
Press is stopped
by operator or
auxiliary equipment
Time
(in min.)
Idle Dialog
time (5 min.)
Forced Dialog
message displays
Operator presses RESET
Dialog Menu displays
Operator enters
downtime reason
with Backfill option
Operator enters Back on Line,
restarts press
Running time
Figure G-1. Forced Idle Dialog Mode Time Line (Downtime Reason Backfilled)
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Press Status/
Operator Actions
SmartPAC
Settings and
Displays
Initial
LETS
Machine
State
Updated
LETS
Machine
State
Running time
Running time
Idle time
Idle time
Press is running
Press is stopped
by operator or
auxiliary equipment
Time
(in min.)
Idle Dialog
time (5 min.)
Forced Dialog
message displays
Operator presses RESET
Operator enters
downtime reason
with Forward Fill option
Dialog Menu displays
Downtime
reason–
Forward fill
Operator enters Back on Line
Idle time
Operator restarts press
Running time
Figure G-2. Forced Idle Dialog Mode Time Line (Downtime Reason Forward Filled)
Forced Error Dialog Mode
The Dialog Menu can also be programmed to display whenever the press is stopped due to a
SmartPAC 2 fault. This feature, called Forced Error Dialog mode (see Making Downtime
Reporting Settings, page G-7), allows the operator to add detail to a period of downtime that is
initially logged to a specific SmartPAC 2 error but may actually have a different cause.
For example, SmartPAC 2 may be set up to generate an “End of Stock” error whenever the
press runs out of material. This downtime reason is applied to the period of time during which
a new coil is located and brought to the press unless the operator selects a more appropriate
downtime reason, such as “Waiting for Coil,” and, using the backfill option (see Backfilling
vs. Forward Filling, page G-2), applies it to the incompletely documented period. When the
downtime reason is backfilled (see Figure G-3, page G-5 for a schematic time line),
SmartPAC logs one second to the initial error (e.g., “Sensor 5–End of Stock”), assuring that
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the fault is documented, and the remaining time to the new downtime reason (e.g., “Waiting
for Coil”).
Press Status/
Operator Actions
SmartPAC
Settings and
Displays
Initial
LETS
Machine
State
Updated
LETS
Machine
State
Running time
Running time
Press is running
Press is stopped
by SmartPAC
SmartPAC
fault (1 sec.)
Time
(in min.)
Error Dialog
time (5 min.)
Forced Dialog
message displays
Operator presses RESET
Dialog Menu displays
SmartPAC
fault
Downtime
reason–
Backfill
Operator enters
downtime reason
with Backfill option
Operator enters Back on Line,
restarts press
Running time
Figure G-3. Forced Error Dialog Mode Time Line
Downtime reasons can also be “forward filled” in Forced Error Dialog mode.
As in Forced Idle Dialog mode, the Forced Dialog message can be programmed to display a
specified number of minutes after the press stops (see Figure G-3). This Error Dialog Time
setting prevents nuisance faults such as “Counter preset reached” from being reported as
downtime.
Persist Dialog Mode
Periods during which the press is powered down are normally documented as Offline Time
and the period following the next power-up assigned to Idle Time. Periods subsequent to
machine power-ups are documented as Idle Time even when the period immediately
preceding the shutdown has been assigned to an Unplanned Downtime reason. The only
machine states that carry over from the period immediately preceding a shutdown to the
period immediately succeeding a power-up are Changeover Time and Planned Downtime. In
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these cases, the period during which the press is offline and the time immediately following
press power-up are assigned to the machine state in effect when the press was powered down.
SmartPAC 2 can be programmed so that Unplanned Downtime reasons selected from the
Dialog Menu also “persist” through press shutdowns (see Making Downtime Reporting
Settings, page G-7). When this setting is enabled, both the interval during which the press
was powered down and the time following resumption of power to the press are assigned to
the downtime reason in effect when the press was shut down. One second of the period during
which the press was offline is assigned to Offline Time to document this event.
Single-stroke Mode
For hand-fed applications, a special setting can be programmed at the SmartPAC 2 (see
Setting up SmartPAC 2 to Report Downtime, page G-6) that allows the press to operate
continuously in Single-stroke mode without the operator having to enter a downtime reason at
the end of each stroke, when the SmartPAC 2 considers the press to be stopped. Instead of
looking for a change of state (i.e., from Running to Stopped), SmartPAC 2 looks for at least
one press cycle during a pre-programmed interval and, if it detects no stroke, considers that
the press is stopped, reporting subsequent time as Idle Time.
Reset Strokes Counters
Normally, a period of Idle Time, Planned or Unplanned Downtime, or Changeover Time is
ended when the operator selects “Back on Line” from the Dialog Menu and restarts the press
(see Putting the Press “Back on Line,” page G-3). However, since the operator may forget to
select the “Back on Line” item, an alternative way of terminating a period of downtime is
available.
SmartPAC 2 can be programmed to begin logging time following a downtime period to
Running Time after a specified number of press strokes. A Reset Strokes counter (see Making
Downtime Reporting Settings, page G-7) begins incrementing when the press is restarted, and
after the counter reaches its preset, LETS changes the machine state to which it logs press
time from the downtime reason to Running Time. Three different Reset Strokes counters can
be programmed, allowing you to set different restart intervals following periods of Planned
Downtime, Unplanned Downtime, and Changeover time.
Setting up SmartPAC 2 to Report Downtime
To set up SmartPAC 2 to report downtime to LETS, you make downtime reporting settings on
the Set Communications Menu and program downtime reasons on the Dialog Fixed Name
Choice Menu and the Dialog Special Choice Name Menu.
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Making Downtime Reporting Settings
To enable and configure the SmartPAC 2 downtime reporting features described in the
previous section, perform the following steps:
1. At the SmartPAC 2, turn the Program/Run key to “PROG,” then press the “1” and
“CLEAR” keys simultaneously for a second or two until the Main Initialization Menu (see
Figure G-4) displays.
Figure G-4. SmartPAC 2 Main Initialization Menu
2. Highlight the “SETUP DATA COMMS” menu item, using the Up () or Down ()
cursor key, and press ENTER. The Set Communications Menu (see Figure G-5) displays:
Figure G-5. Set Communications Menu
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3. Highlight each menu item you want to set, using the Up () or Down () cursor key,
then do the following:
• To enable or disable a feature, press ENTER until the desired setting is displayed.
• To specify a value for an item (with the exception of IDLE TIMER), press ENTER to
display the Numeric Entry window, key in your entry with the SmartPAC 2 keypad, and
press ENTER again.
NOTICE
Make sure that the DIALOG SCREEN MODE item is set to “16 / 16.” If DIALOG SCREEN
MODE is set to “32 CUSTOM,” you will not be able to access the Dialog Menu. The fault
message “File Not Found” will display when you attempt to do so.
• Leave the DIALOG SCREEN MODE item set to “16 / 16,” the default. The “32
CUSTOM” setting is for SFC customers only.
• To select a value for IDLE TIMER, press ENTER until the desired value is displayed.
• To display screens on which you can program Dialog Menu entries, press ENTER with
the cursor resting in the SET SPECIAL NAMES or SET CANNED NAMES field.
Table G-1 explains each field on the Set Communications Menu and provides instructions
on how to make settings.
Table G-1. Set Communications Menu Settings
Field
Settings
RSR/SBR CPU NUMBER
When SmartPAC 2 is connected to LETS, this field must be set
to “1.” Other CPU Number values may be used when
SmartPAC 2 is connected to certain legacy software products
that require each SmartPAC 2 to be assigned a unique
identifier.
FORCED IDLE DIALOG
Indicates whether SmartPAC 2 displays the Forced Dialog
message and Dialog Menu after the press has been stopped
by the operator or by auxiliary equipment not connected to
SmartPAC 2. The number of minutes after the press has
stopped before the Forced Dialog message appears is
specified in the IDLE DIALOG TIME field (see next entry). At
the appearance of the Forced Dialog message, the operator
must select a downtime reason on the Dialog Menu in order to
restart the press. This setting allows time that elapses after
the press is stopped by the operator or by equipment not
connected to SmartPAC 2 to be documented with a downtime
reason rather than as Idle Time. There are two settings:
ENABLED Forced Idle Dialog mode enabled
DISABLED Forced Idle Dialog mode disabled
IDLE DIALOG TIME
G-8
Specifies the number of minutes (1-60) after the press has
stopped in Forced Idle Dialog mode before the Forced Dialog
message displays. This setting allows you to prevent Forced
Idle Dialog from being triggered by brief stops. Suggested
initial value: 5 minutes.
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Table G-1. Set Communications Menu Settings (Cont.)
Field
Settings
FORCED ERROR DIALOG
Indicates whether SmartPAC 2 displays the Forced Dialog
message and Dialog Menu after the press has been stopped
by a SmartPAC 2 fault. The number of minutes after the press
has stopped before the Forced Dialog message appears is
specified in the ERROR DIALOG TIME field (see next entry).
At the appearance of the Forced Dialog message, the operator
must select a downtime reason on the Dialog Menu in order to
restart the press. This setting allows time that elapses after
the press is stopped due to a SmartPAC 2 fault to be assigned
a different downtime reason. There are two settings:
ENABLED Forced Error Dialog mode enabled
DISABLED Forced Error Dialog mode disabled
ERROR DIALOG TIME
Specifies the number of minutes (1-60) after the press has
stopped in Forced Error Dialog mode before the Forced Dialog
message displays. This setting allows you to prevent reporting
of SmartPAC 2 nuisance faults such as “Counter preset
reached.” Suggested initial value: 5 minutes.
PERSIST DIALOG
Indicates whether an Unplanned Downtime reason from the
Dialog Menu that is assigned before a press shutdown
continues to be applied to the period during which the press is
down and to the time after the press is powered up again.
Normally, the interval during a press shutdown is assigned to
“Offline Time” and the period after the press is powered up to
“Idle Time.” There are two settings:
ENABLED Persist Dialog mode enabled
DISABLED Persist Dialog mode disabled
AUTO BACKFILL
DIALOG SCREEN MODE
Indicates whether time occurring after the press has been
stopped up to the point when the operator selects a downtime
reason is automatically documented with that reason. When
this item is disabled, the operator is given the option of
backfilling or forward filling downtime following selection of a
downtime reason. When this item is enabled, the downtime
reason selected by the operator is automatically backfilled.
There are two settings:
ENABLED
Auto Backfill enabled
DISABLED
Auto Backfill disabled
This item, which is set to “16 / 16” by default, should not be
changed. The “32 CUSTOM” setting is for SFC customers
only. If you set this item to “32 CUSTOM,” the message “File
Not Found” will display when you access the Dialog Menu.
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Table G-1. Set Communications Menu Settings (Cont.)
Field
Settings
UNPLANNED RESET
STROKES
Specifies the number of strokes that must occur after the press
is restarted following a period of Unplanned Downtime,
Planned Downtime, or Changeover Time before LETS begins
documenting the machine state as “Running Time.” This
setting prevents additional press time from being attributed to
a downtime reason when the operator forgets to select the
“BACK ON LINE” item from the Dialog Menu. The number of
strokes you specify should be the maximum number of press
cycles that are likely to be needed to return the press to
production. Valid entries: 1-9999. Suggested settings:
PLANNED RESET
STROKES
CHANGEOVER RESET
STROKES
Set the Unplanned Reset Strokes counter to two strokes more than
the maximum number of strokes required to fill an empty die. This
setting should give the operator sufficient time to complete a
response to the downtime cause (such as Coil Change) that requires
the longest time to address.
Set the Planned Reset Strokes counter to the lowest number of
strokes required to return the press to production following a lunch or
other break.
Set the Changeover Reset Strokes counter to the maximum number
of strokes required to complete a die setup.
SINGLE STROKE MODE
This setting, which is used for hand-fed applications when the
press is being run in Single-stroke mode, indicates whether
LETS counts press cycles (or parts made) within the period
specified in the IDLE TIMER field (see next entry) to determine
whether the press is “running.” When this field is set to
“ENABLED,” LETS only documents the press as “Idle” when
no cycles occur (i.e., no parts are made) during an Idle Timer
period. There are two settings:
ENABLED Single-stroke Mode enabled
DISABLED Single-stroke Mode disabled
IDLE TIMER
Specifies the number of seconds during which SmartPAC 2
counts the number of press strokes in Single-stroke mode to
determine a production rate for hand-fed applications. This
value should be twice the cycle time for the slowest hand-fed
job run on a press. For example, if the slowest job produces
an average of 6 parts per minute, the Idle Timer should be set
to 20 seconds (6 parts per minute = 10-second cycle time; 2 x
10 seconds = 20 seconds). Available selections: 5, 10, 15, 20,
30, and 60.
SET SPECIAL NAMES
Displays the Dialog Special Choice Name Menu, on which you
can create up to 16 custom downtime reasons for display on
the Dialog Menu and specify the order in which they will
appear (see Creating Special Names on the Dialog Special
Choice Name Menu, page G-13).
SET CANNED NAMES
Displays the Dialog Fixed Name Choice Menu, on which you
can select up to 14 pre-programmed, or “canned,” downtime
reasons for display on the Dialog Menu and specify the order
in which they will appear (see Selecting Canned Names on the
Dialog Fixed Name Choice Menu, page G-11).
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Programming Downtime Reasons
The SET SPECIAL NAMES and SET CANNED NAMES items on the Set Communications
Menu allow you to specify the downtime reasons that appear on the Dialog Menu and the
order in which they are presented. The items you program on these two menus will be the
menu selections available to the operator when the Dialog Menu displays in Forced Idle
Dialog or Forced Error Dialog mode, or when the operator accesses the menu at other times.
“Canned” names are downtime reasons whose text has been pre-programmed into the
SmartPAC 2. “Special” names are downtime reasons whose text you assign. You can select
up to 14 “canned” names and create up to 16 “special” names. The Dialog Menu can include
both “canned” and “special” entries, displaying up to 30 items.
NOTICE
It is recommended that you create a standardized list of downtime reasons for all your presses.
Having the Dialog Menu display the same downtime reasons in the same order on all SmartPAC
2s will help to minimize reporting errors.
When planning the order in which you want Dialog Menu items to display, you should
attempt to predetermine the downtime causes that are likely to occur most frequently and
place these at the beginning of the downtime reason sequence.
Selecting Canned Names on the Dialog Fixed Name Choice Menu
When you select the SET CANNED NAMES item on the Set Communications Menu, the
Dialog Fixed Name Choice Menu (see Figure G-6) displays. This menu allows you to select
the “Canned” names that will appear on the Dialog Menu. “Canned” names are downtime
reasons whose text has already been programmed into the SmartPAC 2. You can select up to
14 of these pre-programmed entries for inclusion in the Dialog Menu.
Figure G-6. Dialog Fixed Name Choice Menu
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You select a “canned” name by entering a sequence number to the right of the name’s text
entry. The sequence number specifies the position in which that item will appear on the
Dialog Menu. For example, in the screen shown in Figure G-6, the item LUBE PROBLEM
has a sequence number of 7 and, so, will appear seventh on the Dialog Menu. Since “special”
downtime reasons may also appear on the Dialog Menu, be sure to maintain the necessary
intervals in your “canned” name numbering scheme to accommodate these items.
To prevent a “canned” name from appearing on the Dialog Menu, set its sequence number to
0.
It is recommended that you include the following “canned” items in the Dialog Menu:
• TOOL CHANGE–This downtime reason is logged to the Changeover Time machine state,
enabling LETS to track time for tool changes separately from other unplanned downtime
and create special Changeover reports. “Tool Change” is the only Unplanned Downtime
reason that is assigned to time when power to the press is off. Powering down the press is
often necessary during tool changeover.
• PLANNED DOWN–This entry is logged to the Planned Downtime machine state, which
includes time for planned lunch or coffee breaks, meetings, training, etc. Planned
Downtime is not used in calculating Overall Equipment Effectiveness (OEE) and,
therefore, does not reduce the OEE value.
• BACK ON LINE–This selection enables the operator to end a downtime event. When
BACK ON LINE is selected, the machine state will change from “Unplanned Downtime,”
“Planned Downtime,” or “Changeover Time” to “Running Time” if the press is running or
from one of these “downtime” states to “Idle Time” if the press is stopped.
• OPER. NUMBER–This “canned” name allows the operator to enter an operator number,
enabling LETS to assign a period of press time such as a shift to a particular operator.
To select the pre-programmed downtime reasons that will appear on the Dialog Menu and the
order in which they will appear, do the following:
1. On the Set Communications Menu, highlight the SET CANNED NAMES item, using the
Up () or Down () cursor key, and press ENTER. The Dialog Fixed Name Choice
Menu (see Figure G-6) displays with the cursor resting in the OPER. NUMBER field.
2. Press ENTER, and when the Numeric Entry window appears, type the numeric position in
which you want that item to appear on the Dialog Menu, or type “0” if you want to prevent
the item from displaying on the Dialog Menu. Press ENTER to save your entry and return
to the Dialog Fixed Name Choice Menu.
3. Move the cursor to the BACK ON LINE field, using the Down () cursor key, and repeat
step 2. Do the same for the remaining menu items.
NOTICE
Remember to leave intervals between sequence numbers to allow room for “special”
downtime reasons. See Creating Special Names on the Dialog Special Choice Name
Menu, page G-13.
If the same sequence number is assigned to both a “canned” and a “special” name, both
entries will display in that position on the Dialog Menu with the “special” name shown first.
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4. When you are finished setting the sequence of “canned” names, press RESET to save your
entries and return to the Set Communications Menu.
Creating Special Names on the Dialog Special Choice Name Menu
When you select the SET SPECIAL NAMES item on the Set Communications Menu, the
Dialog Special Choice Name Menu (see Figure G-7) displays. This menu allows you to select
the “special” names that will appear on the Dialog Menu. “Special” names are downtime
reasons created by the user. Each name can be up to 12 characters in length, and you can
include up to 16 of them in the Dialog Menu.
Figure G-7. Dialog Special Choice Name Menu
You specify the order in which “special” names appear on the Dialog Menu by entering a
sequence number to the right of each text entry. The sequence number specifies the position
in which that item will appear on the Dialog Menu. Since “canned” downtime reasons may
also appear on the Dialog Menu, be sure to maintain the necessary intervals in your “special”
name numbering scheme to accommodate these items.
To prevent a “special” name from appearing on the Dialog Menu, set its sequence number to
0.
To program “special” downtime reasons for inclusion in the Dialog Menu, perform the
following steps:
1. On the Set Communications Menu, highlight the SET SPECIAL NAMES item, using the
Up () or Down () cursor key, and press ENTER. The Dialog Special Choice Name
Menu (see Figure G-7) displays with the cursor resting in the SPEC. 1 field.
2. Press ENTER, and when the Alphabetic Entry window displays, type the text (12
characters maximum, including spaces) of the downtime reason that you want to appear
on the Dialog Menu; then, press F6 to save your entry and return to the Dialog Special
Choice Name Menu.
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3. Press the Right () cursor key to move the cursor to the column for the SPEC. 1 sequence
number.
4. Press ENTER, and when the Numeric Entry window displays, type the numeric position
in which you want that downtime reason to appear on the Dialog Menu; then, press
ENTER to save your entry and return to the Dialog Special Choice Name Menu.
NOTICE
Remember to leave intervals between sequence numbers to allow room for “canned”
downtime reasons. See Selecting Canned Names on the Dialog Fixed Name Choice
Menu, page G-11.
If the same sequence number is assigned to both a “canned” and a “special” name, both
entries will display in that position on the Dialog Menu with the “special” name shown first.
5. Move the cursor to the SPEC. 2 field, using the Down () cursor key, and repeat steps 2
through 4. Do the same for the remaining menu items.
6. When you have finished programming “special” downtime reasons, press RESET to save
your entries and return to the Set Communications Menu.
Documenting Downtime on the Dialog Menu
A downtime reason can be selected on the Dialog Menu either in response to the Forced
Dialog message or when the operator wants to change a previous downtime entry or add detail
to reported downtime.
Documenting Downtime in Response to the Forced Dialog Message
With Forced Idle Dialog mode or Forced Error Dialog mode enabled (see Making Downtime
Reporting Settings, page G-7), the operator is prompted to enter a downtime reason on the
Dialog Menu whenever SmartPAC 2 detects that the press has stopped under the appropriate
circumstances. This message is shown in Figure G-8, page G-15.
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F1
F2
F3
F4
F5
F6
F7
F8
Figure G-8. SmartPAC 2 Run Mode Main Menu with Forced Dialog Message Displayed
To respond to this prompt, perform the following steps:
1. Press RESET to clear the message. The Dialog Menu (see Figure G-9) displays.
F1
F2
F3
F4
F5
F6
F7
F8
Figure G-9. Dialog Menu
2. Highlight the downtime reason you want (in Figure G-9, MECH PROBLEM is selected as
an example), using the Up () or Down () cursor key, and press ENTER.
3. If Auto Backfill has been enabled on the Set Communications Menu (see Table G-1,
page G-9), the downtime reason you selected is automatically “backfilled” (i.e., assigned
to the period from the time that the press was stopped up to entry of the next downtime
reason or the BACK ON LINE selection). If a SmartPAC 2 fault has already been
assigned to this period of press inactivity, that fault will be documented as having
consumed 1 second and the remainder of the period filled with the downtime reason you
selected. If the period has been documented as Idle Time, your downtime reason will
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replace that entry. The SmartPAC 2 will display a message stating that the downtime
reason has been sent to the host computer.
4. If Auto Backfill has been disabled, the window shown in Figure G-10 displays.
F1
F2
F3
F4
F5
F6
F7
F8
Figure G-10. Dialog Menu with F2/F3 Option Window Displayed
Press the F2 (Change Prev. Reason) function key to “backfill” the selected downtime
reason, in other words, to assign it to the period from the time that the press was stopped
up to entry of the next downtime reason or the BACK ON LINE selection. If a SmartPAC
2 fault has already been assigned to this period of press inactivity, that fault will be
documented as having consumed 1 second and the remainder of the period filled with the
downtime reason you selected. If the period has been documented as Idle Time, your
downtime reason will replace that entry.
or
Press F3 (Keep Prev. Reason) to leave documentation of the period up to the present
unchanged and “forward fill” the selected downtime reason, in other words, assign it to
the period from the present up to entry of the next downtime reason or the BACK ON
LINE selection.
The SmartPAC 2 will display a message stating that the downtime reason has been sent to
the host computer.
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Documenting Downtime in Other Situations
You can report downtime reasons to LETS at any time without being prompted by the Forced
Dialog message.
EXAMPLE: UPDATING A DOWNTIME REASON
The operator stops the press for what he assumes is a feed problem and selects the downtime reason
“FEED PROBLEM” from the Dialog Menu. After further investigation, he finds that the feed is working
properly but the air supply to the feed is intermittent. The operator accesses the Dialog Menu, selects
“AIR PROBLEM” from the list of downtime reasons, and chooses the F2 (Change Prev. Reason)
option. LETS changes the reason for the downtime period from “FEED PROBLEM” to “AIR
PROBLEM.”
To report downtime without being prompted, perform the following steps:
1. On the Main Run Menu (see Figure G-11), select the DIALOG MENU item.
F1
F2
F3
F4
F5
F6
F7
F8
Figure G-11. SmartPAC 2 Run Mode Main Menu with DIALOG MENU Item Selected
2. On the Dialog Menu, highlight the downtime reason you want, using the Up () or Down
() cursor key, and press ENTER.
3. If Auto Backfill has been enabled on the Set Communications Menu (see Table G-1,
page G-9), the downtime reason you selected is automatically “backfilled” (i.e., assigned
to the period from the time that the press was stopped up to entry of the next downtime
reason or the BACK ON LINE selection). If a SmartPAC 2 fault has already been
assigned to this period of press inactivity, that fault will be documented as having
consumed 1 second and the remainder of the period filled with the downtime reason you
selected. If the period has been documented as Idle Time, your downtime reason will
replace that entry. The SmartPAC 2 will display a message stating that the downtime
reason has been sent to the host computer.
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4. If Auto Backfill has been disabled, the window shown in Figure G-10 displays.
Press the F2 (Change Prev. Reason) function key to “backfill” the selected downtime
reason, in other words, to assign it to the period of Idle Time or downtime up to entry of
the next downtime reason or the BACK ON LINE selection. If a downtime reason other
than a SmartPAC 2 fault has been assigned to this period, the downtime reason you
selected will replace it. If a SmartPAC 2 fault has been assigned to this period, that fault
will be documented as having consumed 1 second and the remainder of the period filled
with the downtime reason you selected. If the period has been documented as Idle Time,
your downtime reason will replace that entry.
or
Press F3 (Keep Prev. Reason) to leave documentation of the period up to the present
unchanged and “forward fill” the selected downtime reason, in other words, assign it to
the period from the present up to entry of the next downtime reason or the BACK ON
LINE selection.
The SmartPAC 2 will display a message stating that the downtime reason has been sent to
the host computer.
Creating Hot Keys for Dialog Menu Functions
You can create Hot Keys on the Main Run Menu (see page 3-11 for an overview) for
selections on the Dialog Menu, enabling you to perform Dialog Menu tasks from the Run
Menu. To do so, perform the following steps:
1. On the Main Run Menu, select the DIALOG MENU item.
NOTICE
The SmartPAC 2 must be in an Idle state when you program Hot Keys. Make sure to
select BACK ON LINE before attempting to make Hot Key assignments.
2. On the Dialog Menu, highlight the BACK ON LINE item and press ENTER to place the
SmartPAC 2 in an Idle state. You are returned to the Main Run Menu.
3. Repeat step 1 to access the Dialog Menu again.
NOTICE
The keystrokes you use to select a downtime reason for a Hot Key are recorded. Make
sure to scroll to the desired selection using the fewest number of keystrokes.
4. Highlight the Dialog Menu selection for which you want to create a Hot Key, using the Up
() or Down () cursor key. Use the fewest number of keystrokes possible in scrolling
to the item.
5. Press the “2” and “0” keys simultaneously for a few seconds until the Hot Keys
Instruction Window displays (see Figure 6-4, page 6-4), then press the function key you
want to make the Hot Key for the selected menu item.
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Reporting Scrap and Good Parts to LETS
If you are running LETS-compatible firmware, SmartPAC 2 enables you to document scrap
so that scrap counts can be reported to LETS. The scrap counter, which appears on the
Counters screen in Run mode, maintains a cumulative total of all user scrap entries for the
currently running job, resetting to zero when the job is complete.
The cumulative scrap count reduces by that amount the number of good parts reported to
LETS. The good parts count is maintained in the Good Parts Count field on the Counters
screen (see Figure G-13, page G-20). If you wish to adjust the Good Parts counter upward,
you can do so in up to 1,000-part increments in Run mode and in larger increments in Program
mode.
To enable scrap entries and Good Parts counter adjustments to be made in Run mode, you
must set the CHANGE COUNT and CHG GOOD PRTS CNT items on the Security Access
Menu in Initialization mode to “PROGRAM AND RUN MODES,” as shown in Figure G-12.
(To display the Security Access Menu, select SECURITY ACCESS from the Main
Initialization Menu–see Figure G-4, page G-7.)
If you want to allow scrap entries to be made in Run mode but prevent Good Parts counter
adjustments, you must set the CHG GOOD PRTS CNT item on the Security Access Menu to
“NO CHANGES ALLOWED” while leaving the CHANGE COUNT item set to
“PROGRAM AND RUN MODES.”
F1
F2
F3
F4
F5
F6
F7
F8
Figure G-12. Security Access Menu with CHANGE COUNT and CHG GOOD PRTS CNT
Items Set to “PROGRAM AND RUN MODES”
By default, the Good Parts counter does not increment during a fault condition. If you wish
the counter to increment even when there is a fault, set the COUNTER INCREMENT MODE
item on the Position Sensor screen to “INC ALWAYS” (see page 4-5).
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Making Scrap Entries
To document scrap for a currently running job, do the following:
1. With the tool loaded and running, select “COUNTERS” on the Main Run Menu (see
Figure G-11, page G-17) to display the Counters screen (see Figure G-13).
F1
F2
F3
F4
F5
F6
F7
F8
Figure G-13. Counters Screen with “Scrap Value” Function (F3) Shown
2. Press F3 (Scrap Value). The Scrap Value Entry window displays (see Figure G-14).
F1
F2
F3
F4
F5
F6
F7
F8
Figure G-14. Counters Screen with Scrap Value Entry Window Displayed (30 Items Shown)
3. If this is your first scrap entry for the job, perform this step; otherwise, go to step 4.
Key in the amount of scrap you wish to document, following the directions in the window,
and press ENTER. (Figure G-14 shows a scrap entry of “30” as an example.)
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When you press ENTER, the Scrap Value Entry window disappears, and the value you
keyed in is displayed beneath the “Scrap Value” caption to the left of the F3 function key,
as shown in Figure G-15, where a scrap value of “30” is used as an example. The Good
Parts counter is reduced by the amount of your scrap entry (e.g., 900-30=870 in
Figure G-15).
F1
F2
F3
F4
F5
F6
F7
F8
Figure G-15. Counters Screen with Scrap Value Updated to 30 Items
NOTICE
INDIVIDUAL SCRAP ENTRIES MUST INCLUDE CURRENT SCRAP TOTAL
The Scrap Value counter maintains a cumulative total of the scrap items documented for
each job. In order to increment this counter, the value you enter in the Scrap Value Entry
window (see Figure G-14, page G-20) must include the current scrap total–in other words,
you must add the number of scrap items you wish to document to the current value shown
in the Scrap Value counter. The Good Parts counter, on the other hand, is reduced by the
actual number of scrap pieces you are reporting in this session, in other words, the
difference between your scrap entry and the current Scrap Value total.
For example, if the count in the Scrap Value field is “30,” and you want to include an
additional 10 parts in the count, you would enter “40” (not “10”) in the Scrap Value Entry
window. When you are returned to the Counters screen, the Scrap Value counter would
display 40 parts; the Good Parts counter would be reduced by 10 parts.
4. If you have made previous Scrap Value entries for this job, key in the sum of the scrap
count you wish to document this time and the current total shown in the Scrap Value field,
and press ENTER. See Figure G-16, page G-22, in which “40” is used as the sample scrap
input.
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F1
F2
F3
F4
F5
F6
F7
F8
Figure G-16. Counters Screen with Scrap Value Entry Window Displayed (40 Items Shown)
You are returned to the Counters screen. The value you entered in the Scrap Value Entry
window is displayed beneath the “Scrap Value” caption to the left of the F3 function key
(see Figure G-17, in which a scrap total of “40” is used as an example). The Good Parts
counter is reduced by the difference between the amount of your Scrap Value entry and the
current Scrap Value (e.g., 1,720-(40-30)=1,710 in Figure G-17).
F1
F2
F3
F4
F5
F6
F7
F8
Figure G-17. Counters Screen with Scrap Value Updated to 40 Items
5. Repeat step 4 for the remaining scrap entries associated with the current job until the job is
completed.
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Adjusting the Good Parts Counter
NOTICE
You can only increase the value maintained by the Good Parts counter. You cannot decrease the
Good Parts counter except by entering scrap values.
NOTICE
You cannot adjust the Good Parts counter if the CHG GOOD PRTS CNT item on the Security
Access Menu has been set to “NO CHANGES ALLOWED.”
The Run mode Counters screen enables you to increase the Good Parts count to adjust for
count inaccuracies, such as when good parts may be produced but not counted in Setup mode
or during Fault conditions. The count can be increased by up to 1,000 parts at a time.
The Counters screen in Program mode allows you to increase Good Parts by larger amounts
(see Adjusting the Good Parts Counter in Program Mode, next page). This capability is
useful if new firmware is installed in the middle of a job, causing the Good Parts counter to
reset to zero.
Adjusting the Good Parts Counter in Run Mode
To increase the Good Parts count in Run mode, do the following:
1. Select the GOOD PARTS COUNT field on the Counters screen.
2. When the Good Parts Entry window (like the window shown in Figure G-14) displays,
key in the number of good parts you want to add (1,000 parts maximum), and press
ENTER. A Confirmation window like the one shown in Figure G-18 displays.
Figure G-18. Good Parts Counter Adjustment Confirmation Window
3. Press the Up () cursor key to confirm that you want to change the Good Parts counter
value. You are returned to the Counters screen with your adjustment reflected in the
GOOD PARTS COUNT field.
NOTICE
If you attempt to enter a value greater than 1,000 or one that reduces (rather than increases) the
Good Parts count, an error message will display briefly.
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Adjusting the Good Parts Counter in Program Mode
NOTICE
In Program mode, you can increase the Good Parts count in increments greater than 1,000.
To increase the Good Parts count in Program mode, do the following:
1. On the Counters screen in Run mode, press RESET to return to the Main Run Menu.
2. Turn the Program/Run key to “PROG” to display the Main Program Menu.
3. Select “GO TO THE TOOL MANAGER” to display the Tool Manager screen.
4. Press F4 (Edit Tool) with the loaded tool selected to display the Tool Program Menu.
5. Select COUNTERS to display the Counters screen.
6. Perform steps 1 through 3 of the procedure for adjusting the Good Parts counter in Run
mode, above.
G-24
Reporting Downtime and Scrap to LETS
Glossary
NOTICE
Cross-references to other glossary entries are shown in italics.
actuation
A change in the state or condition of a sensor.
actuation angle
See dwell.
actuation block
A graphical indicator on the Sensor Status screen in Run mode,
showing whether a sensor is actuated.
ANSI
Stands for American National Standards Institute, a U.S.
clearinghouse and coordinating body for voluntary standards
activity on the national level.
auto enable by sensor
A die protection mode in which an individual sensor is
automatically actuated after a specified number of strokes.
auto enable by tool
A die protection mode in which all sensors in a tool are
automatically actuated after a specified number of strokes.
batch counter
One of three counters that can be set to increment when either the
good parts or strokes counter increments and to either top-stop
the press or signal programmable limit switch (PLS) outputs
when its preset is reached. See counter.
cam channels
Relays that open and close on signals from the programmable
cam switch to turn auxiliary equipment on and off.
checksum
A numeric value calculated when a tool is stored in memory and
when it is loaded. The two values must match or SmartPAC 2
displays a fault message.
communications
Data sent by SmartPAC 2 to one of its installed options (e.g.,
SFI) or received from an installed option.
counter
A SmartPAC 2 feature that maintains a count of the number of
strokes made by the press, the number of good parts produced, or
the number of strokes that must occur before a programmed
output is actuated. See batch counter, total hits counter.
critical angle
The point in the ram stroke after which a stop signal to the press
cannot prevent the die from closing.
diode
A component that reduces or eliminates electrical noise.
Glossary
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dwell
The range of angles during which a sensor or cam is actuated, or
“on.” Also called actuation angle.
emergency stop
A signal sent to the press in response to a malfunction that stops
the press immediately.
error message
A message appearing on the SmartPAC 2 LCD that indicates a
fault condition, identifies the problem, and may suggest how to
correct it.
manual enable
A die protection mode in which sensors are manually enabled or
disabled by the operator.
messaging
A SmartPAC 2 feature that allows e-mails to be sent from
SmartPAC 2 to networked computers, pagers, text-enabled cell
phones and other devices. This feature is set up in SmartView.
NEMA 12
A rating that certifies that an electrical device is protected against
dust, water, and oil.
on-off setting
Stroke angle settings at which the cam channel is to turn “on” and
“off.”
OSHA
Stands for Occupational Safety and Health Administration, a
government agency that has established regulations for
mechanical power presses including presence-sensing devices for
point-of-operation guarding.
ram angle clock
A graphical indicator on the SmartPAC 2 display that shows the
position of the press’s ram in degrees.
reset
A command issued by the operator that allows the press to
resume operation after it has been stopped due to a malfunction.
The “reset” command clears the fault message from the
SmartPAC 2 display. The command is issued by pressing the
RESET key.
security access
Settings made in Initialization that control the amount of access
SmartPAC 2 users are given to SmartPAC 2 functions.
smart stop
A type of stop programmed for a die protection sensor that sends
an emergency stop to the press when a sensor fault occurs before
the critical angle or a top stop if the fault occurs after the critical
angle. See critical angle, emergency stop, and top stop.
suppressor
A component that reduces or eliminates electrical noise.
GL-2
Glossary
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Tool Template
A tool on the Tool Manager screen that you can program with
settings shared by multiple tools, then use as a “template” to copy
the common settings to those tools.
top stop
A signal sent to the press in response to a malfunction that stops
the press at the top of its current stroke (0°).
total hits counter
A counter that maintains a count of the total number of hits made
by a tool, used in determining when a tool needs regrinding. See
counter.
Glossary
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Glossary
Index
–A–
AC wiring
connecting to SmartPAC 2, 2-15
grounding, 2-15
running in conduit, 2-15
alerts (preventive maintenance)
clearing, B-14
setting conditions for, B-10
viewing, B-13
alphanumeric tool numbers, setting, 4-4
auto enable
setting the auto enable by sensor counter, 5-24
setting the auto enable by tool counter, 5-21
–B–
backup (tool and initialization data),
performing, 4-27
batch counters. See also counters
setting increment mode, 5-13
setting output mode, 5-13
board
installing a new DiProPAC board, 2-22
replacing a DiProPAC board, 2-20
replacing a ProCamPAC board, 2-18
replacing a SmartPAC 2 board, E-1
board layouts
Cam Output, 2-28
DiProPAC, 2-21
DiProPAC installed on SmartPAC 2 board, 2-12
ProCamPAC, 2-13
ProCamPAC installed on SmartPAC 2
board, 2-12
SmartPAC 2, 2-17
–C–
cam channels
adjusting programmed settings, 6-19
deleting settings, 5-46
naming, 4-7
programming, 5-39
programming a DSV on delay time, 5-46
programming a timed output setting, 5-44
programming an on/off setting, 5-41
programming multiple on/off settings, 5-42
setting global cams, 4-10
testing, 2-36
viewing cam timing, 6-19
viewing the cam summary, 5-47, 6-20
viewing the global cam summary, 5-47, 6-20
cam output assembly. See ProCamPAC output
assembly
cam output relays. See relays, cam output
Index
checkout tests, performing, 2-35
CLEAR key (SmartPAC 2), using, 3-4
clock, setting, 4-38
communications
faults, 7-8
performing a loopback test, 4-37
setting parameters for Wintriss data collection
software, 4-30, F-7, G-7
verifying, 4-36
viewing transmit and receive data, 4-37
counters
adjusting good parts count for reporting to
LETS, G-23
adjusting good parts count for reporting to
SFC, F-25
adjusting in Program mode, 5-11
adjusting in Run mode, 6-8
clearing the total hits counter, 5-12
entering preset values, 5-11
entering scrap counts for reporting to
LETS, G-20
entering scrap counts for reporting to SFC, F-23
preset reached messages, 7-2
programming, 5-9
resetting batch counters, 6-9
setting batch pre-load counts, 5-15
setting increment angle, 5-14
setting increment mode for batch counters, 5-13
setting output mode for batch counters, 5-13
setting parts per stroke or strokes per part, 5-14
setting the auto enable by sensor counter, 5-24
setting the auto enable by tool counter, 5-21
setting the strokes counter for a green special
sensor, 5-30
critical angle, setting for a sensor set to smart
stop, 5-27
cursor keys (SmartPAC 2)
using to highlight letters in entry windows, 3-6
using to increment/decrement numeric
values, 3-5
using to move the highlight bar, 3-5
using to set timing, 3-6
custom names
creating for cam channels in Initialization
mode, 4-9
creating for sensors in Initialization mode, 4-11
selecting for sensors in Program mode, 5-23
cutout dimensions, SmartPAC 2 panel mount, 2-9
–D–
date, setting, 4-38
DC power, wiring linear transducer to, 2-14
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decimal places (tool information)
formats, 4-20
setting, 4-20
delay time, setting for a DSV on cam channel, 5-46
diagnostics, setting menu items, 4-35
dimensions. See mounting dimensions
diodes, installing, 2-30
DiPro Sensor Interface (DSI) 2, connecting sensors
to, 2-23
DiProPAC. See also sensors (die protection)
adding or upgrading, 2-20
board layouts, 2-21
installing new board, 2-22
replacing board, 2-20
verifying installation, 2-34
display (SmartPAC 2)
layout, 3-12
selecting an item, 3-13
downtime, reporting to LETS, G-1
downtime, reporting to SFC, F-1
DSV on cam channel
setting the delay time, 5-46
wiring a press-in-motion signal for, 2-32
–E–
e-mail
adding/changing messages in SmartView, D-14
adding/changing recipient addresses in
SmartView, D-14
enabling in Initialization, 4-31
enabling in SmartView, D-2
sending messages, 6-26
sending messages to Wintriss Tech. Support, 6-27
setting up in Initialization, 4-32
setting up in SmartView, D-2, D-14
emergency stop
faults, 7-3
setting as sensor stop type, 5-26
testing emergency stop circuit, 2-36
wiring emergency stop circuit, 2-16
enable mode (sensor), setting, 4-12
enclosure, SmartPAC 2
grounding AC wiring, 2-15
mounting, 2-7
ENTER key (SmartPAC 2), using, 3-9
error messages. See faults
error/event log
sending in an e-mail to Wintriss Tech.
Support, 6-27
using to troubleshoot SmartPAC 2 problems, 7-8
viewing, 6-23
Ethernet, connecting cable to SmartPAC 2, 2-18
events, viewing in the error/event log, 6-23
–F–
faults
displaying multiple faults, 6-5
equipment problem faults, 7-3
I-2
responding to, 7-1
sensor faults, 7-5
tool programming faults, 7-3
viewing in the error/event log, 6-23
final checkout. See checkout tests, performing
firmware (SmartPAC 2)
downloading updated firmware from
Wintriss, C-7
installing updated firmware, 4-39, C-2
ordering updated firmware, C-1
front panel (SmartPAC 2), components, 1-3
function keys (SmartPAC 2), using, 3-11
–G–
global cams
setting, 4-10
viewing the global cam summary, 5-47, 6-20
good parts count, reporting to LETS, G-19
good parts count, reporting to SFC, F-22
green sensors
adjusting the ready signal, 6-11
overview, 5-18
programming the ready signal, 5-28, 5-33
selecting as sensor type, 5-25
green special sensors
adjusting the stroke preset, 6-13
programming the stroke preset, 5-30, 5-36
–H–
HELP key (SmartPAC 2), using, 3-8
hot keys
deleting, 6-5
overview, 3-11
programming, 6-3
programming for dialog menu functions, F-21,
G-18
toggling between two sets, 6-28
–I–
Info Center, 1-2
Initialization mode
entering and exiting, 4-1
main menu, 4-1
navigation, 3-17
overview, 3-16
input check circuit. See press-in-motion signal,
wiring
installation guidelines, 2-3
installed options. See options (installed), viewing
IP address, changing type in SmartView, D-4
–K–
key switch, Program/Run, 3-10
key(s), using
CLEAR key, 3-4
cursor keys, 3-4
ENTER key, 3-9
function keys, 3-11
Index
SmartPAC 2 Servo User Manual
HELP key, 3-8
hot keys, 3-11
number keys, 3-2
RESET key, 3-9
keyboard (computer), using to enter names, 4-39
keyboard (SmartPAC 2), using, 3-2
–L–
language, selecting, 4-6
LETS (Line Efficiency Tracking Software)
reporting downtime to, G-1
reporting good parts count to, G-19
reporting scrap count to, G-19
setting communications with SmartPAC 2, G-7
linear transducer
adjusting upper/lower limits, 6-22
connecting to DC power source, 2-14
mounting, 2-10, A-1
setting maximum upper limit, 4-14
setting offset, 4-14
setting resolution, 4-14
setting upper/lower limits, 5-50, 6-22
testing upper/lower limits, 2-36
wiring, 2-11, A-3
locked display, entering password to unlock, 6-5
loopback test, performing, 4-37
–M–
magnetostrictive linear transducer. See linear
transducer
messaging
enabling in Initialization mode, 4-32
sending a remote message in SmartView, D-13
sending e-mail messages in SmartPAC 2, 6-26
mounting dimensions
linear transducer, 2-11, A-2
ProCamPAC output assembly, 2-27
SmartPAC 2 enclosure, 2-7
SmartPAC 2 panel mount, 2-9
–N–
name(s)
assigning to tools, 5-9
creating custom names for cam channels, 4-9
creating custom names for sensors, 4-11
selecting for cam channels, 4-7
selecting for PM items, B-8
selecting for sensors, 5-23
setting for a press, 4-7
network
backing up tool settings to, 4-27
changing settings, 4-34, D-4
connecting SmartPAC 2 to, 2-18
programming settings, D-2
requirements for SmartView, D-1
setting up, 4-31, D-1
new tool, loading, 6-24
number keys (SmartPAC 2), using, 3-2
Index
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numeric tool numbers, setting, 4-4
–O–
operating modes
entering and exiting, 3-15
Initialization mode, 3-16
overview, 3-14
Program mode, 3-18
Run mode, 3-20
options (installed), viewing, 4-5
output mode, setting for batch counters, 5-13
–P–
panel mount, SmartPAC 2
installing, 2-8
mounting and cutout dimensions, 2-9
password
assigning a new PM monitor password, B-8
changing defaults, 4-25
checking, 4-25
entering the PM monitor password, B-4
entering to unlock a protected screen, 4-24, 6-5
lost or forgotten password, 4-24
ping utility, using in SmartView, D-15
power, turning on to SmartPAC 2, 2-33
presets (counter)
preset reached messages, 7-2
setting and clearing, 5-11
press
selecting press type in SmartView, D-2
setting press name, 4-7
setting press type, 4-35
press-in-motion signal, wiring, 2-32
preventive maintenance (PM) monitor
assigning a new password, B-8
clearing an alert, B-14
entering the password, B-4
initializing, B-6
installing, B-3
making Initialization settings, B-4
modifying the tracking frequency in Run
mode, B-14
operation, B-2
selecting PM item names, B-8
setting tracking frequency, B-11
setting tracking units, B-10
using in Run mode, B-12
viewing PM status, B-13
ProCamPAC
board layouts, 2-13
replacing board, 2-18
testing cam channels, 2-36
upgrading, 2-18
verifying installation, 2-34
ProCamPAC output assembly
board layout, 2-28
connecting relays to equipment, 2-30
installing diodes, 2-30
I-3
1131400
SmartPAC 2 Servo User Manual
mounting, 2-26
running wiring in conduit, 2-26
selecting relays for cam channels, 2-26
wiring, 2-26
Program mode
entering and exiting, 5-1
main menu, 5-1
navigation, 3-19
overview, 3-18
Program/Run key switch (SmartPAC 2),
using, 3-10
pulse
setting batch counter output mode to, 5-13
setting duration of pulsed batch counter
output, 5-13
–R–
ram angle clock
setting cam channel timing on, 5-42, 5-45
setting green sensor ready signal on, 5-29
ram angle window, opening, 6-6
ram position
adjusting upper/lower limits, 6-22
setting upper/lower limits, 5-50, 6-22
testing upper/lower limits, 2-36
viewing, 5-50, 6-22
viewing cam on/off settings, 5-41, 5-44
ready signal
adjusting for green sensors, 6-10
overview, 5-17
programming for green sensors, 5-28, 5-33
red sensors
faults, 7-7
overview, 5-18
selecting as sensor type, 5-25
relays, cam output
connecting to equipment, 2-30
installing diodes, 2-30
installing suppressors, 2-30
selecting for each channel, 2-26
remote messages, sending in SmartView, D-13
remote reset switch, wiring, 2-32
RESET key (SmartPAC 2), using, 3-9
restore (tool and initialization data),
performing, 4-27
Run mode
entering and exiting, 6-2
main menu, 6-1
navigation, 3-21
overview, 3-20
–S–
scrap count, reporting to LETS, G-19
scrap count, reporting to SFC, F-22
screens (SmartPAC 2)
e-mailing screen captures, 3-22
layout, 3-12
making screen captures, 3-22
I-4
security
access settings, 4-23
access types, 4-22
changing passwords, 4-26
setting access privileges, 4-22
sensor summary, viewing, 5-31
sensor-disabled output, wiring, 2-32
sensors (die protection)
adjusting the ready signal for green sensors, 6-10
adjusting the stroke preset for green special
sensors, 6-10
changing sensor settings, 5-31
deleting a sensor, 5-32
enabling/disabling, 5-52, 6-7
faults, 7-5
naming, 5-23
programming, 5-16, 5-21, 5-33
programming the ready signal for green
sensors, 5-28, 5-33
programming the stroke preset for green special
sensors, 5-30, 5-36
sensor terminology, 5-17
sensors available from Wintriss, 1-5
setting enable mode, 4-12
setting sensor type, 5-25
setting stop type, 5-26
setting the auto enable by sensor counter, 5-24
setting the auto enable by tool counter, 5-21
setting the critical angle for sensors set to smart
stop, 5-27
turning a sensor on or off, 5-54
types, 5-18
viewing actual on/off angles, 6-11
viewing sensor settings, 5-31
viewing sensor status, 5-52, 6-14
viewing the sensor summary, 5-31, 6-14
setup mode
enabling, 4-14
enabling/disabling counters, 4-4
wiring circuit, 2-32
SFC (ShopFloorConnect Asset Utilization
Software)
reporting downtime to, F-1
reporting good parts count to, F-22
reporting scrap count to, F-22
setting communications with SmartPAC 2, F-7
smart stop, setting as sensor stop type, 5-26
SmartPAC 2 board layout, 2-17
SmartView
changing IP address type, D-4
changing network settings, D-4
enabling, 4-32, D-2
enabling e-mail, D-2
installing, D-6
network requirements, D-1
operation, D-10
programming network settings, D-2
selecting press type, D-2
sending remote messages, D-13
Index
SmartPAC 2 Servo User Manual
setting up e-mail, D-2
setting up the network, D-1
using the main page, D-11
using the ping utility, D-15
using the press status information page, D-12
using the setup page, D-10
specifications, SmartPAC 2, 1-7
status (sensor), viewing, 5-52, 6-14
stop circuits
running in conduit, 2-16
wiring, 2-16
stop type (sensor), setting, 5-26
stroke preset
adjusting for green special sensors, 6-10
programming for green special sensors, 5-30,
5-36
suppressors, installing, 2-30
–T–
test tool, creating and loading, 2-35
tests. See checkout tests, performing
time, setting, 4-38
toggle, setting batch counter output mode to, 5-13
tool information
abbreviations for units, 4-20
changing tool parameters, 6-21
decimal place formats, 4-20
entering tool parameters, 5-48
setting formats for, 4-17
tool number mode, setting, 4-4
tool template, copying to a new tool, 5-5
tool(s)
assigning names to, 5-9
backing up SmartPAC 2 settings, 4-27
changing settings, 5-6
copying settings from an existing tool to a new
tool, 5-4
copying tool template to a new tool, 5-5
creating a new tool, 5-3
creating and loading a test tool, 2-35
deleting a tool, 5-7
entering tool information, 5-48
loading a new tool in Program mode, 5-5
loading a new tool in Run mode, 6-24
loading a tool to access Run mode, 6-3
programming, 5-8
restoring SmartPAC 2 settings, 4-29
Index
1131400
tool programming faults, 7-3
top stop
setting as sensor stop type, 5-26
setting batch counter output mode to top
stop, 5-13
testing top stop circuit, 2-36
wiring top stop circuit, 2-16
tracking frequency (preventive maintenance)
modifying, B-14
setting, B-11
tracking units (preventive maintenance),
setting, B-10
transducer. See linear transducer
–U–
units (tool information), abbreviations, 4-20
USB disk
backing up and restoring tool settings, 4-27
saving SmartPAC 2 information to, 4-39
–W–
wiring
general recommendations, 2-3
running in conduit, 2-3
wiring connections
AC power, 2-15
aux I/O, 2-39
DC power for transducer, 2-15
DiPro Sensor Interface (DSI) 2, 2-23, 2-24
linear transducer, 2-14, A-4
press-in-motion signal, 2-32, 2-38
ProCamPAC output assembly, 2-26
remote reset switch, 2-32
sensor-disabled output, 2-32
setup mode circuit, 2-32
SFI and module ports, 2-38
spare 1 and WPC ports, 2-38
spare 3 and 4 ports, 2-39
special and PACNet ports, 2-38
stop circuits, 2-16
–Y–
yellow sensors
faults, 7-6
overview, 5-18
selecting as sensor type, 5-25
I-5
1131400
I-6
SmartPAC 2 Servo User Manual
Index
Wintriss Manuals
Wintriss Product
AutoSet (1500, 1500 Plus, 1504, 1504 Plus)
AutoSetPAC (Tonnage Monitor)
Die Protection Handbook
DiPro 1500
DSI 2 Sensor Interface
LETS Machine Interface (LMI)
MultiPAC Types 1 and 2
MultiPAC Types 4 and 5
ProCam 1500
ProPAC (Process Monitor-In-die Measurement)
RamPAC (Shut Height, Counterbalance &
Cushion Control)
Servofeed Interface-Coe/Wintriss
Servofeed Interface-CWP/Wintriss
Servofeed Interface-DiPro
Servofeed Interface-Electrocraft/Wintriss
Servofeed Interface-Indramat/Wintriss
Servofeed Interface-ProCam
Servofeed Interface-SmartPAC
Servofeed Interface-Waddington/Wintriss
SFC Machine Interface (SMI)
Shadow V Safety Light Curtain
Shadow VI Safety Light Curtain
Shadow VII Safety Light Curtain
Shadow 8 Safety Light Curtain
SmartPAC (w/ DiProPAC & ProCamPAC)
SmartPAC Hydraulic
SmartPAC Run Mode (Spanish)
SmartPAC w/ WPC II Integration
SmartPAC 2 (w/ DiProPAC & ProCamPAC)
SmartPAC 2 Hydraulic
SmartPAC 2 Servo
SmartPAC 2 w/ WPC 2000 Integration
SmartPAC 2 w/WPC 2000 Run Mode (Spanish)
WaveFormPAC (Advanced Load Analyzer)
Wintriss Brake Monitor
Wintriss Clock Display
WPC II Wintriss Press Control
WPC 1000 Wintriss Press Control
WPC 2000 Wintriss Press Control
WPC 2000 Option 2
*
Installation
Manual Doc. No.
User Manual/CD
Doc. No.
DA71747
DA71413
N.A. *
DA71428
N.A. *
N.A. **
DA71409
DA71410
DA71430
DA71411
DA71412
DA71447
DA71443
1130300 *
DA71447
DA66970 *
DA71974 **
DA71443
DA71443
DA71447
DA71443
DA71443
DA71415
DA71416
DA71429
DA71417
DA71418
DA71431
DA71420
DA71419
N.A. **
DA71433
DA71422
N. A. *
N. A. *
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DA71435
N. A. *
DA71440
DA71406
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DA71437
DA71407
N. A. *
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DA71432
N. A. *
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DA71443
DA71443
DA71447
DA71443
DA71443
DA71447
DA71443
DA71443
1140800**
DA71449
DA71445
1129400 *
1139300 *
DA71454
DA71451
DA71443 *
DA71455
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DA71443
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DA67206 *
DA71453
DA71446
DA71444
DA71442
Installation Manual not available; User Manual available in hard copy only. Die Protection Handbook available in
hard copy (1102400) and on CD (1130300).
** Installation Manual not available. User Manual available on CD only.
Wintriss Manuals
SmartPAC 2 Setup Sheet
Tool Name and Number:
Counter Presets
Batch 1 (Ch. 6)
Batch 2 (Ch. 7)
Batch 3 (Ch. 8)
Top Stop
Top Stop
Top Stop
Toggle
Toggle
Toggle
Pulse for _______mS
Pulse for _______mS
Pulse for _______mS
Strokes
Strokes
Strokes
Good Parts
Good Parts
Good Parts
Preset Value
Output mode
(circle one)
Increment mode
(circle one)
Increment angle
(degrees)
This tool should be serviced when the TOTAL HITS count reaches
Strokes / Part:
- OR -
Parts / Stroke:
Tool Information
Item
Tool Memo box text
(30 characters, total):
Value
Units
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __
ProCamPAC Cam Switch – SmartPAC 2 Setup Sheet
Channels 1 - 8
Tool Name and Number:
Ch. #
Cam Name (function)
same for all tools
Global TIMED DSV-ON
ON/OFF
cam? 4 max. Time to Multiple arcs for ON/OFF
only.
ON angle shut-off
after
6 extras, total
+
Not Ch. ON Time
press
Arc #
ON OFF
6, 7 or 8 in mS
stops, in Normally 1
angle angle
seconds
arc per
channel,
can be up
to 4
(
)
1
°
sec
mS
2
°
sec
mS
3
°
sec
mS
4
°
sec
mS
5
°
sec
mS
6
°
sec
mS
7
°
sec
mS
8
°
mS
sec
Arc 1
Arc 2
Arc 3
Arc 4
Arc 1
Arc 2
Arc 3
Arc 4
Arc 1
Arc 2
Arc 3
Arc 4
Arc 1
Arc 2
Arc 3
Arc 4
Arc 1
Arc 2
Arc 3
Arc 4
Arc 1
Arc 2
Arc 3
Arc 4
Arc 1
Arc 2
Arc 3
Arc 4
Arc 1
Arc 2
Arc 3
Arc 4
ProCamPAC Cam Switch – SmartPAC 2 Setup Sheet
Channels 9 - 15
Tool Name and Number:
Ch. #
Cam Name (function)
same for all tools
Global TIMED DSV-ON
ON/OFF
cam? 4 max. Time to Multiple arcs for ON/OFF
(
)
ON angle
+
ON time
in mS
shut off
only.
after
6 extras, total
press
Arc #
ON OFF
stops, Normally 1
angle angle
in
arc per
seconds channel,
can be up
to 4
9
°
sec
mS
10
°
sec
mS
11
°
sec
mS
12
°
sec
mS
13
°
sec
mS
14
°
sec
_____ms
15
°
mS
sec
Arc 1
Arc 2
Arc 3
Arc 4
Arc 1
Arc 2
Arc 3
Arc 4
Arc 1
Arc 2
Arc 3
Arc 4
Arc 1
Arc 2
Arc 3
Arc 4
Arc 1
Arc 2
Arc 3
Arc 4
Arc 1
Arc 2
Arc 3
Arc 4
Arc 1
Arc 2
Arc 3
Arc 4
DiProPAC Die Protection – SmartPAC 2 Setup Form
Sensors 1-16
Tool Name and Number:
Sensor
Number
1
Sensor Name
(function)
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Auto Enable Counter
Sensor Type
(circle one)
Stop Type
(circle one)
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
ON
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
ON
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
ON
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
ON
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
ON
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
ON
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
ON
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
ON
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
ON
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
ON
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
ON
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
ON
G
R
Y
GC GQ
GS _____strokes
E-STOP
TOP STOP
SMART STOP
ON
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
ON
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
ON
G
E-STOP
TOP STOP
SMART STOP
ON
G
R
Y
GC GQ
GS ______strokes
Critical Angle
X
°
Ready Signal
Timing
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
(for Smart Stop)
G=GREEN STD; R=RED; Y=YELLOW; GC=GREEN CONSTANT; GQ=GREEN QUICK CHECK; GS=GREEN SPECIAL
DiProPAC Die Protection – SmartPAC 2 Setup Form
Sensors 17-32
Tool Name and Number:
Sensor
Number
17
Sensor Name
(function)
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Auto Enable Counter
Sensor Type
(circle one)
Stop Type
(circle one)
Ready Signal
Timing
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
Linked to
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
G
R
Y
GC GQ
GS _____strokes
E-STOP
TOP STOP
SMART STOP
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
G
R
Y
GC GQ
GS ______strokes
E-STOP
TOP STOP
SMART STOP
G
E-STOP
TOP STOP
SMART STOP
G
R
Y
GC GQ
GS ______strokes
Critical Angle
X
°
Sensor #____
Linked to
Sensor #____
Linked to
Sensor #____
Linked to
Sensor #____
Linked to
Sensor #____
Linked to
Sensor #____
Linked to
Sensor #____
Linked to
Sensor #____
Linked to
Sensor #____
Linked to
Sensor #____
Linked to
Sensor #____
Linked to
Sensor #____
Linked to
Sensor #____
Linked to
Sensor #____
Linked to
Sensor #____
Linked to
Sensor #____
(for Smart Stop)
G=GREEN STD; R=RED; Y=YELLOW; GC=GREEN CONSTANT; GQ=GREEN QUICK CHECK; GS=GREEN SPECIAL
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