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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

I-24 Reporting Downtime and Scrap to LETS

Adjusting the Good Parts Counter in Program Mode

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.

In Program mode, you can increase the Good Parts count in increments greater than 1,000.

NOTICE

Default Chapter7
- Table of Contents7
Chapter 1. Introduction29
- WPC 2000 and Control Reliability29
- Smartpac 2 with WPC 200029
- Resolver-Based Operation34
- Smartpac 2 Front Panel34
- Figure 1-1. Smartpac 2 Front Panel35
- WPC 2000 Operator Station36
- Figure 1-2. Operator Station Components (Side-Mounted Run/Inch Palm Buttons)36
- Smartpac 2 Settings37
- Sensors Available for Dipropac38
- Procampac Programmable Cams39
- Smartpac 2'S Three Modes of Operation39
- Smartpac 2 with WPC 2000 Specifications40
Chapter 2. Installation45
- Installation Guidelines47
- Figure 2-1. Installation Overview48
- Connecting Wires to Terminal Block Connectors49
- Terminating Cable Shields50
- Figure 2-2. Correct Way to Attach Wires to Terminal Block Connectors50
- Figure 2-3. Connecting Shield Drain Wire to Ground Stud50
- Checking the Press51
- Installing WPC 200051
- Installing WPC 2000 Options78
- Installing Smartpac 291
- Installing Smartpac 2 Options100
Wiring Diagrams105
- Table 2-19. Dipro Sensor Interface (DSI) 2 to Smartpac 2 Wiring, Sensors 9-16106
- Setting up Smartpac 2 with WPC 2000115
- Installing Revised Firmware in WPC 2000129
- Performing Checkout Tests131
- What Next157
- Wiring Tables157
- Table 2-27. WPC 2000 Main Processor Board, TB101-TB104: Wiring Connections158
- Table 2-28. WPC 2000 Power Supply (TB105) Wiring Connections159
- Table 2-34. Smartpac 2 Spare 1 Port (5) and WPC Port (6) (TB105) Wiring Connections160
Chapter 3. Smartpac 2 Keyboard, Displays and Operating Modes161
- Comparing Smartpac 2 with Original Smartpac162
- Smartpac 2 Keyboard163
- Smartpac 2 Display Layout in Run Mode173
  - Selecting an Item on a Display174
- Smartpac 2 Operating Modes175
- Screen Capture183
  - Screen Capture in Smartpac 2 Main Versions Earlier than V 5.3.1183
  - Screen Capture in Smartpac 2 Main Versions V 5.3.1 and Later185
Chapter 4. Smartpac 2 Initialization Mode187
- Entering and Exiting Initialization Mode188
- Initializing WPC 2000 Parameters189
- Resolver Zero189
  - Moving the Ram to Top Dead Center (TDC)189
  - Setting the Resolver Zero Position190
- Position Sensor191
  - Position Sensor Mode191
  - Resolver Motion Mode (Normal Motion - Link Motion)192
  - Angle Wheel Rotation (Clockwise - Counterclockwise)192
  - Tool Number Mode192
  - Table 4-2. Numeric and Alphanumeric Tool Number Modes193
  - Counter Setup Mode194
  - Counter Increment Mode194
- Installed Options195
- Press Name196
- SELECT CAM NAMES (Optional)196
- Figure 4-7. Cam Channel Name Menu (16-Channel Procampac)197
- AUTO ADVANCE and Slow RPM (Optional)198
  - Calculating the Auto Advance Constant199
  - Setting Auto Advance Constants and Slow RPM200
- SET GLOBAL CAMS (Optional)201
- Figure 4-10. Global Cams Menu202
- CUSTOM SENSOR NAMES (Optional)203
- SENSOR ENABLE MODE (Optional)204
  - Selecting Sensor Enable Mode204
  - Enabling Setup Mode205
- Tool Information205
- Figure 4-14. Tool Information Setup Screen206
- Figure 4-16. Tool Information Units Selection Screen207
- Table 4-3. Abbreviations for Units on Tool Information Setup Screen208
- Press Control209
  - User Interlocks210
  - Figure 4-20. Select Stop Name Screen212
  - Press Parameters213
  - Figure 4-22. Initialize Parameters Warning Message220
  - Press Options221
  - Table 4-11. Switch 8 Settings (S101): Top-Stop Mode for F and H Errors225
  - Table 4-12. Switch 8 Settings (S101): Auxiliary Output 1 Response to Interrupted Stroke226
  - Figure 4-24. S102 Option Switch off and on Settings228
  - Table 4-14. Switch 6 Settings (S102): Selecting Concurrent Time for Multiple Op. Stations229
  - Input Status230
  - Figure 4-26. WPC Buttons and Switches Input Status Screen231
  - Figure 4-28. WPC Interlock Group 1 Input Status Screen232
- Security Access233
  - Table 4-15. Security Access Settings234
  - Setting Security Access235
  - Changing Passwords236
  - Figure 4-32. Set Passwords Menu237
  - Additional Security238
- Backup/Restore238
  - Backing up Tools to a USB Disk238
  - Figure 4-34. Backup/Restore Control Menu239
  - Restoring Tools from a USB Disk240
- SETUP DATA COMMS (Optional)241
- Setup Network242
  - E-Mail Function243
  - Smartview Function244
  - Setup E-Mail244
  - Figure 4-39. Alphanumeric Entry Window with Default Mail Server Displayed245
  - Change Network Settings246
  - Press Type246
- Diagnostics247
  - Communications248
  - Set Clock250
  - Save to Usb Disk251
  - Update Firmware251
- Using Smartpac 2 with a Link-Motion Press251
  - Setting Link Motion252
  - Using a Servofeed Interface with Link Motion252
- Using a Computer Keyboard to Enter Names254
Chapter 5. Smartpac 2 Program Mode255
- Entering and Exiting Program Mode255
- Tool Manager256
- Tool Program Menu262
- TOOL NAME or TOOL ID262
- Counters263
- DIE PROTECTION (Optional)270
- CAM SWITCH (Optional)292
- Press Control302
- Figure 5-56. Press Control Parameters Screen303
- Tool Information304
- Figure 5-58. Tool Information Screen305
- SENSOR ENABLE/DISABLE & STATUS (Optional)306
Chapter 6. Smartpac 2 Run Mode309
- Entering and Exiting Run Mode310
- Loading a Tool310
- Programming Hot Keys311
- Settings Locked, or Password Required312
- Displaying Multiple Faults313
- Opening the Crankshaft Angle Window314
- Disable (Enable) Sensors314
- Figure 6-8. Main Run Menu with SENSORS ENABLED Display315
- Counters316
- DIE PROTECTION (Optional)317
  - Figure 6-12. die Protection Menu (Run Mode)318
  - Adjusting the Ready Signal for Green Sensors319
  - Adjusting the Stroke Preset for Green Special Sensors321
  - Viewing the Sensor Summary321
  - Show Sensor Status322
  - Adjusting Dipropac 32 Sensors323
  - Figure 6-17. die Protection Sensor Menu for Sensors 17-32324
  - Figure 6-19. Green Special Sensor Stroke Count Screen, Run Mode325
- CAM SWITCH (Optional)326
  - Viewing Cam Timing327
  - Viewing the Global Cam Summary328
  - Viewing the Cam Summary328
- Brake Monitor328
  - Determining the Stopping Time of Your Press329
  - Performing the 90× Stop-Time Test330
  - Calculating the Safety Distance331
  - Table 6-2. Shadow Light Curtain Response Time and Object Sensitivity333
- Press Control338
  - Adjusting Program Settings338
  - Figure 6-24. Press Control Parameters Screen339
  - Displaying Overrun Sensor On/Off Angles340
- Tool Information341
- Error/Event Log342
- Load New Tool343
- Figure 6-28. Tool Manager Screen344
- Messaging345
  - Sending E-Mail to Wintriss Technical Support346
- Toggle Hot Keys347
- Operating the Press347
  - Responding to an Interrupted Stroke347
  - Selecting Operating Mode348
  - Operating the Press in Inch Mode349
  - Operating the Press in Single-Stroke Mode351
  - Operating the Press in Automatic Single-Stroke Mode357
  - Operating the Press in Continuous Mode358
  - Operating the Press in Automatic Continuous On-Demand Mode360
  - Operating the Press in Bar Mode361
  - Multiple Operator Stations362
Chapter 7. Fault Messages363
- Responding to Fault Messages364
- Lockout Message365
- Brake Monitor Faults365
  - Brake Warning LED365
  - Stop Time Exceeded365
- Messages for Press Control Problems367
- Counter Preset Reached Messages385
- Messages for Equipment or Brake Monitor Problems386
- Messages for Programming Problems389
- Messages for Sensor Faults390
- Miscellaneous Fault Messages392
- Troubleshooting Using the Error/Event Log393
- Resetting Ross DM2 DSV Faults393
- Figure 7-4. Ross DM2 DSV Showing Reset Button394
Appendix A. Extracts from OSHA Regulations and ANSI395
Standards395
- Controls399
Appendix B. Specifications for User-Built Operator Stations413
- Run Button Installation413
- Switch Requirements414
Appendix C. Smartpac Preventive Maintenance (PM) Monitor415
- About Smartpac PM Monitor415
- Installing the PM Monitor417
  - For New Systems from the Factory417
  - For Existing Systems417
- Using the PM Monitor in Initialization Mode418
- Using the PM Monitor in Run Mode426
Appendix D. Updating Smartpac 2 Firmware429
- Updating Firmware Using a USB Disk429
- Installing Firmware from a Replacement Compact Flash (CF) Card437
- Figure D-5. Firmware Load Menu with "RELOAD CURRENT FIRMWARE" Highlighted438
- Figure D-7. Smartpac 2 Display with "Loading Firmware" Message439
Appendix E. Smartview Remote Viewing and E-Mail Setup441
- Network Requirements441
- Network Setup441
- Table E-1. Smartpac 2 Board: PS 2 and Y-Cable Configuration444
- Installing Smartview446
- Smartview Operation450
- Remote Messaging453
- E-Mail Setup454
- Smartview Ping Utility455
- Figure E-12. Mabry Internet Ping Window456
- Figure E-14. Ping Utility Window with Example of a Successful Ping457
Appendix F. Upgrading from Original Smartpac to Smartpac 2459
- Backing up Tools on Original Smartpac459
- Figure F-1. Backup/Restore Control Menu460
- Removing Smartpac 1 and Mounting Smartpac 2461
- Wiring the Smartpac 2462
- Table F-13. Smartpac 1 to Smartpac 2 Wiring Changes: Remote Reset (Optional)468
- Table F-15. Smartpac 1 to Smartpac 2 Wiring Changes: SFI (Optional)469
  - AC Wiring on Smartpac 2470
- Restoring Tools to Smartpac 2470
- Figure F-3. Backup/Restore Control Menu with Restore Confirmation Message Displayed471
- System Checkout472
Appendix G. Replacing Smartpac 2 PC Board473
- Unpacking the Replacement Board473
- Installing the Replacement Board474
- Figure G-1. Smartpac 2 PC Board475
- Figure G-2. Firmware Load Menu with "RELOAD CURRENT FIRMWARE" Highlighted477
Appendix H. Reporting Downtime and Scrap to SFC479
- Machine States to Which SFC Logs Press Time479
- Smartpac 2 Downtime Reporting Features480
- Setting up Smartpac 2 to Report Downtime485
  - Making Downtime Reporting Settings485
  - Figure H-4. Smartpac 2 Main Initialization Menu486
- Table H-1. Set Communications Menu Settings487
- Documenting Downtime on the Dialog Menu494
- Reporting Scrap and Good Parts to SFC500
Appendix I. Reporting Downtime and Scrap to LETS505
- Machine States to Which LETS Logs Press Time505
- Smartpac 2 Downtime Reporting Features506
- Setting up Smartpac 2 to Report Downtime510
- Documenting Downtime on the Dialog Menu518
- Reporting Scrap and Good Parts to LETS523
Appendix J. Option 1 User Inputs529
- Table J-1. Option 1 User Inputs: Input Type and Stop Type530
- Installing the Option 1 Board531
- Figure J-1. Option 1 Board Installed on WPC 2000 Main Processor Board532
- Wiring Option 1 User Inputs533
  - Table J-2. WPC 2000 Option 1 Board: Wiring Connections, TB601534
  - Figure J-3. WPC 2000 Option 1 Board: LED Map535
- Changing User Input Stop Type536
- Viewing the Status of User Inputs537
- Troubleshooting538
- Option 1 User Input Setup Sheet540
Glossary541
Index557

Brand	Wintriss
Model	SmartPAC 2
Category	Control Systems
Language	English

Wintriss SmartPAC 2 User Manual

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